US3457341A - Process for spinning mixed filaments - Google Patents

Process for spinning mixed filaments Download PDF

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Publication number
US3457341A
US3457341A US641524A US3457341DA US3457341A US 3457341 A US3457341 A US 3457341A US 641524 A US641524 A US 641524A US 3457341D A US3457341D A US 3457341DA US 3457341 A US3457341 A US 3457341A
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filaments
yarn
orifices
copolymer
homopolymer
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Expired - Lifetime
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US641524A
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English (en)
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William Joseph Duncan
Charles Frank Fisher
Frank Houston Moye
Samuel Allen Piercy
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EIDP Inc
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EI Du Pont de Nemours and Co
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    • 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
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor

Definitions

  • ABSTRACT OF THE DISCLOSURE A process for producing multilobal mixed filament yarns which increases operability of spinning and yields improved mixed shrinkage yarns.
  • the copolymer is extruded through larger orifices in the same spinneret than the homopolymer while maintaining the relative viscosity of the copolymer at a value at least as high as the homopolymer.
  • This invention relates to the production of synthetic yarns and more particularly to an improved process for multilobal mixed filament synthetic polycarbonamide yarns.
  • United States Patent 3,225,534 discloses and claims differential shrinkage yarns containing filaments of different polymer compositions which shrink differently when heat treated. Such yarns produce fabrics with enhanced bulk, covering power, and desirable aesthetic quality. As disclosed by United States Patent 3,225,534, it is desirable to employ non-round filament shapes such as multilobal filaments in the production of such yarns. Particularly desirable are the trilobal shapes disclosed and claimed in United States Patents 2,939,201 and 2,939,202.
  • the copolymer When diflerent polymer compositions such as a copolymer and a homopolymer are extruded from ditferent orifices in the same spinneret to produce multilobal filaments, the copolymer is usually extruded at the same melt viscosity and consequently at a lower relative viscosity than that of the homopolymer in order to obtain substantially the same cross-sectional shape for the two sets of filaments.
  • the various process elements must be controlled within narrow limits to achieve the desired product characteristics and level of operability.
  • the invention disclosed herein provides an improvement in the process for producing a mixed filament yarn by extruding multilobal filaments from a homopolymer and a copolymer, comprising the steps of (a) maintaining the relative viscosity of the copolymer at least as high as the relative viscosity of the homopolymer; (b) extruding the homopolymer and copolymer through separate orifices in the same spinneret.
  • the orifices through which the copolymer is extruded must be sufliciently larger than the orifices through which the homopolymer is extruded to provide filaments of each which have substantially the same cross-sectional configuration.
  • a further improvement in the process comprises quenching the extruded filaments by directing the flow of quench medium to first impinge upon the copolymer filaments and thereafter to impinge upon the homopolymer.
  • FIGURE I is a schematic diagram of the face of a spinneret 1 showing rows of orifices 2 and 3.
  • FIGURE II is an enlarged schematic cross-sectional view of one of the orifices of row 2.
  • FIGURE III is an enlarged schematic cross-sectional view of one of the orifices of row 3.
  • a 48% aqueous solution of hexamethylenediammonium adipate (66 nylon salt) is charged into an evaporator.
  • a 40% aqueous solution of hexamethylenediammonium isophthalate (6-I nylon salt), prepared by combining equimolar portions of hexamethylenediamine and isophthalic acid, is added to the evaporator in suflicient amount to provide 8% by weight of hexamethylenediammonium isophthalate based on the total weight of dry salt present.
  • the salt solution is then evaporated to a concentration level, at which point the temperature is about 138 C.
  • the 75 salt solution is then charged to an autoclave and heated to a temperature of about 242 C.
  • the pressure is then reduced over a period of 85 minutes to atmospheric pressure and the temperature increased to 270-275" C.
  • the polymer is then held 40 minutes at this temperature and extruded in the form of a ribbon which is quenched on a water-cooled casting wheel and cut into /2 inch flake in the conventional manner.
  • the polymer flake has a relative viscosity of 40.
