US3491178A - Method for spinning bicomponent polypropylene filaments - Google Patents

Method for spinning bicomponent polypropylene filaments Download PDF

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Publication number
US3491178A
US3491178A US774541A US3491178DA US3491178A US 3491178 A US3491178 A US 3491178A US 774541 A US774541 A US 774541A US 3491178D A US3491178D A US 3491178DA US 3491178 A US3491178 A US 3491178A
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Prior art keywords
filaments
crimp
filament
percent
heat
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Expired - Lifetime
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US774541A
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English (en)
Inventor
Morio Nishioka
Toshiyuki Nanbu
Hiroyuki Nakamura
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Mitsubishi Rayon Co Ltd
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Mitsubishi Rayon Co Ltd
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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
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • 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
    • D01D5/23—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool by asymmetrical cooling of filaments, threads, or the like, leaving the spinnerettes
    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/26—Composite fibers made of two or more materials

Definitions

  • This invention relates to composite polypropylene fibers and methods for producing the same. More' particularly this invention relates to composite polypropylene fibers having superior crimp characteristics and methods for producing the same.
  • Polypropylene fibers have many advantages such as low specific gravity, high tenacity, high abrasion resistance, high elasticity, small creep and the like, but they are inferior to wool in the point of bulkiness. Excellent bulk of wool is based upon its characteristic crimps. Hence, many attempts have been made to produce polypropylene fibers having wool-like appearance and high bulkiness by crimping the fibers while retaining their well-known advantages.
  • Crimped polypropylene fibers have been heretofore produced by means of mechanical crimping process while utilizing their thermoplasticity as in the case of other thermoplastic fibers. Since the mechanical crimping process has various drawbacks, a process which is characterized in producing crimped fibers by providing fibers with potential crimp at the step of spinning and relaxing them at a step after stretching has been developed recently. According to this process, it is possible to omit the mechanical processing step necessary to produce crimped fibers.
  • An object of the present invention is to provide polypropylene composite fibers having superior properties and excellent crimp characteristics and to provide methods for producing the same.
  • Another object of the present invention is to produce polypropylene composite fibers having high percentage of crimp and high stability of crimp and to provide methods for producing the same.
  • a still further object of the present invention is to provide polypropylene composite fibers having good appearance and uniform crimps and to provide methods for producing the same.
  • two kinds of propylene type polymers are spun into composite filaments in such a way as at least one kind of polymer possesses more than 0.2 of beta-orientation and more than 1.2 of intrinsic viscosity [1;] and the difference of birefringence of the two polymers is more than 5x10 in the state of unstretched filament, resulting unstretched filaments are stretched at a temperature lower than C. and then relaxed to develop crimps.
  • the beta-orientation described here and elsewhere herein is a measure which indicates degree of orientation of microcrystal in fibers.
  • the intrinsic viscosity [17L- is that of polymers in fiber state and measured in tetraline at a temperature of C.
  • the difference of bircfringence of the two polymers in a composite filament can be found by following procedure. In the case of sideby-side composite filament such as shown in figure, the retardation R and R in A and B parts can be measured individually in both dotted line zones of A and B parts by interference color and diagram of interference.
  • the thickness of each part can be calculated by assuming x and y coordinate having its origin at the center of fiber cross-section, measuring x coordinates of parts indicating interference colors at both A and B parts X and X and calculating Y and Y from the equation of circle.
  • the thickness of two parts are 2Y and ZY Let ZY be d and 2Y be d then birefringence in both A and B parts can be calculated by equations of Thus the difference of birefringence can be calculated from the following equation,
  • propylene polymers having intrinsic viscosities of 0.8 to 3.5 measured at the state of polymer are used.
  • a homopolymer of propylene can be used by itself but in general propylene polymer containing various stabilizers, fillers, plasticizers, substances capable to give fluidity and the like are used.
  • 2-hydroxy-4-octoxy-benzophenone 2-hydroxy-4-dodecyloxy benzophenone
  • 2-[2'- hydroxy-5'-(l,1,3,3 tetramethyl butyl)phenyl]benzotriazole and the like are useful.
  • trioctadecyl phosphite didodecyl-3.3'-thiodipropionate, dioctadecyl 3.3- thio dipropionate, diethyl-l1.l1'-thio undecanate, tridodecyl phosphite, dodecyl sulfide, octadecyl sulfide and the like can be used.
  • silicon oxide, titanium dioxide, and as plasticizers tricresyl phosphate, dioctyl phthalate and sebacate, decyl dilauryl stearate and the like are used.
  • modified propylene polymers are preferably used instead of propylene homopolymer.
  • propylene polymers containing 1 to 30 percent of vinyl pyridine polymer or copolymers those containing 1 to 20 percent of polyesters such as polyethylene terephthalate, those containing 1 to 20 percent of metal salt of alkylester of sulfoisophthalic acid, those graft-copolymerized with vinyl pyridine, those graft-copolymerized with vinyl pyridine and styrene, those graft-copolymerized with various vinyl compounds and those containing one or more than one kind of the compounds represented by a general formula of (in which R is an alkyl radical having 7 to 29 carbon atoms, R is an alkyl radical having 1 to 18 carbon atoms, M is Al, Zn, or Mg, m and n are either 1 or 2, m+n is always 2 or 3, R is an alkyl radical having 7 to 29 carbon atoms, M is Zn, Al, Sn or C0, m is 1, 2 or 3, n
  • propylene polymers admixed with emulsifiercontaining vinyl pyridine, those admixed with vinyl pyridine copolymer and dyeing assistant, those admixed with sulfophthalic acid alkylester, those containing polyethylene and metal salt of higher fa y a id or normal hydrocarbon having molecular weight of 500 to 3000, those con taining fluid paraffine, kerosene or tetrachloroethane, those containing a compound represented by a formula of (in which R is hydrogen atom, alkyl radical, alkoxy radical or acyl radical, Y is hydrogen atom or hydroxy radi cal, Z is S, SO, S0 CH or CO, M is Co, Ni, Zn or Al) alone or together with metal alcoholate of higher aliphatic acid and/ or basic metal salt of higher fatty acid, are also preferably used.
  • composition of two kinds of propylene polymers may be different or the same.
  • two kinds of propylene polymers having different intrinsic viscosities at the state just before spinning are preferably used.
  • the difference of intrinsic viscosities of polymers in the state of fiber is preferably less than 0.6.
  • at least one kind of polymer must possess an intrinsic viscosity [i of at least 1.2.
