WO1997006295A1 - Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve - Google Patents

Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve Download PDF

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Publication number
WO1997006295A1
WO1997006295A1 PCT/US1995/009909 US9509909W WO9706295A1 WO 1997006295 A1 WO1997006295 A1 WO 1997006295A1 US 9509909 W US9509909 W US 9509909W WO 9706295 A1 WO9706295 A1 WO 9706295A1
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WIPO (PCT)
Prior art keywords
yarn
filaments
rdr
filament
yarns
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PCT/US1995/009909
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English (en)
Inventor
David George Bennie
Robert James Collins
Hans Rudolf Edward Frankfort
Stephen Buckner Johnson
Benjamin Hughes Knox
Joe Forrest London, Jr.
Elmer Edwin Most, Jr.
Girish Anant Pai
Original Assignee
E.I. Du Pont De Nemours And Company
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.)
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Publication date
Application filed by E.I. Du Pont De Nemours And Company filed Critical E.I. Du Pont De Nemours And Company
Priority to DE69516910T priority Critical patent/DE69516910T2/de
Priority to PCT/US1995/009909 priority patent/WO1997006295A1/fr
Priority to JP50839097A priority patent/JP3346575B2/ja
Priority to KR1019980700791A priority patent/KR100488381B1/ko
Priority to ES95929383T priority patent/ES2147613T3/es
Priority to EP95929383A priority patent/EP0843750B1/fr
Publication of WO1997006295A1 publication Critical patent/WO1997006295A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/082—Melt spinning methods of mixed yarn
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch

Definitions

  • the invention concerns improvements in and relating to melt-spinning fine continuous filament polyester yarns and particularly to an improved process for preparing such yarns of high filament count (HFC) having improved uniformity such as makes these yarns especially suitable for textile end-uses that may require downstream processing without breaking filaments and for use in dye-critical textile applications.
  • HFC high filament count
  • Polyester filament yarns of denier per filament (dpf) less than about 1 are commercially available, but are more costly to make than filament yarns of more conventional dpf (similar to that of cotton).
  • Our so-called "parent” application No. 07/647,371 (now abandoned in favor of a continuation-in-part application now issued as U.S. Patent No. 5,250,245, as was a companion case, now issued as U.S. Patent No. 5,288,553, the disclosure of both of which are hereby incorporated herein by reference) was concerned with the preparation of such fine filaments by a novel direct melt-spinning process.
  • Some fiber producers have, therefore, spun two (or more) separate smaller fine filament "bundles" and have then co-mingled (interlaced) the separate smaller bundles to provide a single HFC yarn of the desired total yarn denier (D Y ) equal to that of the larger dpf LFC yarn that is to be .replaced.
  • V s (dpf) s ⁇ (V s )/9000, where V s is the spinning withdrawal speed and is at least 2Rm/min;
  • SF Spin Factor
  • n minus (-) 0.8
  • FED # filaments per "useful" extrusion area in cm 2
  • Quality levels of the filaments are desirably measured by along-end denier (i.e., a low Denier Spread (DS), desirably less than 2.5%, particularly less than about 2.0%, preferably less than about 1.5%, and especially about 1.0% or less, it being understood that these uniformity criteria are increasingly difficult to obtain as the dpf is reduced), structure uniformity (as measured by the along-end draw tension (coefficient of) variation (DTV,%) which should desirably be less than 1 %, and is discussed more in detail in relation to Spin Factor (SF), especially referring to Figure 1, hereinafter) and mechanical quality (as measured by
  • T B normalized tenacity-at-break-denier
  • capillary dimensions herein and in the art can be extremely important. Such dimensions are preferably such that the L/D ratio is at least 2, and the L/D 4 value is at least 335 mm- 3 .
  • melt-spinning productivity P s
  • N s withdrawal speed
  • RDR me residual spun draw ratio
  • the resulting interlaced multi-filament yarns are believed new, as will be indicated, because they number at least 150 filaments of fine denier, up to 2.2 spun dpf (dpf) s , and up to 1 dpf, when drawn, and yet their filament entanglement shows unitary interlace. They show desirable uniformity, as expressed for the filaments by low DTN values, and desirably by low DS, and for the yarns by high (T B ) n values, as indicated.
  • spin-oriented yarns may be used as such, i.e., in as-spun condition as "direct-use" yarns, and most of them may be drawn in a coupled or split process, single-end or in a form of a sheet of few ends, or in the form of a weftless warp sheet, to provide drawn flat multi-filament yarns having a residual elongation as desired, generally between about 15% to about 40%, and normalized (T B ) n values of at least 5 g/dd, preferably of at least 5.5 g/dd, and especially of at least 6 g/dd.
  • Such drawing may be incorporated as part of a split or coupled draw- texturing process, such as draw air-jet texturing or draw false-twist texturing, in which case the yarns may be drawn to somewhat higher elongation, e.g. up to about 45% .
  • the yarns may, if desired, be subjected to a compression crimping process (e.g., stuffer-box crimping).
  • the HFC yarns of the invention (whether spun or drawn, flat or textured yarns) have unitary interlace and have at least 150 filaments, preferably at least 175 filaments and especially at least 200 filaments.
  • the spun denier (dpf) s of the as-spun filaments is desirably 0.5 to 2.2, and preferably 0.6, 0.65 or 0.7 on up, e.g., to about 2 (dpf) s -
  • the denier per filament of the drawn (e.g., flat or draw-textured) HFC yarns of the invention desirably have a filament denier of about 1 or less and generally up to about 0.8, e.g. 0.2 to 0.8 dpf.
  • Draw-textured HFC yarns of the invention are further characterized by an elongation-to-break of 15% to 45%, a normalized tenacity-at-break-denier of at least 4 g/dd, preferably at least 4.5 g/dd, and a Toray Fray Count of less than 10 per 1000 meters, preferably less than 5 per 1000 meters. Indeed, as may be seen in the Examples, Fray Counts of 0 have been achieved according to the invention.
  • High filament count (HFC) post-bulkable yarns may be prepared by spinning and gently heat-setting an HFC mixed-filament yarn comprised of two or more types of filaments that differ in denier and/or cross-section under conditions selected such as to provide a potential differential shrinkage (because of differential crystallinity) between the filament types, i.e. sufficient to preserve a shrinkage difference of at least 5% (i.e., not to over heat set), and such that when the drawn mixed-filament yarn is heated under relaxed conditions the differing filaments of the HFC drawn mixed-filament yarn still have sufficient differential shrinkage to shrink differentially and so give a yarn having different filament lengths (giving along-end loops) and thereby provide an HFC bulky yarn comprised of core filaments
