US3436298A - Fused fibers of monoolefin polymers and method of manufacture - Google Patents

Fused fibers of monoolefin polymers and method of manufacture Download PDF

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Publication number
US3436298A
US3436298A US517107A US51710765A US3436298A US 3436298 A US3436298 A US 3436298A US 517107 A US517107 A US 517107A US 51710765 A US51710765 A US 51710765A US 3436298 A US3436298 A US 3436298A
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United States
Prior art keywords
fibers
fiber
polymer
assemblage
salt
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Expired - Lifetime
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US517107A
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English (en)
Inventor
George C Oppenlander
Walter W Thomas
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Hercules LLC
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Hercules LLC
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Filing date
Publication date
Application filed by Hercules LLC filed Critical Hercules LLC
Priority to US517107A priority Critical patent/US3436298A/en
Priority to DK636466AA priority patent/DK114334B/da
Priority to DE19661669438 priority patent/DE1669438A1/de
Priority to FR48107A priority patent/FR1514229A/fr
Priority to BE691918D priority patent/BE691918A/xx
Application granted granted Critical
Publication of US3436298A publication Critical patent/US3436298A/en
Anticipated expiration legal-status Critical
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/098—Metal salts of carboxylic acids
    • 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
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric

Definitions

  • This invention relates to novel structures which are bonded assemblages of polyolefin fibers and to a process for producing the same.
  • Assemblages of polyolefin fibers have found many uses such as in nonwoven and woven fabrics, backing materials for pile fabrics, filter cloths, tobacco smoke filters, ropes, yarn tapes, clothing insulation, blankets, surgical dressings, inner soles for shoes, gasket material, and the like. For many of these uses it is important that the fibers in the assemblage be interlocked or bonded to other fibers of the structure. This bonding or interlocking of the fibers gives a cohesion to the structure as well as additional strength.
  • bonded assemblages of polyolefin fibers can be prepared by a process which avoids all of the above difiiculties.
  • This process comprises forming an assemblage of fibers comprising fibers of a polymer of an zx-monoolefin containing from about 0.2% to about 10% by weight of the polymer of a carboxylic acid salt of a metal selected from the group consisting of calcium, barium, iron, nickel, and cobalt, said salt having a melting temperature below the temperature at which the fiber is 3,436,298 Patented Apr.
  • the assemblage can comprise exclusively these so-called metal salt-modified fibers, i.e., fibers of a polymer of an a-monoolefin containing the metal salt of a carboxylic acid, or it can comprise a blend of these metal salt-modified fibers with other fibers, either synthetic or natural, such as, for example, fibers or unmodified polypropylene, polyester, polyamide, acrylic polyers, poly(vinyl chloride), poly(vinylene chloride), viscose or acetate rayon, cotton, glass, and the like, provided, of course, sufiicient of the metal salt-modified fibers are present to accomplish bonding in accordance with the present invention.
  • the fibers employed in the process of the invention are, as stated above, of polymers of an ot-monoolefin containing from about 0.2% to about 10%, based on the Weight of the polymer, of the metal salt of a carboxylic acid.
  • Particularly useful for these fibers are the homopolyrners, copolymers, and terpolymers of ethylene and a-monoolefins having from 3 to 6 carbon atoms, including, for instance, polyethylene, polypropylene, poly(butene-l), poly(pentene-l), poly(3-methylbutene-l), and poly (4- methylpentene-l), copolymers of ethylene and propylene, terpolymers of ethylene, propylene and diene such as dicyclopentadiene, and the like.
  • the metal salts of the present invention are calcium, barium, iron, nickel, or cobalt salts of carboxylic acids and have melting temperatures below the temperature at which the fiber is spun.
  • the carboxylic acid component of such salts are organic acids containing one or more carboxyl groups and can be either saturated or unsaturated. Particularly preferred are the aliphatic acids, i.e., acyclic or alicyclic acids containing from 4 to 20 carbon atoms, and most preferably fatty acids containing 8 to 18 carbon atoms.
  • Such salts include, by way of example, salts of isobutyric, isovaleric, caproic, 2- ethylbutyric, Z-methylpentanoic, n-octanoic, 2-ethylhexanoic, 2,2,4,4-tetramethylpentanoic, 2,4,6-trimethylheptanoic, 5,7-dimethyloctanoic, pelargonic, lauric, tridecanoic, myristic, palmitic, stearic, naphtenic, 3-methylcyclohexane carboxylic, 4-isopropylcyclohexane carboxylic, cyclohex ane acetic, bicyclo(2,2,1) heptane carboxylic, octly succinic, Z-decylglutaric, 2,5-dibutyl adipic, sebacic, oleic, linoleic, a-pheny
  • the metal salts of mixtures of acids are also suitable.