  • the polyhexamethylene adipamide-polyhexamethylene isophthalamide copolymer (66/ 6-1) flake and the polyhexamethylene adipamide (66) flake, the latter prepared in the conventional manner and having a relative viscosity of 43, are melted separately in screw melters.
  • the relative viscosity of the 66/ 6-1 polymer increases to 45 during processing while the 66 polymer remains at a level of about 43.
  • the two molten polymers are fed separately to separate sand filters of a common spinneret assembly. After filtration the 66 polymer is fed to one row of 7 orifices in the spinneret and the 66/6-I copolymer to an adjacent row of 7 orifices.
  • a meter plate of the type described in United States Patent 3,095,607, is situated above the spinneret to insure denier uniformity among the filaments.
  • the spinneret orifices are Y-shaped and are oriented relative to the quenching air as illustrated in the drawing. Each arm of the Y-shaped orifices through which the 66 polymer is extruded is 3 mils wide and 15 mils long while the copolymer orifices are larger, each arm eing 4 mils wide and 15 mils long.
  • the filaments are quenched in a conventional quenching chamber with cross flow air and converged into a yarn at a guide below the chimney.
  • the yarn is then passed 3 /2 times around a feed roller with its associated separator roll and then 2 /2 times around a draw roll and separator roll, the draw roll having a higher peripheral speed whereby the yarn is drawn to a ratio of 2.5.
  • the yarn is then passed to a second draw roll located in a heated compartment having an air temperature of C. where the yarn is drawn sufliciently to give a total draw ratio of 3.2.
  • the yarn is passed around a second roll in the heated compartment and then back around the draw roll for 7 /2 turns, the second roll having the same peripheral speed as the draw roll so that the yarn is subjected to a constant length heat treatment.
  • the yarn then passes from the heat compartment directly to and around a roll having a lower peripheral speed whereby the yarn is permitted to retract about 2.5% in length.
  • the yarn is then passed through an interlacing jet of the type described in United States Patent 3,069,836.
  • the yarn is then wound into a package in the conventional manner.
  • the denier of the final yarn is 40. Examination of the yarn reveals that the filaments have an average modification ratio of 2.1 and that the 66 filaments do not vary substantially from the 66/ 6-I filaments in this respect.
  • the filaments have a tip radius ratio of 0.25 and a lobe angle of 32 degrees on the average.
  • Properties of the yarn, designated as yarn A are shown in the table below together with other pertinent data.
  • properties of a yarn spun in a similar fashion, designated as yarn B, except that the spinneret orifices are all the same size and the viscosity is varied to give matching modification ratios are also shown in the table.
  • the higher shrinkage differential and slightly higher modulus of yarn A more than offsets the slight reduction in tenacity as compared to yarn B.
  • the processability of the yarn as indicated by filament breaks is far superior for yarn A.
  • the shape of the filament cross section may be defined as disclosed in United States Patent 2,939,201 by the modification ratio, the tip ratio, and arm angle.
  • the modification ratio is the most important parameter and it is a primary objective to provide yarn in which the filaments have substantially the same modification ratio.
  • relative viscosity signifies the ratio of flow time in a viscometer of a polymer solution containing 8.2% by Weight of polymer relative to the flow time of the solvent by itself. Measurements of relative viscosity are made with 5.5 grams of polyamide in 50 ml. of formic acid (90%) at 25 C.
  • the yarn is first conditioned in an atmosphere of 72% relative humidity at 75 for at least 24 hours.
  • Yarn shrinkage is determined using a loop of approximately 70 centimeters in length prepared by carefully tying two ends together so as not to stretch the yarn. The range of the loop is accurately measured as it hangs under a load of 0.1 g.p.d., based on the original denier of the yarn. The measurement is made as quickly as possible after removal of the sample from the yarn package. The loop is then carefully folded in cheese cloth and placed in vigorously boiling water for minutes. It is then dried under relaxed conditions for 20 minutes to 4 hours before the final length measurement. The final length is then determined under a load of 0.1 g.p.d. as previously described. The shrinkage is calculated as the percentage decrease in length based on the original yarn length.
  • the process of this invention surprisingly produces yarns having the desired characteristics, i.e., the desired shrinkage difference between the filaments, strength, etc. at a lower draw ratio than previously achieved. This leads to a marked improvement in process operability, i.e., reduction in broken filaments and increased yield of firstgrade yarn.
  • this process yields yarns With improved characteristics such as higher differential shrinkage and higher modulus, both of which contribute to improved fabric aesthetics.
