IE860906L - Water-dispersible synthetic fiber - Google Patents

Water-dispersible synthetic fiber

Info

Publication number
IE860906L
IE860906L IE860906A IE90686A IE860906L IE 860906 L IE860906 L IE 860906L IE 860906 A IE860906 A IE 860906A IE 90686 A IE90686 A IE 90686A IE 860906 L IE860906 L IE 860906L
Authority
IE
Ireland
Prior art keywords
fiber
water
polyester
dispersible
filaments
Prior art date
Application number
IE860906A
Other versions
IE57360B1 (en
Original Assignee
Du Pont
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=24897610&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=IE860906(L) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Du Pont filed Critical Du Pont
Publication of IE860906L publication Critical patent/IE860906L/en
Publication of IE57360B1 publication Critical patent/IE57360B1/en

Links

Classifications

    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10Organic non-cellulose fibres
    • D21H13/20Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/24Polyesters
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/253Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507Polyesters
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16Synthetic fibres, other than mineral fibres
    • D06M2101/30Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32Polyesters

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Artificial Filaments (AREA)
  • Polyesters Or Polycarbonates (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

Water-dispersible synthetic fiber of scalloped-oval cross-section to promote dispersibility, and so better uniformity, softer feel and more opacity to the resulting wet-laid fabrics.