  • Two kinds of propylene polymers are heated to melt at a temperature of 170 C. to 320 C. and spun to form composite filaments.
  • the heating temperature of two kinds of polymer can be different. Accordingly the object of the present invention can be attained by heating to melt two kinds of propylene polymers having the same intrinsic viscosity [:1] and the same composition at different temperature and spinning to produce composite filaments. And the object of the present invention can also be achieved by spinning two propylene polymers having the same intrinsic viscosity but different composition.
  • Extruded filaments are generally taken up at a velocity of 200 to 1000 m./min. to give unstretched filaments.
  • at the state of unstretched filaments at least one kind of polymer possesses more than 0.2 of B-orientation and more than 1.2 of intrinsic viscosity Besides these, it is necessary to select spinning temperature, cooling condition, take-up speed and the like such a way that the difference of birefringence of two polymers becomes more than 5 10 preferably more than 10 10- When these conditions are not satisfied, poly propylene composite fibers having superior properties and crimp characteristics cannot be produced. Unstretched filaments are stretched at a temperature lower than 80 C. and then relaxed to develop crimps. When the stretching temperature is higher than 80 C.
  • the stretch ratio is in general, 2 to 4 times. Even when stretched filaments are relaxed at room temperature, it is possible to develop crimps but when stretched filaments are heated by dry hot air, hot water, steam and the like in a relaxed state, it is possible to develop greater amount of crimp and to increase the stability of crimp.
  • Heat treatment may be carried out at the state of skein or between two sets of rollers.
  • spinning apparatus'lt is also possible to use well-known apparatus in which the arrangement of orifices at the surface of spinneret is improved.
  • filaments can be subjected to heat treatment in a relaxed state, but it is also possible to apply heat treatment in a relaxed state to knitted or woven fabrics directly converted from filaments wound up on bobbins or pirns.
  • heat treatment can be carried out at various steps. Filaments are cut into suitable length and spun into yarns after being stretched and/or heat-treated. Blend spinning and mixed weaving with other fibers may be possible. Fibers thus obtained possess not only high crimp recovery but also high elasticity.
  • these fibers show the function of elastic fibers after finishing the function of crimped fibers.
  • the utilities of fibers are exceedingly enlarged.
  • they are used as filaments like conventional processed yarns, and are used as staple fibers by controlling the development of crimps. From these staple fibers, fabric cloths having high stretchability can be produced.
  • stretched filaments are (d) maintained at the state under tension of less than 3 mg./d., and then heat treated under tension while giving 5 to 50 percent of shrinkage or (e) alternatively, are heat-treated at a temperature of 60 C. to 140 C. while over-feeding 5 to 30 percent. It is preferable to determine various conditions of overfeed amount, heat treatment temperature, and heat treatment time so as to give less than 10 percent of shrinkage of resulting filaments. This heat-treatment for relaxation can be carried out continuously with other step.
  • the stretched filaments are first provided with more than 0.1 g./d. of tension, then maintained under tension of less than 0.003 g./d., subsequently subjected to heat treatment under tension while giving 5 to 50 percent of shrinkage.
  • heat-treating stretched filaments for relaxation under slight tension it is possible to prevent yarn from forming local clusters of the yarn-constructing filaments.
  • clustered filaments are present in yarn, the development of crimps after heat shrinkage treatment is not sufiicient and not uniform and appearance of crimped filaments is not preferable.
  • EXAMPLE 1 Two kinds of polypropylene were made into composite filaments at conditions shown in Table 1 by use of spinning apparatus of screw-gear pump type and subjected to stretching. The spinning ratio of two kinds of polypropylenes was 50:50. Spun filaments were in crimped state when they were made into skein after being stretched but for the more sufiicient crimp development, they were heat-treated for 30 minutes by steam of C. in a relaxed state. Properties of resulting filaments are shown an intrinsic viscosity of more than 1.2, and wherein two in Table 1. In this table, Nos. 7 to 10 were control. polymers in said filaments have a difference in blrefrlng- TABLE 1 A component B component Spinning Spinning Spinning temp. at temp. at temp. at Experiment N o. nozzle C.) [1;]0 screw C.) [1 B-orientatlon AnX10 [1;]G screw C.)
  • This polymer contained 10 percent by weight of fluid parafline.
  • [ 11G means intrinsic viscosity of pelleted polymer.
  • b-c Percentage of crimp recovery 100 ex OrimptSstability is the percentage of recovery length at the 10th time to that at the first time after repetition of 10 times of the above-mentioned perimen EXAMPLE 2 ence of more than 5 10 and a difference in intrinsic viscosity of less than 0.6, said producing step including the steps of melting at least one propylene polymer having an intrinsic viscosity of 1.0 to 2.8 at a temperature of 170320 C., composite spinning the polymer to form composite filaments and taking up the filaments at a velocity of 200 to 1000 m./min., stretching the filaments to 2 to 4 times, and relaxing the stretched filaments.
  • a method according to claim 1 in which the EXAMPLE 4 stretched filaments are heat-treated at a temperature of The same experiment as in No. 2 of Example 1 w C. to 140 C. while being overfed in a proportion of repeated except that the distribution of the proportion of 5 30Pefent and then aX two kinds of polymers in spun composite filaments is
  • a method according to claim 10 in which the stretched filaments are maintained under tension of less than 3 mg./d., the filaments are heat-treated under tension while afforded 5 to 50 percent of shrinkage and then relaxed.
  • stretched filaments are afiorded more than 0.1 g./d. of tension, maintained under tension of less than 0.03 g./d., heat-treated under tension while afforded 5 to 50 percent shrinkage and then relaxed.
  • a method according to claim 10 in which the stretched filaments are subjected to a first heat-treatment under tension of less than 3 mg./d. at a temperature higher than 50 C. and then to a second heat-treatment at a temperature at least as high as that of the first heattreatment and in such a manner that the filament length is longer than that of the first heat-treated filament and more than 5 percent shorter than that of non-treated filamerits, and then the filaments are relaxed.
  • a method according to claim 10 in which the spun unstretched filaments are stretched at a low stretch ratio so as to make the elongation-at-break of filament not lower than 95 percent, heat-treated at a temperature of 70 C. to 160 C., further stretched at a low stretch ratio so as to make the elongation-at-break of filament not lower than percent and then relaxed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Artificial Filaments (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Multicomponent Fibers (AREA)
US774541A 1964-02-04 1968-11-08 Method for spinning bicomponent polypropylene filaments Expired - Lifetime US3491178A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP551564 1964-02-04
JP1169264 1964-03-03