  • the surface filaments after boil-off shrinkage desirably have a (dpf) ABO of less than 1, and Preferabty less than 0.8; and the total yarn average (dpf) Y (after boil-off) should generally be less than 1 (as shown, e.g., in Example 5).
  • Figure 1 is a plot of draw tension variation (DTV,%) versus the Spin Factor SF, defined hereinbefore.
  • Undrawn yarns of the invention preferably have DTV-values of less than 1%, and are spun so the SF is in the range of 0.2 to 1 as shown by the lightly dashed lines.
  • Figure 2 is a representative plot of percent boil-off shrinkage (S) versus percent elongation-to-break (Eg) wherein straight Lines 1, 2, 3, 4, 5, 6, 7, and 8 represent (1-S/S m )-values of 0.85, 0.7, 0.6, 0.4, 0.2, 0.1, 0.05, and 0, respectively, and curved Line 9 represents a typical shrinkage versus elongation-to-break relationship for a series of yarns formed, for example, by increasing spinning speed, but keeping all other process variables unchanged. Changing other process variables (such as dpf, polymer viscosity) produces a "family" of similar curved lines that are of essentially similar configurations.
  • the vertical dashed lines denote ranges of E ⁇ -values for preferred filaments of the invention, i.e., Eg values of 40% to 175%, with 160% as a practical upper limit, based on age stability, and especially up to 140%.
  • Preferred filaments of the invention denoted by the "widely-spaced" //////-area are especially suitable as draw-feed yarns, being defined by E B -values of about 90% to 160% and (1-S/S m ) value of at least about 0.05 (line 7).
  • Preferred filaments of the invention especially suitable for direct-use, i.e. without further drawing and/or heating, are denoted by the "densely-spaced" ⁇ area bordered by Eg-values of about 40% to about 90% and (1-S/S m ) ratio at least about 0.85 (line 1).
  • Figures 3 and 4 are partial schematic representations of partial spinneret arrangements having high filament extrusion density (FED).
  • the arrays are designed to optimize flow of cooling air through the extrusion bundle, and to minimize coalescence of freshly-extruded filaments and poor spinning performance and poor along-end uniformity of the quenched filament bundle.
  • Such arrangement is described in allowed application No. 08/214,717 (DP-4555H), filed by Aneja et al. on March 16, 1994, from which the 5-ring arrangement of Fig. 3 was taken, merely for convenience.
  • the orifices can be arranged in more rings to give an HFC yarn, while being staggered similarly, so as to increase the number of filaments spun from a single spinneret. This is shown in Fig. 4 for spinning 200 filaments from a single spinneret.
  • the polyester polymer used for preparing spin-oriented filament yarns of the invention is the same as for the "parent" application; that is, the polyester polymer is an ethylene terephthalate polymer selected to have a relative viscosity (LRV) in the range about 13 to about 23, a zero-shear melting point (T m o ) in the range about 240°C to about 265°C; and desirably a glass-transition temperature (T g ) in the range about 40°C to about 80°C (wherein T m o and T g are measured from the second DSC heating cycle under nitrogen gas at a heating rate of 20°C per minute).
  • LDV relative viscosity
  • T m o zero-shear melting point
  • T g glass-transition temperature
  • the said polyester polymer is a linear condensation polymer composed of alternating A and B structural units, where the A's are hydrocarbylene dioxy units of formula [-O-R'-O-] and the B's are hydrocarbylenedicarbonyl units of formula
  • Suitable polyethylene terephthalate)-based polymer may be formed by a DMT-process, e.g., as described by H.
  • Polyester polymers used herein, may, if desired, be modified by incorporating ionic dye sites, such as ethylene-5-M-sulfo-isophthalate residues, where M is an alkali metal cation, for example in the range of about 1 to about 3 mole percent.
  • ionic dye sites such as ethylene-5-M-sulfo-isophthalate residues, where M is an alkali metal cation, for example in the range of about 1 to about 3 mole percent.
  • DEG diethylene glycol
  • copolyesters may be used as mentioned in Most U. S.
  • Patent 4,444,710 Pacofsky U. S. Patent 3,748,844, Hancock U. S. Patent 4,639,347, and Frankfort and Knox U. S. Patents 4,134,882 and 4,195,051.
  • representative branching agents may be used to reduce shrinkage as mentioned in Knox U. S.
  • Patent 4,156,071 MacLean U. S. Patent 4,092,229, and Reese U. S. Patents 4,883,032, 4,996,740, and 5,034,174; and polymer of higher viscosity (e.g., by about +0.5 to about +1.0 LRV units) may be used to control yarn shrinkage (e.g., the extent of crystallization).
  • the withdrawal speed is controlled by use of a feed roll, which preferably cooperates with a let down roll before the windup, using an S-wrap configuration.
  • the single filament bundle is intelaced to provide a unitary interlaced yarn, as described by Bunting and Nelson in U.S. Patent No. 2,985,995 and by Agers in
  • untextured filaments and yarns are referred to herein as "flat”, and as-spun (undrawn) flat yarns intended for drawing as “feed” or as “draw- feed” yarns.
  • As-spun (undrawn) yarns which can be used as a "textile” yarn without need for further drawing and/or heat treatment are referred to herein as "direct-use” yarns.
  • a "textile" yarn should generally have certain minimum properties, such as sufficiently high modulus and yield point, and sufficiently low shrinkage, which distinguish such "textile” yarns from conventional feed yarns that require further processing before they have the minimum properties for processing into textiles and subsequent use.