Description

This invention concerns new synthetic polymeric water-dispersible fiber, particularly of poly(ethylene terephthalate), and its preparation. ' There has been increased interest in recent years in water-dispersible synthetic fiber, especially of polyester fiber. Such water-dispersible fiber is used in various non-woven applications, including paper-making and wet-laid non-woven fabrics, sometimes as part of a blend, often with large amounts of wood pulp, or fiberglass, but also in applications requiring only polyester fiber, i.e., unblended with other fiber. This use, and the requirements therefor, are entirely different from previous more conventional use as tow or staple fiber for conversion into textile yarns for eventual use in woven or knitted fabrics, because of the need to disperse this fiber in water instead of to convert the fiber into yarns, e.g., by processes such as carding, e.g. in the cotton system. It is this requirement for water-dispersibility that distinguishes the field of the invention from .previous, more conventional polyester staple fiber.
Most such water-dispersible polyester fiber is of poly(ethylene terephthalate), and is prepared in essentially the same general way as conventional textile polyester staple fiber, except that most water-dispersible polyester fiber is not crimped, whereas any polyester staple fiber for use in textile yarns is generally crimped while in the form of tow, before conversion into staple fiber. Thus, water-dispersible polyester fiber has generally been prepared by nelt-spinning the polyester into filaments, combining the filaments to form a tow, drawing, applying a suitable coating to impart 5 water-dispersible properties, generally in the same way as a finish is applied to a tow of conventional textile filaments, and then, generally without any crimping (or with imparting only some mild wavy undulations in some cases to provide extra bulk and a three-dimensional 10 matrix), converting the tow into staple. Some prior polyester staple fiber has been prepared in uncrimped form, e.g. for use as flock in pile fabrics, but for such use, water-dispersibility has not been required.
Polyester fibers are naturally hydrophobic, so it 15 is necessary to apply to the polyester a suitable coating, as disclosed by Ring et al. in U.S. Patent No. 4,007,083, Hawkins in U.S. Patent Nos. 4,137,181, 4,179,543 and 4,294,883, and Viscose Suisse in British Patent No. 958,350, to overcome the inherent hydrophobic character of 20 the polyester fiber without creating foam or causing the fibers to flocculate. It is this coating that has distinguished water-dispersible polyester fiber from more conventional polyester staple fiber, rather than any inherent characteristic feature of the polyester itself, 25 or of its shape, such as the cross-section. Heretofore, so far as is knonw, the cross-section of all commercial water-dispersible polyester fiber has been round. Indeed the cross-section of most commercial polyester staple fiber has generally been round, because this has been 30 preferred.
Although, hitherto, most synthetic polymeric water-dispersible fiber has been formed of polyester, being inexpensive and plentiful, increasing amounts of polyolefins and polyamides are beginning to be used for 35 water-dispersible fibers, and so the invention is not limited only to polyesters, but covers other synthetic polymers.
According to the present invention, there is provided a synthetic polymer fiber rendered water-dispersible by a coating promoting water-dispersibility, wherein the fibers are of scalloped-oval cross-section, the scalloped-oval cross-section being defined as follows: a. by major and minor axes of symmetry which are perpendicular to each other; b. by a ratio of length A to width B, measured along the axes of symmetry, of from 1.4 to 2.4; c. by a lobe located on each extremity of the major axis which has a tip radius ratio r^/R of 0.20 to 0.45, where ri is the radius of the lobe tip and R is the radius of a circle circumscribed about the oblong cross-section; d. by a tip radius ratio r2/R at each extremity of the minor axis of 0.8 to 2.1 times the tip radius ratio r^/R of the lobes on the major axis; e. by indentations between the extremities of the major and minor axes, and; f. by the shortest distance d between two indentations on opposite sides of the major axis being from 1.2 to 2.0 times the radius r^ of the lobes on the major axis.