  • Yarns produced by the process of this invention also have the advantage that the higher shrinkage, load bearing, component has the higher modulus so that the yarn tends to retain its bulk to a greater degree under the stresses imposed in the fabric.
  • the orifices through which the copolymer is extruded must be somewhat larger than the homopolymer orifices. While the relationship between orifice size and modification ratio is somewhat em i ical, an increase in orifice size of about 30-35% will be required Where the viscosity of the copolymer is about the same or slightly higher than that of the homopolymer A further increase in orifice size is required if the copolymer viscosity is increased beyond this point.
  • the increase in size is preferably made by increasing the width of the arms and maintaining the length constant.
  • the spinneret orifices are arranged relative to the flow of quenching medium so that the quenching gas impinges first on the copolymer filaments and then on the homopolymer filaments.
  • the filaments may be wound into a package and subsequently drawn on a drawtwister.
  • the filaments may be passed directly to the drawing stage without intermediate winding into a package.
  • the filaments are subjected to heat treatment after drawing to equalize the retraction of the filaments and prevent loopiness when the filaments are removed from the package for processing into fabric.
  • Homopolyamides suitable for use in the process of this invention include those derivable from polymerizable monoaminocarboxylic acids or their amide-forming derivatives, e.g., polycaproamide and those derived from the reaction of diamines with dicarboxylic acids or their amide-forming derivatives, e.g., polyhexamethylene adipamide.
  • other suitable polyamides are those prepared from the polymers disclosed in United States Patents 2,071,253, 2,130,523, and 2,130,948.
  • the copolymers may be prepared from mixtures of diamines, dibasic acids, and amino acids such as those disclosed in the above patents.
  • the apparatus used to produce the fibers of the invention is of the type disclosed in United States Patent 3,- 095,607.
  • the figures are schematic representations of a spinneret face and orifices therein.
  • the spinneret face has at least two rows of orifices through which molten polymer is extruded to form fibers.
  • the orifices are of a Y configuration having equal angles between each arm of the Y.
  • Row 2 represents copolymer orifices and the orifices from which the homopolymer is extruded are represented by row 3.
  • More than one row of orifices for each of the polymers can be employed without affecting the final product if the arrangement segregates the orifices into two groups, i.e., the copolymer orifices should not be intermingled with the homopolymer orifices.
  • FIGURE II and FIGURE III are enlarged cross-sectional views of a copolymer orifice from row 2 and a homopolymer orifice from row 3, respectively.
  • the relative viscosity of the copolyamide is maintained at a level equal to or higher than the relative viscosity of the homopolyamide, variance in cross section of filaments is encountered if orifices of equal size are used. Therefore, to obtain filaments of substantially equal size and modification ratio, a larger orifice must be used to extrude the copolymer. Preferabl the change in dimension of the orifice is only in the Width of the arm and not in length.
  • FIGURES II and III are representative of the orifices used in the example, a 4 x mil copolymer orifice and a 3 x 15 mil homopolymer orifice.
  • FIGURE I also shows the desired direction of fiow of the quenching medium to obtain optimum operability of the process. If the quenching flow were to impinge first upon the newly spun homopolymer filament, some blowing of the homopolymer stream into the adjacent c0- polymer stream would be encountered. This cannot be tolerated in an efificient operation, thus the fiow of quenching medium is directed first to impinge upon the co olymer stream and then upon the homopolymer stream.
  • a process for producing a mixed filament yarn by extruding multilobal filaments from a homopolyamide and a copolymer of said homopolyamide comprising the steps of (a) maintaining the relative viscosity of said copolymer at least as high as the relative viscosity of said homopolyamide, (b) extruding said homopolyamide and said copolymer through a plurality of separate orifices in the same spinneret, said orifices through which said copolymer is extruded being sufficiently larger than said orifices through which said homopolyamide is extruded to provide filaments of said copolymer and homopolyamide having substantially the same cross section.
  • the relative viscosities of the said polyamides being at least 40.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Artificial Filaments (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
US641524A 1967-05-26 1967-05-26 Process for spinning mixed filaments Expired - Lifetime US3457341A (en)