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US3491178A true US3491178A (en) 1970-01-20

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US (1) US3491178A (no)
BE (1) BE657850A (no)
DE (1) DE1494683A1 (no)
FR (1) FR1420793A (no)
GB (1) GB1085808A (no)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3904730A (en) * 1969-01-28 1975-09-09 Mitsui Petrochemical Ind Process for the preparation of polypropylene crimped fibers
US3968196A (en) * 1971-03-29 1976-07-06 Cosden Oil & Chemical Company Method of co-extrusion of polyvinylidene fluoride/polystyrene multiple-layered sheeting
US4051293A (en) * 1971-03-29 1977-09-27 Cosden Oil & Chemical Company Co-extrusion of polyvinylidene fluoride/polystyrene multiple-layered sheeting
US5622772A (en) * 1994-06-03 1997-04-22 Kimberly-Clark Corporation Highly crimpable spunbond conjugate fibers and nonwoven webs made therefrom
US5876840A (en) * 1997-09-30 1999-03-02 Kimberly-Clark Worldwide, Inc. Crimp enhancement additive for multicomponent filaments
US6287689B1 (en) 1999-12-28 2001-09-11 Solutia Inc. Low surface energy fibers
US6410138B2 (en) 1997-09-30 2002-06-25 Kimberly-Clark Worldwide, Inc. Crimped multicomponent filaments and spunbond webs made therefrom
US6630087B1 (en) 2001-11-16 2003-10-07 Solutia Inc. Process of making low surface energy fibers