A scalloped-oval cross-section has been used heretofore for other polyester fibers, as described herein. Other than the cross-section, the water-dispersible fiber of the invention may be essentially similar to prior water-dispersible polyester or other synthetic polymer fibers, although the advantages described hereinafter may provide the opportunity for additional modifications. The invention will be described hereinafter with special reference to polyester fiber, although it will be recognized that other synthetic polymers, such as polyamides and polyolefins, may also be used. .
The fibers of the invention may be made conveniently by melt-spinning and drawing polyester filaments of appropriate denier per filament (dpf), and applying thereto a suitable coating to impart water-dispersible characteristics. The filaments are then generally cut into staple of whatever length is desired for the end-use contemplated. - 4a - The present invention further provides a process for preparing polyester fiber having a coating promoting water-dispersibility by melt-spinning the polyester into filaments, drawing the tow and cutting the filaments into 5 staple, wherein the polyester is spun into filaments of scalloped-oval cross-section, the scalloped-oval cross-section being defined as follows: i a. by major and minor axes of symmetry which are perpendicular to each other; b. by a ratio of length A to width B, measured along the axes of symmetry, of from 1.4 to 2.4; c. by a lobe located on each extremity of the major axis which has a tip radius ratio r-j /R of 0.20 to 0.45, where r-| is the radius of the lobe tip and R is the radius of a circle circumscribed about the oblong cross-section; d. by a tip radius ratio r2/R at each extremity of * 5 the minor axis of 0.8 to 2.1 times the tip radius ratio r^/Rof the lobes on the major axis; e. by indentations between the extremities of the major and minor axes, and; f. by the shortest distance d between two indentations on opposite sides of the major axis being from 1.2 to 2.0 times the radius r-j of the lobes on the major axis, the filaments being coated with a segmented synthetic copolyester of poly(ethylene terephthalate) repeat units and 15 poly(oxylalkylene) groups derived from a poly(oxyalkylene) glycol having an average molecular weight in the range of 300 to 6,000, and cut to fibers of cut length of 5 to 90 mm.
The use of a scalloped-oval cross-section for the 20 water-dispersible fiber of the invention has, surprisingly, been found to promote dispersibility, in comparison with a round cross-section, and this imparts to * the resulting wet-laid fibers better uniformity, a softer feel, more opacity and good permeability, as will be seen in the Example.
Figure 1 shows a scalloped-oval cross-section for a stylized fiber according to the invention.
Figure 2 shows a typical spinneret orifice for spinning filaments of the invention.
As indicated above, a scalloped-oval cross-section has already been used for more conventional polyester staple fiber, that has been spun into filaments and drawn, cut, converted into spun yarn, and used in woven or knitted fabrics. Such fiber has not had the water-dispersible characteristics required for this invention. Similarly, polyester filaments having a scalloped-oval cross-section are already known from Gorrafa U. S. Fat. No. 3,914,488, which suggested use in fur-like fabrics. Oriented polyester filaments of scalloped-oval cross-section have also been described by Frankfort et al.in U. S. Pat. Nos. 4,134,882 and 4,195,051, having been prepared by spinning at a very high speed (6,000 ypm (5486 m/min)), which high speeds could also be used to prepare oriented polyester filaments as a substrate for applying thereto a suitable coating to impart water-dispersible characteristics, and thereby obtain water-dispersible fiber according to the invention. None of this art concerns the field of the present invention.
However, the polyester filamentary substrates for making the water-dispersible fiber of the invention may be prepared by the techniques described therein, or by appropriate modifications of these or other known techniques of making polyester filaments of non-round cross-section.
Gorrafa U.S. Pat. No. 3,914,488 discloses parameters for a scalloped-oval cross-section and Figure 1 is essentially as shown therein. Thus, a scalloped-oval is of essentially oval 5 shape, with a significant difference between the lengths of major and minor axes, and differs significantly from prior art round and multi-lobal filaments in this respect, so that it would be misleading herein to consider all four rounded portions of the scalloped-oval as lobes (as did 10 Gorrafa) in view of the terminology used in other prior art for symmetrical multi-lobal cross-sections. However, preferred dimensions, essentially as described by Gorrafa may be characterised as follows: Considering Figure 1, the cross-sectional 15 configuration of fibers may be determined from a photomicrograph of the fiber cross-section.