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US64152467A 1967-05-26 1967-05-26

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US (1) US3457341A (instruction)
BE (1) BE715620A (instruction)
FR (1) FR1567531A (instruction)
LU (1) LU56146A1 (instruction)
NL (1) NL6807280A (instruction)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514350A (en) * 1982-09-23 1985-04-30 Celanese Corporation Method for melt spinning polyester filaments
US4605364A (en) * 1982-09-23 1986-08-12 Celanese Corporation Melt-spinning apparatus for polyester filaments
US4812361A (en) * 1984-11-21 1989-03-14 Mitsubishi Rayon Co., Ltd. Acrylic fiber having Y-type section and process for producing the same
US5234650A (en) * 1992-03-30 1993-08-10 Basf Corporation Method for spinning multiple colored yarn
US5652001A (en) * 1993-05-24 1997-07-29 Courtaulds Fibres Limited Spinnerette
US6103181A (en) * 1999-02-17 2000-08-15 Filtrona International Limited Method and apparatus for spinning a web of mixed fibers, and products produced therefrom
US20050072737A1 (en) * 2003-08-21 2005-04-07 Ward Bennett Clayton Polymeric fiber rods for separation applications
US20050136781A1 (en) * 2003-12-22 2005-06-23 Lassig John J. Apparatus and method for nonwoven fibrous web
US20050151805A1 (en) * 2002-12-23 2005-07-14 Ward Bennett C. Porous substrate for ink delivery systems
US20050189292A1 (en) * 2004-03-01 2005-09-01 Filtrona Richmond, Inc. Bicomponent fiber wick
US20050221082A1 (en) * 2002-03-01 2005-10-06 Marlow Stephen W Methods for the maunfacture of mixed polyamide yarns
US20060012072A1 (en) * 2004-07-16 2006-01-19 Hagewood John F Forming shaped fiber fabrics
US20060034886A1 (en) * 2004-07-23 2006-02-16 Ward Bennett C Bonded fiber structures for use in controlling fluid flow
US20100084783A1 (en) * 2002-11-12 2010-04-08 Fiberweb Corovin Gmbh Non-round spinneret plate hole
CN109790644A (zh) * 2016-09-30 2019-05-21 米歇尔.范德威尔公司 喷丝头

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3161914A (en) * 1961-07-28 1964-12-22 British Nylon Spinners Ltd Spinnerets for producing heterofilaments
US3225534A (en) * 1961-03-31 1965-12-28 Du Pont Differential shrinkage yarn
US3244785A (en) * 1962-12-31 1966-04-05 Du Pont Process for producing a composite sheath-core filament
US3271837A (en) * 1964-09-25 1966-09-13 Du Pont Method of manufacturing stockings from two-component filaments
US3297807A (en) * 1964-08-05 1967-01-10 Schweizerische Viscose Process for the manufacture of spontaneously crimping composite filaments
US3320633A (en) * 1965-08-25 1967-05-23 Du Pont Apparatus for forming two component yarns
US3341891A (en) * 1962-08-06 1967-09-19 Toyo Rayon Co Ltd Production of a composite filament and a spinneret assembly
US3365873A (en) * 1964-09-26 1968-01-30 Kanebo Ltd Method of treating a composite filament

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3225534A (en) * 1961-03-31 1965-12-28 Du Pont Differential shrinkage yarn
US3161914A (en) * 1961-07-28 1964-12-22 British Nylon Spinners Ltd Spinnerets for producing heterofilaments
US3341891A (en) * 1962-08-06 1967-09-19 Toyo Rayon Co Ltd Production of a composite filament and a spinneret assembly
US3244785A (en) * 1962-12-31 1966-04-05 Du Pont Process for producing a composite sheath-core filament
US3297807A (en) * 1964-08-05 1967-01-10 Schweizerische Viscose Process for the manufacture of spontaneously crimping composite filaments
US3271837A (en) * 1964-09-25 1966-09-13 Du Pont Method of manufacturing stockings from two-component filaments
US3365873A (en) * 1964-09-26 1968-01-30 Kanebo Ltd Method of treating a composite filament
US3320633A (en) * 1965-08-25 1967-05-23 Du Pont Apparatus for forming two component yarns