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2952033A (en) * 1957-10-16 1960-09-13 Chemstrand Corp Apparatus for annealing filamentary tow
US3093444A (en) * 1961-07-10 1963-06-11 Du Pont Process of preparing a helically crimped polypropylene filament
US3106442A (en) * 1956-07-17 1963-10-08 Montecantini Societa Generale Method of producing dimensionally stable polypropylene fibers
FR1342403A (fr) * 1961-11-24 1963-11-08 Schweizerische Viscose Procédé de fabrication de fils de polyoléfines contenant des filaments composites
US3215486A (en) * 1962-04-17 1965-11-02 Toyo Spinning Co Ltd Fixation of polypropylene fibers impregnated with dyestuffs and other treating agents
US3233023A (en) * 1962-02-27 1966-02-01 Ici Ltd Spinning of polypropylene
US3256258A (en) * 1961-05-05 1966-06-14 Du Pont Fibers
US3323190A (en) * 1963-06-12 1967-06-06 Hercules Inc Elastic polypropylene yarn and process for its preparation
US3399259A (en) * 1965-04-20 1968-08-27 Ici Ltd Method for producing bicomponent polypropylene filaments
US3408433A (en) * 1965-06-23 1968-10-29 Ici Ltd Method and apparatus for spinning heterofilaments

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3106442A (en) * 1956-07-17 1963-10-08 Montecantini Societa Generale Method of producing dimensionally stable polypropylene fibers
US2952033A (en) * 1957-10-16 1960-09-13 Chemstrand Corp Apparatus for annealing filamentary tow
US3256258A (en) * 1961-05-05 1966-06-14 Du Pont Fibers
US3093444A (en) * 1961-07-10 1963-06-11 Du Pont Process of preparing a helically crimped polypropylene filament
FR1342403A (fr) * 1961-11-24 1963-11-08 Schweizerische Viscose Procédé de fabrication de fils de polyoléfines contenant des filaments composites
GB979083A (en) * 1961-11-24 1965-01-01 Schweizerische Viscose Process for the manufacture of spontaneously crimping polyolefine filaments
US3233023A (en) * 1962-02-27 1966-02-01 Ici Ltd Spinning of polypropylene
US3215486A (en) * 1962-04-17 1965-11-02 Toyo Spinning Co Ltd Fixation of polypropylene fibers impregnated with dyestuffs and other treating agents
US3323190A (en) * 1963-06-12 1967-06-06 Hercules Inc Elastic polypropylene yarn and process for its preparation
US3399259A (en) * 1965-04-20 1968-08-27 Ici Ltd Method for producing bicomponent polypropylene filaments
US3408433A (en) * 1965-06-23 1968-10-29 Ici Ltd Method and apparatus for spinning heterofilaments

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3904730A (en) * 1969-01-28 1975-09-09 Mitsui Petrochemical Ind Process for the preparation of polypropylene crimped fibers
US3968196A (en) * 1971-03-29 1976-07-06 Cosden Oil & Chemical Company Method of co-extrusion of polyvinylidene fluoride/polystyrene multiple-layered sheeting
US4051293A (en) * 1971-03-29 1977-09-27 Cosden Oil & Chemical Company Co-extrusion of polyvinylidene fluoride/polystyrene multiple-layered sheeting
US5622772A (en) * 1994-06-03 1997-04-22 Kimberly-Clark Corporation Highly crimpable spunbond conjugate fibers and nonwoven webs made therefrom
US5876840A (en) * 1997-09-30 1999-03-02 Kimberly-Clark Worldwide, Inc. Crimp enhancement additive for multicomponent filaments
US6410138B2 (en) 1997-09-30 2002-06-25 Kimberly-Clark Worldwide, Inc. Crimped multicomponent filaments and spunbond webs made therefrom
US6709996B2 (en) 1997-09-30 2004-03-23 Kimberly-Clark Worldwide, Inc. Crimped multicomponent filaments and spunbond webs made therefrom
US6287689B1 (en) 1999-12-28 2001-09-11 Solutia Inc. Low surface energy fibers
US6630087B1 (en) 2001-11-16 2003-10-07 Solutia Inc. Process of making low surface energy fibers

Also Published As

Publication number Publication date
GB1085808A (en) 1967-10-04
BE657850A (no) 1965-04-16
DE1494683A1 (de) 1969-10-30
FR1420793A (fr) 1965-12-10

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