The length of cross-section along the major axis X is indicated by A, which is also 2R, the circumscribing radius for the cross-section. The width of the 20 cross-section along the minor axis Y is indicated by B. The ratio of length to width of the cross-section is A/B.
In the melt-spinning of filaments, the polymer tends to flow so as to produce smooth curves or combinations of smooth curves and straight lines in the 25 periphery of the cross-section. For the purpose of measurement, the periphery may be considered to be composed of straight lines and arcs of circles. Using this concept, filaments of the invention have a lobe located at each end of the major cross-sectional axis, the 30 extreme portion of the lobe being an arc of a circle, and being preferably more than a semicircle. The radius of each lobe tip is indicated by r^. Likewise, at each end of the minor axis Y of the cross-section, there is another arc, whose radius is indicated by While Figure 1 shows the centers of curvature for both arcs at the same point on the minor axis, this is not essential. The centers of curvature may be separated, for example, as described by Gorrafa. The tip radius ratio for the lobes on the major axis is r^/R and for the extremities of the minor axis is rj/R.
Another feature of the cross-section is the distance d which is the distance between two scallopings measured across the major axis of the fiber cross-section, as described by Gorrafa.
Dimensions are in the following proportions: - the ratio of length to width A/B of the cross-section from 1.4 to 2.4, tip radius ratio r^/R for the lobes on the major axis between 0.20 and 0.45, and the tip radius ratio r2/R on the minor axis from 0.8 to 2.1 times the tip radius ratio r^/R. The cross-section must be properly scalloped to provide the desirable properties of the invention; for this reason, the ratio d/2x , is from about 0.6 to 1.0 While the above features may appear to be complicated, they are quite simple to measure on enlarged photomicrographs of cross-sectional views.
The preparation of the polyester staple fiber is otherwise conventional, involving the steps of melt-spinning polymer into filaments, collecting the filaments into a tow, drawing the tow, and applying a suitable coating to impart water-dispersible characteristics. If low shrinkage is desired, the drawn filaments are generally annealed.
Selection of an appropriate coating to promote water-dispersibility is important, and more of such coating is generally required than for comparable weights of fiber of round cross-section of similar dpf, because of the larger surface area of the periphery of the scalloped-oval cross-section. It is especially important to provide good boundary lubrication properties. For this reason, an ethoxylated coating is preferred.
Suitable coatings may be as disclosed in Hawkins, U.S. Pat. Nos. 4,137,181, 4,179,543 and 4,294,883 or a synthetic copolyester of poly(ethylene terephthalate) units and poly(oxyalkylene) of groups derived from a poly(oxyalkylene) glycol having an average molecular weight in the range of 300 to 6,000, as disclosed, e.g. in Mclntyre, et al. U.S. Pat. Nos. 3,416,952, 3,557,039 and 3,619,269, referred to therein; other useful segmented copolyesters are disclosed in Raynolds, U.S. Patent No. 3,981,807.
Such polyester fiber is generally prepared first in the form of a continuous filamentary uncrimped tow or, if extra bulk is required, and a more three-dimensional matrix, the filaments may be provided with mild wave-like undulations by a mild crimping-type process, and the uncrimped or mildly wave-like filaments are cut to the desired cut length, i.e. to form the water-dispersible fiber, which is generally sold in the form of bales, or other packages of cut fiber. Suitable cut lengths are generally from about 5 to about 90 mm (1/4 to 3 inches), generally up to 60 mm (2-1/2 inches), and of length/diameter (L/D) ratio from about 100:1 to about 2000:1, preferably about 150:1 to about 2000:1, it being an advantage of the invention that good performance has been obtainable with preferred water-dispersible fiber of the invention with an L/D ratio higher than we have considered satisfactory with prior art water-dispersible polyester fiber. For instance, machine manufacturers have generally recommended that the L/D ratio not exceed 500:1, and many operators have considered even this figure unrealistically high. A suitable denier per filament is generally from about 0.5 to about 20 (about 0.58 to about 22 dtex). The coating is generally present in amount about 0.04 to about 1.0% of the weight of fiber (OWF%), it being an advantage that smaller amounts may generally be used than we have considered satisfactory according to the prior art.