  • polyester filaments in other forms such as bundles or tows, which may then be converted into staple fiber, and used as such in accordance with the balance of properties that is desirable and may be achieved as taught hereinafter.
  • a main purpose of the present invention has been to solve the productivity problems and disadvantages of the prior art, namely having to melt spin separate filament bundles of lower number of filaments and having to combine 2 or more such separate filament bundles to provide the desired total yarn denier (D Y ) by interlacing or co-mingling such lesser bundles (having less filaments) to provide the desired total yarn denier (D Y ) prior to draw-warping or after draw- texturing and, in doing this, to provide filaments of sufficient along-end structural uniformity, measured herein by along-end draw tension variation (DTV,%), along- end denier spread (DS,%), which indicates sufficient physical uniformity, and mechanical quality, as measured by the yarn tenacity-at-break-denier normalized to a polymer LRV of 20.8, for use in textile processing (i.e., providing uniform textile yarns with essentially no broken filaments, herein referred to as "frays").
  • Fine filament yarns of this invention may be subjected to warp drawing, air-jet texturing, false-twist texturing, gear crimping, and stuffer-box crimping, for example.
  • Process B is far preferable to more expensive solutions, such as modifying the "bent configuration” to eliminate this "twist trap” phenomenon by moving the heater and/or spindle, or replacing the existing "bent” machines and buying “tall” linear configuration FTT machines, or buying Murata belt machines, which are more costly solutions than Process B (one aspect of this invention).
  • Our new filaments (and bundles/tows made therefrom) may be crimped, if desired, and cut into staple and flock. Fabrics made from these improved yarns may be surface-treated by conventional sanding and brushing to give suede-like tactility.
  • Our new low shrinkage filament yarns may be used as direct-use flat textile yarns. The new yarns may be used as feed yarns for air-jet texturing and stuffer-box crimping, wherein no drawing need be carried out.
  • the improved combination of filament strength and uniformity makes these filaments especially suited for end-use processes that require fine filament yarns without broken filaments (or filament breakage), and/or require uniform dyeing with critical dyes.
  • Fine denier filament polyester yarns of the invention are especially suitable for making high-end density moisture-barrier fabrics, such as rainwear and medical garments.
  • the surface of the knit and woven fabrics can be napped (brushed or sanded).
  • the filaments may be treated (preferably in fabric form) with conventional alkali procedures.
  • Our new fine filaments may also be used as coverings for elastomeric yarns (and strips), preferably by air entanglement as described by Strachan in U. S. Patent No. 3,940,917.
  • the fine filaments of the invention may be co-mingled on-line during spinning or off-line with higher denier polyester (or nylon) filaments to provide for cross-dyed effects and/or mixed-shrinkage post-bulkable potential, where the bulk may be developed off-line, such as overfeeding in presence of heat while beaming/slashing or in fabric form, such as in the dye bath.
  • the degree of interlace and type/amount of finish applied during spinning may generally be selected based on the textile processing needs and final desired yarn/fabric aesthetics.
  • the filament surface frictional characteristics may be changed by selection of cross-section, delusterants, and through such treatments as alkali-etching Further, the frictional characteristics may be enhanced to be more silk-like by use of silicon dioxide versus titanium dioxide delusterants. Other inert metal oxides may be used as delusterants.
  • the spin- oriented polyester filaments, used herein, may advantageously be treated with caustic applied to freshly-extruded filaments, as described by Grindstaff and Reese U.S. Patents Nos. 5,069844, 5069,845 and 5,069,846 to provide the polyester filaments with improved moisture-wicking properties, more akin to those of the nylon filaments.
  • any type of draw winding machine may be used; post heat treatment of the feed and/or drawn yarns, if desired, may be applied by any type of heating device (such as heated godets, hot air and/or steam jet, passage through a heated tube, microwave heating, etc.); finish application may be applied by convention roll application, herein metered finish tip applicators are preferred and finish may be applied in several steps, for example during spinning prior to drawing and after drawing prior to winding; interlace may be developed by using heated or unheated entanglement air-jets and may be developed in several steps, such as during spinning and during drawing and other devices may be used, such as use of tangle-reeds on a weftless sheet of yarns.
  • any type of draw winding machine may be used; post heat treatment of the feed and/or drawn yarns, if desired, may be applied by any type of heating device (such as heated godets, hot air and/or steam jet, passage through a heated tube, microwave heating, etc.); finish application may be applied by convention
  • feed filaments may be supplied and/or processed according to the invention in the form of a yarn or as a bundle of filaments that does not necessarily have the coherency of a true "yarn", but for convenience herein a plurality of filaments may often be referred to as a yarn or bundle, without intending specific limitation by such term.