  • the salts can be employed as such or can be used as mixtures thereof with other of the metal salts or with the free acid.
  • the use of a 2:1 to 5:1 mixture of the metal salt and a carboxylic acid having 4 to 18 carbon atoms is particularly preferred.
  • the metal salts can 'be admixed with the polyolefin by any of the usual procedures for incorporating an additive in a solid material.
  • a simple method is to dissolve the metal salt in a low boiling solvent such as benzene. or acetone and, after thoroughly mixing the solution with the polyolefin in flake or other such form, evaporating the solvent; or it can be incorporated by various means of mechanical mixing, as by grinding, milling, or the like.
  • the amount of the metal salt incorporated in the polyolefin can vary from about 0.2% up to about 10% by weight of the polyolefin, or higher. Normally, a maximum amount of about 4% will be sufiicient to accomplish the objects of the present invention. The optimum amount Will usually be between about 0.4 and about 2%, depending primarily upon the particular metal salt employed and the degree of bonding desired.
  • the polyolefin can also contain small amounts of stabilizers, such as heat and light stabilizers, ultraviolet light absorbers, antacids such as calcium soaps, antioxidants, and the like, as well as other materials such as pigments, dyes, fillers, and the like, provided they do not interfere with the process of the invention.
  • stabilizers such as heat and light stabilizers, ultraviolet light absorbers, antacids such as calcium soaps, antioxidants, and the like, as well as other materials such as pigments, dyes, fillers, and the like, provided they do not interfere with the process of the invention.
  • the fibers employed in the assemblages of this invention can be monofilaments or multifilaments and are prepared by the well-known procedures normally used for the preparation of synthetic fibers. Briefly, this comprises extruding or spinning the molten polyolefin containing the metal salt through an orifice containing a single hole or a plurality of very fine holes, and then drawing the polymer away from the orifice, preferably at a greater rate than the rate of extrusion to effect a substantial drawdown of the filament in the molten state prior to solidification thereof.
  • the conditions and particularly the temperature for melt-spinning polyolefins into fibers are well known to the art and can vary over a relatively wide range depending upon the physical and chemical properties of the polyolefin and can even vary for identical compositions according to the preference of skilled operators. In general, temperatures within the range of about 200 to about 325 C., and preferably from about 250 to about 300 C., will normally produce a melt of sufficient fluidity to fiow evenly from the orifice.
  • the solidified filaments can then be combined into a multifilament yarn and subjected to a cold draw at a temperature below the melting point whereby a desired amount of molecular orientation is imparted to the fiber. If desired, these molecularly oriented filaments can then be crimped, usually by mechanical means such as a stufling box crimper and/ or chopped into relatively short staple fibers, usually on the order of one to several inches in length.
  • the fibers used in the invention can advantageously be prepared by the procedure described above, it must be understood that the process is not so limited.
  • the molecular orientation step can be omitted if the greater dimensional stability of the unoriented fiber under the influence of heat is desired.
  • the crimping step can be omitted if uncrimped fiber is desired, or the chopping step can be omitted if continuous filament is desired.
  • the invention can be practiced with assemblages of fibers prepared by any method known to the art. Thus, it is applicable to bundles of continuous filament, crimped or otherwise, or of short fibers or staple yarns, nonwoven webs of randomly deposited fibers, nonwoven webs having individual fibers oriented or aligned along a particular axis, woven fabrics of the fibers, knit fabrics of the fiber, groupings of continuous filament laid up parallel to each other, and the like.
  • the invention is especially valuable for nonwoven webs wherein the fibers are randomly deposited since in these webs the entanglement of the fibers yields a greater number of potential bOnding sites, and to needle-punched nonwoven webs wherein the degree of fiber entanglement is even further increased.
  • the fused assemblages of the invention such as, for example, fused tapes or yarns, can also be used as such or can be knitted or woven, with or without other fibrous materials, into fabrics for such uses as carpet backings and the like.
  • the type of bond which is produced in the practice of the present invention is unlike the prior art bonds in that it is a unique surface adhesion of fiber to fiber at points of contact between them and is the result of a heatsoftening or tackifying of the surface of the fiber at a temperature below the crystalline melting point of the polymer followed by a cooling, whereby the softened surfaces of the fiber solidify and become bonded to other fibers at points of contact therewith.