The process for preparing * such water-dispersible polyester fiber comprises the steps of melt-spinning the polyester into filaments of * scalloped-oval cross-section, forming a tow of such filaments, drawing, and then coating the filaments in the 10 tow with such synthetic copolyester, and, at an appropriate time, converting such coated filaments into staple fiber.
The coating is preferably cured on the filaments by heating the coated filaments, or the resulting staple 15 fiber, if desired, to a temperature of about 100° to about 190° to improve durability.
The invention is further illustrated in the following Example, in which all parts and percentages are by weight, unless otherwise indicated, and OWF is (solids) 20 "of weight of fiber". Reference is made to several measurements of yarn properties, such as tensile properties (tenacity and elongation-to-break), which are measured according to the methods described in Frankfort et al. U.S. Patent No. 4,134,882. It will be understood 25 that other conditions can be used e.g., other designs of . orifice, such as are shown by Gorrafa, U.S. Patent No. 3,914,488.
Example The following fibers, Fiber A, a comparison of 30 round cross-section, and Fiber X, a fiber of the invention ^ of scalloped-oval cross-section, were both spun from poly(ethylene terephthalate) of intrinsic viscosity 0.64, containing 0.3% Ti02 as a delusterant.
Fiber A was spun at 1600 ypm (1463m/min) into filaments with conventional radial air quenching using a 900 hole spinneret, with round holes 0.015 inches (0.381mm) in diameter and capillary length of 0.030 inches (0.762mm), a 270°C block, and polymer throughout 68.2 pounds/hour (30.9kg/hr). Denier per filament was 3.67. Fiber A was then oriented by running over a set of feed rolls at 29.3 ypm (26.8m/min), followed by a set of draw rolls at 80.0 ypm (73.2m/min), and delivered to a conveyer by puller rolls at 80.1 ypm (73.24m/min). Between feed roll sections the filaments were treated in a 45°C water bath.
Between feed and draw rolls the rope was sprayed with water at 98°C. Between draw and puller rolls a commercial water-dispersible coating (50/50 mixture of potassium salt of mono and diacid phosphate esters of lauryl alcohol/tallow alcohol ethoxylated with 25 moles of ethylene oxide) was applied. The filaments were then relaxed free in an oven at 150°C for 6 minutes.
Fiber X was produced in a similar manner to Fiber A except that 1054 filaments of 2.98 dpf and scalloped-oval cross-section were spun through capillaries as shown in Figure 2, with block temperature 274°C, and throughput 67 pounds/hour (30.4kg/hour). Roll speeds for the orientation were feed rolls 34.1 ypm (31.2m/min), draw rolls 80.2 ypm (73.2m/min) and puller rolls 79.1 ypm (72.3m/min), and a higher level of water-dispersible coating was used to offset the scalloped-oval1s approximately 13% higher surface area.
Fiber X cross-sections had dimensions in the following average proportions: A/B = 1.57, r^/R =0.38, r2/R = 0.42 and d/2ri = 0.83.
The properties of the drawn coated filaments are compared in Table 1.
Table 1 Sample A X Cross-section Round scalloped-oval dpf (dtex pf) 1.47(1 .62) 1.51 (1 .67) coating OWF(%) 0.4 0.7 Boil-off shrinkage(%) 1.0 0.2 Dry heat shrinkage (196°C) (%) 2.45 3.1 Tenacity at break (g/d Xg/dtex) 4.5 (4.10) 4.7 (4.27) 10 Elongation at break(%) 42 36 Tenacity at 2% elongation(g/d)(g/dtex) 0.93 (0.85) 0.90 (0.82) Both types were cut to form water-dispersible fiber of 1/4, 3/8, 1/2 and 3/4 inch (6.35nxn, 9.53rrm, 12.7Qrtm and 19.05rmt) cut lengths and were tested on an inclined wire Fourdrinier machine.
Fibers were dispersed for three minutes in a small pulper at 0.75% consistency (kg fiber per 100 kg slurry, or furnish).
The cylindrical pulper was approximately 3 feet (0.91m) in diameter By 6 feet (1.83m) deep. Fibers were then mixed with 20 unrefined sulphite pulp to form a 50% polyester blend and diluted to 0.1% consistency in a 10 cubic meter stock tank. This stock was further diluted in the headbox of the machine to 0.0143% consistency and formed into a 0.5 meter wide wet lay nonwoven fabric at 20 meters/minute. A spray of an acrylic binder, Acronyl 240D was spray applied at the end of the Fourdrinier wire. The fabric was then cured in a through air drier at 150°C. Finished fabric weight averaged 40 grams/square meter.