  • the draw tension variation was measured on the DuPont "Draw Tension Instrument"at a draw-ratio of 1.707X for as-spun yarns having elongations of at least 90% at 185°C over a heater length of 1 meter at 185 ypm (169.2 mpm) wherein casablanca type rolls (vs. nip rolls) are used to control tension.
  • DTV draw tension variation
  • DYNAFIL DYNAFIL
  • TEXTECHNO a fixed-strain device which uses a non-contact heater (length about 30 inches), and normal set up is a 1.6X draw ratio.
  • Yarns having denier spread (DS) values in the range of 2 to 2.5% are denoted by the letter “N” (indicating not preferred but according to the invention).
  • Yarns having a preferred normalized tenacity-at-break-denier (T B ) n of at least 6 g/dd are denoted by a letter “T”.
  • Yarns having elongation-to-break (E B ) values in the range of 160 to 175% are noted by the letter “E”, as such yarns have lower age-stability than draw-feed yarns of lower elongation-to-break, e.g., of 90- 160%, (preferably 90-140%).
  • Yarns 1 to 46, 84 to 150, and 159 to 185 were melt- spun using spinneret capillaries of length (L) 36 mil (0.914 mm) and diameter (D) 9 mil (0.229 mm).
  • Yarns 47 to 83 were melt-spun using spinneret capillaries of LxD 21 mil ⁇ 7 mil (0.533 mm x 0.178 mm).
  • Yarns 151 to 158 were melt-spun using spinneret capillaries of LxD 18 mil ⁇ 6 mil (0.457 mm x0.152 mm).
  • Yarns 1 to 46 were 168 filament yarns spun from a spinneret having a FED of 6.54 #/cm 2 ; yarns 47 to 150 were 200 filament yarns spun from a spinneret having a FED of 7.7 #/cm 2 ; yarns 151 to 158 were 204 filament yarns spun from a spinneret having a FED of 7.94 #/cm 2 ; and yarns 159 to 185 were 250 filament yarns spun from a spinneret having a FED of 9.74 #/cm 2 . As indicated (by the Comparative "C" items), we found that the spinning performance of these HFC yarns deteriorated as the FED increased.
  • our first step was to check and optimize standard process variables and equipment, such as assuring uniform air flow, and optimizing proper convergence length (i.e., long enough to permit convergence without sticky filaments, but short enough to reduce increase in spinline tension from air drag and thereby permit winding up the yarns at lower tensions) and setting the polymer temperature to provide good polymer quality (without thermal degradation).
  • This first step improved the spin performance somewhat, but was still sometimes unacceptable.
  • Our next step was to reconsider the extrusion/quenching process. It was unacceptable for us to reduce FED by double-ending (spinning from 2 packs instead from a single pack) since this would cut productivity by 50% .
  • the spin factor (SF) expression defines an approach to the spinning process as an integrated system and permits selection of process variables according to our invention, to achieve desired yarn property goals.
  • the next step would be to "fine-tune” by careful selection of process variables so as to maintain spin performance and yarn uniformity/quality, at a higher spin productivity P s defined by the product of the spin speed (V s ) and (RDR) S .
  • Item 14 in Table I is an illustration of the successful use of SF to obtain (T B ) n greater than 6g/dd, denier spread (DS) no more than 1 % and draw tension variation (DTV,%) no more than 0.75%.
  • capillaries of LxD 21 x 7 mil gave an over all better spinning process than the capillaries of LxD 36 ⁇ 9 mil (0.914 ⁇ 0.229 mm) at the same mass flow rate.
  • Capillaries have previously been characterized by their [L/D 4 ] ratio (e.g. in USP. No 4,134,882).
  • the 6 ⁇ 18 mil, 7 ⁇ 21 mil, and 9 ⁇ 36 mil capillaries have [L/D 4 , mm -3 ] values of 848, 534 and 335, respectively.
  • [L/D 4 ] metric values of at least 335 are preferred, and at least 500 is especially preferred.
  • the filament arrays were optimized for uniform quenching (as described in relation to Figure 3 and in more detail in allowed application No. 08/214,717 (DP-4555-H), referred to above).
  • spin factor those process parameters not included in Table I may be calculated as described hereinbefore.
  • the type and level of spin finish and interlace were selected based on intended end-use; for example, feed yarns for false-twist texturing have lower levels of interlace than those used as feed yarns for draw-warping. All these yarns are characterized by "random" unitary interlace, i.e., along-end filament entanglement, because all the filaments in each yarn were spun from a single spinneret.
  • Yarns that have been plied have generally contained sections where the original filament bundles have less overall intra-bundle entanglement, i.e., the separately spun bundles retain some of their separate "bundle integrity". This phenomenon has been recognized. For example, when separate bundles of filaments of different polymers (homopolymer and a cationic dyeable modified polymer), dpf, and cross-sections, have been spun and then the separate bundles have been co-mingled into a single interlaced yarn, the along-end mixing has not been as "random" or unitary as if the mixed filaments had been spun from a single extrusion spinneret.
  • Table II summarizes process conditions; namely draw ratio; disc-to-yarn (DY) surface speed ratio was 1.707; heater temperature (Temp, in degrees centigrade); disc stack configuration (C denotes a ceramic disc was used instead of a polyurethane disc); pre/post disc tensions in grams (T1/T2) (no value was measured in some instances); and numbers of broken filaments (Frays per 1000 meters).