  • a heatsoftening or tackifying of the surface of the fiber at a temperature below the crystalline melting point of the polymer followed by a cooling, whereby the softened surfaces of the fiber solidify and become bonded to other fibers at points of contact therewith.
  • the presence of the metal salt in the polyolefin fiber may create at the surface of the fiber during heating uniquely reactive or heat-sensitive sites either by exudation or chemical reaction or otherwise, whereby the surface of the fiber becomes selectively tackier and more adherent.
  • the metal salt-modified fibers it is certain that with the metal salt-modified fibers it is possible by the present invention to create well-bonded fibrous structures without adversely affecting the elevated temperature shrinkage and strength properties of the polyolefin fibers.
  • the heating of the assemblage can be carried out in any desired manner using methods well known to the art, as, for example, using a heated press, hot calender rolls or drum dryers and the like or by heating with hot air, infrared radiation, or high frequency means, i.e., dielectric heating or the like.
  • the temperature at which the assemblage is heated is below the crystalline melting temperature of the polymer but is sufliciently high to heat-soften the surface of the fiber to make it tacky or sticky without at the same time substantially affecting the fibrous structure or strength properties of the fiber.
  • the maximum temperature at which such assemblages can be heated will vary, of course, with the particular polymer employed. Preferably, the maximum temperature will range from about 10 to 15 C. below the crystalline melting point of the polymer since at or below such maximum temperature, optimum structural and strength properties are obtained.
  • RSV denotes reduced specific viscosity, which is the specific viscosity divided by concentration of a 0.1% weight/volume solution of polymer in decahydronaphthalene at 135 C. All parts and percentages are by weight unless otherwise stated, and the percentage of additives is based on the weight of the polymer unless otherwise specified.
  • EXAMPLE 1 Stereoregular polypropylene having a birefringent melting point of about 172 C. and an RSV of 3.2 and containing 0.15% of the reaction product of 2 moles of nonylphenol and 1 mole of acetone (the reaction product comprising a mixture of isopropylidene-bis(nonylphenol) and 2(2'-hydroxyphenyl) 2,4,4 trimethyl-5,6-dinonyl chroman) as antioxidant, was thoroughly blended with 0.92% of a commercial nickel octate consisting of a 3:1 mixture of nickel-Z-ethylhexanoate and 2-ethylhexanoic acid (total nickel content, 13%).
  • a commercial nickel octate consisting of a 3:1 mixture of nickel-Z-ethylhexanoate and 2-ethylhexanoic acid (total nickel content, 13%).
  • the blend was melt spun into continuous filament yarns (820 denier/35 filament) at 550 F.
  • the fusion temperature of the yarn was determined by plying 4 filaments and then drawing the plied yarn from 220 F. feed rolls at 450 ft./min. onto a pair of 6" diameter heated draw rolls using 13 wraps of the yarn, the draw roll temperature being increased in 10 F. increments until the filaments fused into a ribbon in which the filaments could be stripped apart.
  • a carpet backing fabric woven from the fused ribbon (2 mils thick and mils wide) of this example had a good appearance and feel and gave excellent tufting performance.
  • Example 2 The procedure of Example 1 was repeated except that various amounts of other nickel salts were substituted for the nickel octate mixture of Example 1.
  • the compositions of these examples and the fusion temperatures of the ribbons therefrom are tabulated below.
  • Nickels, additive ,Zgjffi 1.
  • an assemblage of pg fibers comprising fibers of polymer of an a-monoolefin 5 containing from about 0.2% to about based on 2 i- Y 310 the weight of the polymer, of a carboxylic acid salt of 3 290 a metal selected from the group consisting of calcium,
  • the article of claim 1 wherein the assemblage is EXAMPLES 9 TO 13 a nonwoven fabric.
  • the products of eompnses tormmg an assemblage 0t fibers eofnpnsmg each of these examples were soft and fibrous and possessed fibers of a Polymer of an 'monoolefin eontemmg from good Strength about 0.2% to about 10% based on the weight of the
  • the bonded fabrics were conditioned for at least 24 polymer of eereoxyhe e Salt metal seleeted from hours at 50% relative humidity and 73 F. and then tested the P calcwfll; barlumi mckel, and according to ASTM Method D 1117 63 to determine cobalt, said salt having a meltlng temperature below the their tensile strength, elongation and fabric weight.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
US517107A 1965-12-28 1965-12-28 Fused fibers of monoolefin polymers and method of manufacture Expired - Lifetime US3436298A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US517107A US3436298A (en) 1965-12-28 1965-12-28 Fused fibers of monoolefin polymers and method of manufacture
DK636466AA DK114334B (da) 1965-12-28 1966-12-08 Fremgangsmåde til fremstilling af et varmebundet fiberprodukt.
DE19661669438 DE1669438A1 (de) 1965-12-28 1966-12-21 Verbundene Vereinigungen von Polyolefinfasern
FR48107A FR1514229A (fr) 1965-12-28 1966-12-27 Structure fusionnée et son procédé de préparation
BE691918D BE691918A (enrdf_load_stackoverflow) 1965-12-28 1966-12-28