Dispersion quality can be judged by the uniformity 30 of the fabric produced from a given sample. As cut length increases, the uniformity of the fabric can generally be expected to suffer significantly. However, great advantages can result from using a longer fiber because the fabric tear strength increases, for example. In 35 practice, therefore, a fabric producer will generally wish to use the longest fiber that will meet his uniformity standards. Thus, a longer fiber with improved, or equivalent uniformity would be preferred. Fabric samples , from Fibers A and X were independently shown to a panel of 10 persons (which was evenly divided between men and i women), who were asked to rank the fabrics in terms of visual uniformity with the results shown in Table 2, the most uniform being ranked at 1, i.e. the lowest score.
Table 2 Rank Fiber Cut Length,inches Average 1 X 1/4 (6.35nm) 1.1 2 A 1/4 (6.35mm) 2.0 3 X 3/8 (9.53nm) 2.9 4 X 1/2 (12.70mm) 4.4 A 3/8 (9.53mn) 4.6 6 A 1/2 (12.7Qnm) 6.2 7 X 3/4 (19.05mm) 6.8 8 A 3/4 (19.05mm) 7.0 As can be seen, each scalloped-oval fabric (X) 20 scored better, i.e. was preferred for fabric uniformity over its round counterpart at the same cut length.
Indeed, the 1/2 inch (12.70mm) Fiber x was actually preferred, by a narrow margin, over its significantly shorter 3/8 inch (9.53mm) Fiber a counterpart.
A common defect in wet lay nonwoven fabrics is two clumps of fibers joined together by a single overlength.
These defects are called dumbbells, or, if single ended, clumps. The number of such defects was determined for known weights of fabric for all cut lengths of both fibers. On the average, Fiber X, the scalloped-oval, had 44% fewer defects/100 grams fabric than the control. This may possibly be caused by the assymetric nature of the fiber bending modulus, which limits the freedom of the scalloped-oval long fibers to respond to swirls in the white water.
Standard physical properties were measured for the set of fabrics at Herty Foundation, Savannah, GA.
Compared each time to Fiber A as 100%, Fiber X had the following average properties: Air Permeability, Gurley 101% Opacity, ISO 2471 108% Bulk, TAPPI T410 om-83 and T411 om-83 96% Tensile Strength, TAPPI T494 om-81 112% Tensile Stretch, TAPPI T494 om-81 93% Tear Strength, TAPPI T414 om-82 100% On balance, Fiber X exhibited advantages in the important areas of higher opacity and higher tensile 15 strength, with minor sacrifices in tensile stretch and bulk. The fabrics of FiberX also have a pleasant soft hand.
When used with the appropriate water-dispersible coating in appropriate amount, the scalloped-oval 20 cross-section fiber of the invention has given a fabric with exceptional dispersion uniformity, opacity and a soft hand.
Fabrics made from 80%/20% blends of craft wood pulp with similar scalloped-oval water-dispersible fiber, 25 with a different coating, have demonstrated consistently better opacity than fabrics of various weights of polyester fibers of round cross-section.
From theoretical considerations, water-dispersible fibers of conventional round cross-section would have been 30 expected to give more uniform dispersions, and, therefore, more uniform wet-laid fabrics. This is because the surface energy required to disperse a fiber (or other articles) is given by: Energy - (Surface Tension) X (Dispersed surface area -35 Undispersed surface area).
The undispersed fiber exists in logs or clumps of many hundreds of fibers, most of which are on the inside of the logs. Therefore the undispersed surface area is negligible compared to the dispersed area, and the energy 5 term can be expressed approximately as: Energy » (Surface Tension) X (Number of fibers) X (Surface area of a fiber).
This energy term describes both the energy required to disperse the fiber, and the free energy 10 driving force for reagglomeration. Therefore, for any given coating, and fiber dpf, fibers with lower area would be expected to provide a more uniform dispersion, hence more uniform fabric. The minimum surface area per unit weight for a given fiber occurs when the cross-section is 15 round, which would be expected, therefore, to be preferred.
Surprisingly, however, these scalloped-oval fibers, in spite of about 15% greater surface area gave more uniform fabrics. Without limiting the invention to 20 anY theory, this may result from the fiber's hydrodynamic shape, which may more effectively use the energy available in the mixer shear field.