  • the draw feed yarns of the invention drawn at a 1.575X draw-ratio at 180°C using a 1/7/1 disc stack (process B) gave a textured yarn having a yarn denier of 164 (0.82 dpf), a tenacity of 3.69 g/d, and elongation-to-break of 43.5%, giving a normalized (T B ) n of 5.3 g/dd, according to the invention.
  • a 220 denier/325 filament yarn and a 220 denier/250 filament yarn were prepared (essentially as in Example 2, except that the 325 filaments were spun at a FED of 10.3 filaments per cm 2 , and the 250 filaments at a FED of 9.74 filaments per cm 2 ) and were draw false-twist textured on a Barrnag FK900 (which has a "bent" double heater configuration) at 450-500 meters per minute at 160°C, using polyurethane discs (D-ring) with a 1.707 disc/yarn ratio (D/Y), other details being given in Table III.
  • the quality of the textured yarns is represented by the normalized tenacity-at-break-denier (T B ) n and in the number of "Frays" per 1000 meters.
  • the yarns were textured using the commercial threadline path (Process A) and by a modified threadline path using Process B, discussed hereinbefore.
  • the yarns textured by Process A had (T B ) n values less than 4 g/dd and fray values significantly greater than 100, in contrast to significantly improved values from Process B (higher (T B ) n values and very low Fray Counts, less than 10).
  • HFC as-spun yarns of filament deniers less than 1 were spun from 2G-T polyester polymer of nominal 21.2 LRV and having a zero-shear melting point T m o of 255 C.
  • Process and product details are stimmarized in Table IV.
  • Yarns having a DTV less than 0.75% are denoted by a letter "P" for preferred.
  • Yarns having a preferred normalized tenacity at break denier (T B ) n of at least 6 g/dd are denoted by a letter "T".
  • Yarns 1-5 were of 168 filaments and spun from spinnerets having a FED of 6.54/cm 2 ; yarns 6-27 were of 200 filaments and spun from spinnerets having a FED of 7.8/cm 2 ; yarns 28 -74 were of 250 filaments and spun from spinnerets having a FED of 9.73/cm 2 .
  • Yarns 1, 6-17, and 28-50 were spun using 7 ⁇ 21 mil (0.178 ⁇ 0.0.533 mm) spinneret capillaries and yarns 2-5, 18-27, and 50-74 were melt-spun using 9 ⁇ 36 mil (0.229 ⁇ 0.914 mm) spinneret capillaries.
  • the high filament count yarns in this Example 4 have filament deniers less than 1. Many may be drawn to filament deniers of less than 0.5, and even less than 0.3 dpf. Yarns #s 3 and 5 have boil-off shrinkages of 11.4 and 4.2,
  • Soft bulky yarns are provided from use of mixed-filament yarns comprised of filaments of differing shrinkages, typically from differences in denier, and/or surface to volume ratio (i.e., cross-sectional shape), with low shrinkage fine filaments (A) providing a desirable soft surface of the bulky yarn and higher denier filaments (B) providing the fabric with improved "body” and "drape” (i.e., less “mushy”).
  • A low shrinkage fine filaments
  • B higher denier filaments
  • (dpf) D ⁇ (dPf) s ⁇ t(1.25/(RDR) s ] ⁇ ; wherein the values of (dpf) D for both filament types are desirably less than 1.
  • the two filament types should differ in their spun (dpf) s , with the high shrinkage filaments (B) being of higher dpf than of the low shrinkage filaments (A).
  • the spinneret capillary dimensions are selected to provide the desired difference, where the ratio of (dpf)s is related to the ratio of spinneret dimensions according to the expression:
  • the above mixed-filament micro-denier HFC yarns may be air-jet textured without drawing, or a drawing step may be part of a draw-air-jet (+ optional heat relaxation) texturing process.
  • EXAMPLE 6 A 225 denier, 200 filament draw-feed HFC "unitary" yarn according to the invention was prepared by melt-spinning 21.5 LRV polyester at 288°C from a single 200-capillary spinneret having a FED of 7.8 filaments per cm2, through capillaries of DxL dimensions of 9 x 36 mil (0.229 mm x 0.914 mm), the freshly-extruded filaments being protected by a short 4.3 cm shroud and then quenched using a radial unit having a laminar air flow rate of 22.8 m/min, the quenched filaments being converged into a unitary bundle by use of a metered finish applicator guide, withdrawn at a speed of 2446 m/min, and the filaments interlaced using an air entanglement jet operating at 36 psig.
  • the air jet used for interlacing the filaments was a standard "stacked" jet, as illustrated generally in Figs. XI and XII of Christini et al. U.S. Pat. No. 3,936,577, that has been in commercial use for some years.
  • a 255 denier 200 filament draw-feed "plied" yarn was prepared by melt-spinning 21.7 LRV polyester at 287°C through two separate spinnerets, each having a FED of 4.4 filaments per cm 2 , through capillaries of DxL dimensions of 12 ⁇ 50 mil (0.305 mm x 1.27 mm), the freshly extruded filaments being air quenched, and separately converged into two 100-filament bundles by use of metered finish tip applicator guides, and both withdrawn at the same speed of 2624 m/min, and the separate 100-filament bundles were then plied into a 200 filament bundle using the same type of air entanglement jet used for the HFC yarn, said jet operating at 42 psig to achieve a similar average interlace nodes/meter as for the HFC yarn.
  • This yarn is referred to below as the "Plied" yarn.
  • the HFC yarn of the invention when considering only averages measured over all 6 packages.
  • the uniformity of the yarns is considered, by noting the maximum distance between nips and the package to package % CV of these maximum distances, the HFC yarn of the invention was shown to have significantly superior uniformity. This significant improvement in along-end uniformity also shows up in better processibility.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Artificial Filaments (AREA)