Applications Claiming Priority (1)

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US517107A US3436298A (en) 1965-12-28 1965-12-28 Fused fibers of monoolefin polymers and method of manufacture

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US3436298A true US3436298A (en) 1969-04-01

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US517107A Expired - Lifetime US3436298A (en) 1965-12-28 1965-12-28 Fused fibers of monoolefin polymers and method of manufacture

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US (1) US3436298A (enrdf_load_stackoverflow)
BE (1) BE691918A (enrdf_load_stackoverflow)
DE (1) DE1669438A1 (enrdf_load_stackoverflow)
DK (1) DK114334B (enrdf_load_stackoverflow)
FR (1) FR1514229A (enrdf_load_stackoverflow)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3650866A (en) * 1969-10-09 1972-03-21 Exxon Research Engineering Co Increasing strip tensile strength of melt blown nonwoven polypropylene mats of high tear resistance
EP0107758A3 (en) * 1982-08-09 1985-01-09 Merak S.P.A. Polyolefinic fibres having improved thermal bonding properties and process for obtaining same
US5135804A (en) * 1983-02-18 1992-08-04 Allied-Signal Inc. Network of polyethylene fibers
US5629080A (en) * 1992-01-13 1997-05-13 Hercules Incorporated Thermally bondable fiber for high strength non-woven fabrics
US5705119A (en) * 1993-06-24 1998-01-06 Hercules Incorporated Process of making skin-core high thermal bond strength fiber
US5882562A (en) * 1994-12-19 1999-03-16 Fiberco, Inc. Process for producing fibers for high strength non-woven materials
US5985193A (en) * 1996-03-29 1999-11-16 Fiberco., Inc. Process of making polypropylene fibers
US6458726B1 (en) 1996-03-29 2002-10-01 Fiberco, Inc. Polypropylene fibers and items made therefrom

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3049466A (en) * 1957-04-23 1962-08-14 Reeves Bros Inc Method of bonding fibrous structures made from fibers or filaments of polyolefine polymers
US3322607A (en) * 1964-08-17 1967-05-30 Du Pont Lubricated polypropylene polyethylene self-bonded nonwoven carpet backing

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3049466A (en) * 1957-04-23 1962-08-14 Reeves Bros Inc Method of bonding fibrous structures made from fibers or filaments of polyolefine polymers
US3322607A (en) * 1964-08-17 1967-05-30 Du Pont Lubricated polypropylene polyethylene self-bonded nonwoven carpet backing

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3650866A (en) * 1969-10-09 1972-03-21 Exxon Research Engineering Co Increasing strip tensile strength of melt blown nonwoven polypropylene mats of high tear resistance
EP0107758A3 (en) * 1982-08-09 1985-01-09 Merak S.P.A. Polyolefinic fibres having improved thermal bonding properties and process for obtaining same
US5135804A (en) * 1983-02-18 1992-08-04 Allied-Signal Inc. Network of polyethylene fibers
US5629080A (en) * 1992-01-13 1997-05-13 Hercules Incorporated Thermally bondable fiber for high strength non-woven fabrics
US5654088A (en) * 1992-01-13 1997-08-05 Hercules Incorporated Thermally bondable fiber for high strength non-woven fabrics
US5733646A (en) * 1992-01-13 1998-03-31 Hercules Incorporated Thermally bondable fiber for high strength non-woven fabrics
US5888438A (en) * 1992-01-13 1999-03-30 Hercules Incorporated Thermally bondable fiber for high strength non-woven fabrics
US5705119A (en) * 1993-06-24 1998-01-06 Hercules Incorporated Process of making skin-core high thermal bond strength fiber
US6116883A (en) * 1993-06-24 2000-09-12 Fiberco, Inc. Melt spin system for producing skin-core high thermal bond strength fibers
US5882562A (en) * 1994-12-19 1999-03-16 Fiberco, Inc. Process for producing fibers for high strength non-woven materials
US5985193A (en) * 1996-03-29 1999-11-16 Fiberco., Inc. Process of making polypropylene fibers
US6458726B1 (en) 1996-03-29 2002-10-01 Fiberco, Inc. Polypropylene fibers and items made therefrom

Also Published As

Publication number Publication date
DK114334B (da) 1969-06-23
DE1669438A1 (de) 1969-10-23
FR1514229A (fr) 1968-05-10
BE691918A (enrdf_load_stackoverflow) 1967-06-28

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