Cited By (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514350A (en) * 1982-09-23 1985-04-30 Celanese Corporation Method for melt spinning polyester filaments
US4605364A (en) * 1982-09-23 1986-08-12 Celanese Corporation Melt-spinning apparatus for polyester filaments
US4812361A (en) * 1984-11-21 1989-03-14 Mitsubishi Rayon Co., Ltd. Acrylic fiber having Y-type section and process for producing the same
US5234650A (en) * 1992-03-30 1993-08-10 Basf Corporation Method for spinning multiple colored yarn
US5393219A (en) * 1992-03-30 1995-02-28 Basf Corporation Apparatus for spinning different colored filaments from a single spinneret
USRE35108E (en) * 1992-03-30 1995-12-05 Basf Corporation Method for spinning multiple colored yarn
US5652001A (en) * 1993-05-24 1997-07-29 Courtaulds Fibres Limited Spinnerette
US6602311B2 (en) * 1999-02-17 2003-08-05 Richard M. Berger Method and apparatus for spinning a web of mixed fibers, and products produced therefrom
EP1154707A4 (en) * 1999-02-17 2009-05-13 Filtrona Richmond Inc METHOD AND APPARATUS FOR SPINNING A NETWORK FROM MIXED FIBERS AND PRODUCTS MANUFACTURED THEREFROM
US6103181A (en) * 1999-02-17 2000-08-15 Filtrona International Limited Method and apparatus for spinning a web of mixed fibers, and products produced therefrom
US7585440B2 (en) * 2002-03-01 2009-09-08 Invista North America S.A R. L. Methods for the manufacture of mixed polyamide yarns
US20050221082A1 (en) * 2002-03-01 2005-10-06 Marlow Stephen W Methods for the maunfacture of mixed polyamide yarns
AU2002245686B2 (en) * 2002-03-01 2008-09-18 Invista Technologies S.A.R.L. Methods for manufacture of mixed polyamide yarns
US20100084783A1 (en) * 2002-11-12 2010-04-08 Fiberweb Corovin Gmbh Non-round spinneret plate hole
US7018031B2 (en) 2002-12-23 2006-03-28 Filtrona Richmond, Inc. Porous substrate for ink delivery systems
US20050151805A1 (en) * 2002-12-23 2005-07-14 Ward Bennett C. Porous substrate for ink delivery systems
US7291263B2 (en) 2003-08-21 2007-11-06 Filtrona Richmond, Inc. Polymeric fiber rods for separation applications
US20050072737A1 (en) * 2003-08-21 2005-04-07 Ward Bennett Clayton Polymeric fiber rods for separation applications
US7168932B2 (en) 2003-12-22 2007-01-30 Kimberly-Clark Worldwide, Inc. Apparatus for nonwoven fibrous web
US20050136781A1 (en) * 2003-12-22 2005-06-23 Lassig John J. Apparatus and method for nonwoven fibrous web
US7290668B2 (en) 2004-03-01 2007-11-06 Filtrona Richmond, Inc. Bicomponent fiber wick
US20050189292A1 (en) * 2004-03-01 2005-09-01 Filtrona Richmond, Inc. Bicomponent fiber wick
US20060012072A1 (en) * 2004-07-16 2006-01-19 Hagewood John F Forming shaped fiber fabrics
US20060034886A1 (en) * 2004-07-23 2006-02-16 Ward Bennett C Bonded fiber structures for use in controlling fluid flow
CN109790644A (zh) * 2016-09-30 2019-05-21 米歇尔.范德威尔公司 喷丝头
US10982352B2 (en) * 2016-09-30 2021-04-20 Nv Michel Van De Wiele Spinneret

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Publication number Publication date
NL6807280A (instruction) 1968-11-27
FR1567531A (instruction) 1969-05-16
LU56146A1 (instruction) 1968-09-11
BE715620A (instruction) 1968-10-16

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