Abstract

L'invention porte sur un procédé direct de filage par fusion destiné à fournir des fils de filament de polyester, de titre fin, à nombre de filaments élevé, aux propriétés mécaniques remarquables, uniformes de bout en bout et à entrelacement unitaire, par filage de tous les filaments de ce fil à nombre de filaments élevé à partir d'une filière unique. On peut utiliser ces fils comme fils à usage direct et comme fils extrudés par étirage pour préparer des fils plats étirés et des fils texturés par étirage.
PCT/US1995/009909 1995-08-04 1995-08-04 Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve WO1997006295A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
DE69516910T DE69516910T2 (de) 1995-08-04 1995-08-04 Verfahren zur herstellung von polyestergarne mit einer hohen anzahl von feinfilamenten
PCT/US1995/009909 WO1997006295A1 (fr) 1995-08-04 1995-08-04 Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve
JP50839097A JP3346575B2 (ja) 1995-08-04 1995-08-04 高フィラメントカウント細フィラメントポリエステル糸の製法
KR1019980700791A KR100488381B1 (ko) 1995-08-04 1995-08-04 높은필라멘트번수의미세필라멘트폴리에스테르사의제조방법
ES95929383T ES2147613T3 (es) 1995-08-04 1995-08-04 Fabricacion de hilos de poliester de filamentos finos continuos de gran numero de filamentos.
EP95929383A EP0843750B1 (fr) 1995-08-04 1995-08-04 Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1995/009909 WO1997006295A1 (fr) 1995-08-04 1995-08-04 Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve

Publications (1)

Publication Number Publication Date
WO1997006295A1 true WO1997006295A1 (fr) 1997-02-20

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PCT/US1995/009909 WO1997006295A1 (fr) 1995-08-04 1995-08-04 Fabrication de fils de filament de polyester, de titre fin, a nombre de filaments eleve

Country Status (6)

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EP (1) EP0843750B1 (fr)
JP (1) JP3346575B2 (fr)
KR (1) KR100488381B1 (fr)
DE (1) DE69516910T2 (fr)
ES (1) ES2147613T3 (fr)
WO (1) WO1997006295A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10360845A1 (de) 2003-12-20 2005-07-21 Corovin Gmbh Weiches Vlies auf Basis von Polyethylen

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5488316A (en) * 1977-12-21 1979-07-13 Toray Ind Inc Method of melt spinning of extremely fine fiber
JPS62243824A (ja) * 1986-04-16 1987-10-24 Teijin Ltd ポリエステル極細繊維の製造方法
WO1992013119A1 (fr) * 1991-01-29 1992-08-06 E.I. Du Pont De Nemours And Company Procede de preparation de minces filaments de polyester
JPH0578911A (ja) * 1991-09-18 1993-03-30 Nippon Ester Co Ltd ポリエステル極細マルチフイラメントの溶融紡糸方法
KR930003356B1 (ko) * 1990-12-24 1993-04-26 주식회사 코오롱 폴리에스터 극세사 제조용 용융 방사장치
US5250245A (en) * 1991-01-29 1993-10-05 E. I. Du Pont De Nemours And Company Process for preparing polyester fine filaments
WO1994003661A1 (fr) * 1992-08-05 1994-02-17 E.I. Du Pont De Nemours And Company Fins filaments creux en polyester
US5288553A (en) * 1991-01-29 1994-02-22 E. I. Du Pont De Nemours And Company Polyester fine filaments

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR0181183B1 (ko) * 1991-01-29 1999-02-01 미리암 디. 메코너헤이 폴리에스테르 미세 필라멘트의 제조

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5488316A (en) * 1977-12-21 1979-07-13 Toray Ind Inc Method of melt spinning of extremely fine fiber
JPS62243824A (ja) * 1986-04-16 1987-10-24 Teijin Ltd ポリエステル極細繊維の製造方法
KR930003356B1 (ko) * 1990-12-24 1993-04-26 주식회사 코오롱 폴리에스터 극세사 제조용 용융 방사장치
WO1992013119A1 (fr) * 1991-01-29 1992-08-06 E.I. Du Pont De Nemours And Company Procede de preparation de minces filaments de polyester
US5250245A (en) * 1991-01-29 1993-10-05 E. I. Du Pont De Nemours And Company Process for preparing polyester fine filaments
US5288553A (en) * 1991-01-29 1994-02-22 E. I. Du Pont De Nemours And Company Polyester fine filaments
JPH0578911A (ja) * 1991-09-18 1993-03-30 Nippon Ester Co Ltd ポリエステル極細マルチフイラメントの溶融紡糸方法
WO1994003661A1 (fr) * 1992-08-05 1994-02-17 E.I. Du Pont De Nemours And Company Fins filaments creux en polyester

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 7934, Derwent World Patents Index; Class A23, AN 79-62363B, XP002002107 *
DATABASE WPI Section Ch Week 9317, Derwent World Patents Index; Class A23, AN 93-140727, XP002002106 *
DATABASE WPI Section Ch Week 9347, Derwent World Patents Index; Class A23, AN 93-375520, XP002002108 *
PATENT ABSTRACTS OF JAPAN vol. 012, no. 122 (C - 488) 15 April 1988 (1988-04-15) *

Also Published As

Publication number Publication date
KR19990036123A (ko) 1999-05-25
EP0843750A1 (fr) 1998-05-27
EP0843750B1 (fr) 2000-05-10
KR100488381B1 (ko) 2006-04-21
DE69516910T2 (de) 2000-12-07
ES2147613T3 (es) 2000-09-16
JP3346575B2 (ja) 2002-11-18
DE69516910D1 (de) 2000-06-15

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