Claims (16)

1. A synthetic polymer fiber rendered water-dispersible by a coating promoting water-dispersibility, wherein the fibers are of scalloped-oval cross-section, the scalloped-5 oval cross-section being defined as follows: a. by major and minor axes of symmetry which are perpendicular to each other; b. by a ratio of length A to width B, measured along the axes of symmetry, of from 1.4 to 2.4; 10 c. by a lobe located on each extremity of the major axis which has a tip radius ratio r^/R of 0.20 to 0.45, where r^ is the radius of the lobe tip and R is the radius of a circle circumscribed about the oblong cross-section; 15 d. by a tip radius ratio r2/R at each extremity of the minor axis of 0.8 to 2.1 times the tip radius ratio r^/R of the lobes on the major axis; e. by indentations between the extremities of the major and minor axes, and; 20 f. by the shortest distance d between two indentations on opposite sides of the major axis being from 1.2 to 2.0 times the radius r^ of the lobes on the major axis.
2. A water-dispersible fiber as claimed in claim 1 , of cut length from 5 to 90 mm, and wherein the length/diameter ratio is from 100:1 to 2000:1.
3. A water-dispersible fiber as claimed in claims 1 or 2, wherein the denier is from 0.5 to 20.
4. A water-dispersible fiber as claimed in any of claims 1 to 3, in the form of a package of cut fiber.
5. Polymer fibers of claim 1 in the form of a continuous filamentary uncrimped tow.
6. A fiber as claimed in any of the preceding claims, wherein the synthetic polymer is polyester.
7. A polyester fiber according to claim 6, consisting essentially of poly(ethylene terephthalate).
8. A polyester fiber as claimed in claim 6, wherein the polyester is poly(ethylene terephthalate) and the fiber is essentially uncrimped, of cut length 5 to 90 mm, of length/diameter ratio 100:1 to 2000:1, and of denier 0.5 to 20, and an ethoxylated water-dispersing coating is present in amount from 0.04 to 1.0% of the total weight of the fiber.
9. A polyester fiber according to claim 7, coated with a water-dispersing coating consisting essentially of a segmented copolyester of poly(ethylene terephthalate) repeat units and poly(oxyalkylene) groups derived from a poly(oxyalkylene) glycol having an average molecular weight in the range of 300 to 6000.
10. A process for preparing polyester fiber having a coating promoting water-dispersibility by melt-spinning the polyester into filaments, drawing the tow and cutting the filaments into staple, wherein the polyester is spun into filaments of scalloped-oval cross-section, the scalloped-oval cross-section being defined as follows: a. by major and minor axes of symmetry which are perpendicular to each other; b. by a ratio of length A to width B, measured along the axes of symmetry, of from 1.4 to 2.4; c. by a lobe located on each extremity of the major axis which has a tip radius ratio r-j/R of 0.20 to 0.45, where r-j is the radius of the lobe tip and R is the radius of a circle circumscribed about the oblong cross-section; d. by a tip radius ratio r2/R at each extremity of the minor axis of 0.8 to 2.1 times the tip radius ratio r-j/R of the lobes on the major axis; e. by indentations between the extremities of the major and minor axes, and; f. by the shortest distance d between two indentations on opposite sides of the major axis being from 1.2 to 2.0 times the radius r-j of the lobes on the major axis, the filaments being - 19 - I coated with a segmented synthetic copolyester of poly(ethylene terephthalate) repeat units and poly(oxyalkylene) groups derived from a poly(oxyalkylene) glycol having an average molecular 5 weight in the range of 300 to 6,000, and cut to fibers of cut length of 5 to 90 mm.
11. A process as claimed in claim 10, wherein the filaments are coated with the copolyester in amount from 0.04 to 1.0% of their weight. 10
12. A process as claimed in claim 10, wherein the coating is cured on the filaments by heating the coated filaments to a temperature of 10 0°C to 190°C.
13. A process for preparing water-dispersible polyester fiber substantially ad described with reference to the 15 Example.
14. Water dispersible polyester fibers whenever prepared by a process as claimed in any one of claims 10 to 13.
15. ' 15. Water-dispersible synthetic polymer fibers substantially as described with reference to and as shown 20 in Figure 1 of the accompanying drawings.
16. Apparatus for producing water-dispersible synthetic - 20 - polymer fibers substantially as described with reference to and as shown in Figure 2 of the accompanying drawings. i t MACLACHLAN & DONALDSON i Applicants* Agents 47 Merrion Square DUBLIN 2
IE906/86A 1985-04-09 1986-04-08 New synthetic water dispersible fiber IE57360B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US72134785A 1985-04-09 1985-04-09

Publications (2)

Publication Number Publication Date
IE860906L true IE860906L (en) 1986-10-09
IE57360B1 IE57360B1 (en) 1992-08-12

Family

ID=24897610

Family Applications (1)

Application Number Title Priority Date Filing Date
IE906/86A IE57360B1 (en) 1985-04-09 1986-04-08 New synthetic water dispersible fiber

Country Status (12)

Country Link
EP (1) EP0198400B1 (en)
JP (1) JPS62502482A (en)
KR (1) KR880002440B1 (en)
CN (1) CN1006310B (en)
AT (1) ATE44786T1 (en)
CA (1) CA1280267C (en)
DE (1) DE3664502D1 (en)
ES (1) ES8800999A1 (en)
FI (1) FI80077C (en)
IE (1) IE57360B1 (en)
NO (1) NO864926L (en)
WO (1) WO1986006111A1 (en)

Family Cites Families (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL125598C (en) 1961-03-15
BE623867A (en) * 1961-11-30
GB1088984A (en) * 1963-06-05 1967-10-25 Ici Ltd Modifying treatment of shaped articles derived from polyesters
DE1635684A1 (en) * 1963-07-24 1969-10-16 Glanzstoff Ag Process for the production of textile surface structures with a felt-like character
US3625754A (en) * 1970-02-02 1971-12-07 Beaunit Corp Surface-modified polyester article
US3703260A (en) * 1970-12-04 1972-11-21 John P Grabske Material spreader
DE2105681C3 (en) * 1971-02-08 1975-10-02 Bayer Ag, 5090 Leverkusen Process for the production of aqueous fiber suspensions
US3914488A (en) * 1973-09-24 1975-10-21 Du Pont Polyester filaments for fur-like fabrics
US3981807A (en) 1973-09-27 1976-09-21 E. I. Du Pont De Nemours And Company Durable textile treating adducts
US4007083A (en) 1973-12-26 1977-02-08 International Paper Company Method for forming wet-laid non-woven webs
US4195051A (en) 1976-06-11 1980-03-25 E. I. Du Pont De Nemours And Company Process for preparing new polyester filaments
US4134882A (en) 1976-06-11 1979-01-16 E. I. Du Pont De Nemours And Company Poly(ethylene terephthalate)filaments
US4179543A (en) * 1976-08-19 1979-12-18 Hoechst Fibers Industries, Division Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4294883A (en) 1976-08-19 1981-10-13 Hoechst Fibers Industries, Div. Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4297414A (en) * 1978-07-07 1981-10-27 Mitsui Petrochemical Industries, Ltd. Reinforcing material for hydraulic substances and method for the production thereof
JPS5725645A (en) * 1980-07-23 1982-02-10 Hitachi Ltd Method of forming fluorescent surface for color-picture tube
US4634625A (en) 1984-10-25 1987-01-06 E. I. Du Pont De Nemours And Company New fabrics, yarns and process

Also Published As

Publication number Publication date
KR880002440B1 (en) 1988-11-12
FI864686A (en) 1986-11-18
JPS62502482A (en) 1987-09-24
DE3664502D1 (en) 1989-08-24
FI864686A0 (en) 1986-11-18
ES553823A0 (en) 1987-12-01
EP0198400A1 (en) 1986-10-22
JPH0331803B2 (en) 1991-05-08
CN1006310B (en) 1990-01-03
ES8800999A1 (en) 1987-12-01
FI80077B (en) 1989-12-29
ATE44786T1 (en) 1989-08-15
FI80077C (en) 1990-04-10
CA1280267C (en) 1991-02-19
IE57360B1 (en) 1992-08-12
KR880700115A (en) 1988-02-15
EP0198400B1 (en) 1989-07-19
WO1986006111A1 (en) 1986-10-23
NO864926L (en) 1986-12-08
CN86102475A (en) 1986-10-15

Similar Documents

Publication Publication Date Title
US4707407A (en) Synthetic water-dispersible fiber
EP0086103B2 (en) Process for producing a non-woven fabric of hot-melt-adhered composite fibers
EP0836655B1 (en) Improvements in polyester filaments and tows
US4713289A (en) Water-dispersible synthetic fiber
EP0396771B1 (en) Wet-process nonwoven fabric and ultrafine polyester fibers therefor
EP0951592B1 (en) Improvements in filament cross sections
GB2132550A (en) Polyester/nylon bicomponent filament
EP0333515A2 (en) Water-dispersible synthetic fibres
EP0198401B1 (en) New water-dispersible synthetic fiber
EP0198400B1 (en) New synthetic water-dispersible fiber
EP0193798A1 (en) Paper-like polyester fiber sheet
JPS6392722A (en) Heat-weldable fiber and nonwoven cloth made thereof
US5145622A (en) Improvements in process for preparing water-dispersible polyester fiber
GB2269603A (en) Process for the production of fluff pulp
JPH0327195A (en) Bulky paper having water-dispersing and dissolving performance and preparation thereof
JPH08246245A (en) Core-sheath conjugate short fiber for nonwoven fabric
WO1993006269A1 (en) Improvement in water-dispersible polyester fiber
NO864927L (en) NEW WATER DISPERSIBLE SYNTHETIC FIBER.