WO2000020668A1 - Fibre thermosoudable - Google Patents

Fibre thermosoudable Download PDF

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Publication number
WO2000020668A1
WO2000020668A1 PCT/GB1999/000678 GB9900678W WO0020668A1 WO 2000020668 A1 WO2000020668 A1 WO 2000020668A1 GB 9900678 W GB9900678 W GB 9900678W WO 0020668 A1 WO0020668 A1 WO 0020668A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibre
fibres
inclusive
weight
polyethylene
Prior art date
Application number
PCT/GB1999/000678
Other languages
English (en)
Inventor
Keith Bailey
David Geoffrey Ellis
Original Assignee
Plasticisers Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Plasticisers Limited filed Critical Plasticisers Limited
Priority to AU32673/99A priority Critical patent/AU3267399A/en
Priority to EP99970133A priority patent/EP1149194A1/fr
Publication of WO2000020668A1 publication Critical patent/WO2000020668A1/fr

Links

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
    • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/12—Applications used for fibers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene

Definitions

  • the present invention relates to synthetic fibres for use in fabric production and related applications. More specifically, the present invention relates to a heat-bondable fibre which is able to bond to itself following the application of heat.
  • the fibres have a low shrink force despite a high degree of shrinkage. This is particularly useful in the field of non-woven fibres to stabilise a non-woven product.
  • Some current methods of stabilising woven products use liquid binders to bind the individual fibres together in a woven product. This improves the stability of the structure as a whole. For example, latex in solution may be applied to the fibre structure and the treated non-woven product is then heated to set the fibres. There are several disadvantages with this approach. The fibres are dulled and there is an energy and environmental cost ( and risk ) associated with the liquids and volatiles extracted during setting and drying. The resulting fabrics also have some of their desirable textile characteristics reduced, or even lost, by stiff binders. Such binders can also affect the appearance of the structure as well as its handling and feel .
  • Two component fibres of the "core-shell” type can be used to introduce bonding into a non-woven product on heating.
  • these have the disadvantage that melted polymeric material can substantially reduce the textile handling properties and aesthetic properties of the material.
  • Fibres of this type have a surface sheath ( shell ) of polymeric material formed from one component having a lower melting point than the one-component material which forms the core.
  • bonding between the contact surfaces (i.e. the outer lower melting point material) of the fibres is achieved by applying both heat and pressure (e.g., by calendering).
  • the outer layers of adjacent fibres melt and fuse together.
  • Such core-shell fibres dominate the fabric structure and properties which they are used. This has the disadvantage that in three dimensional fabric structures such fibres are too much in evidence throughout the structure, even when present in low concentration.
  • the fibres therefore play too great a part in the appearance and properties of the fabric. This is particularly true in coloured products where design and appearance of the material is a key selling feature. Furthermore, the nature of these two-component fibres means that they are expensive to produce and are not readily or cost-effectively produced in a variety of colours, types or shape so as to complement the colours and fibres they are blended with in finished fabric products.
  • Polyolefin shrink fibres which shrink and develop contraction forces within the blend of fibres of which they formed a small part are also known.
  • the contraction (tension) forces developed are often quite large and may be O.lg/denier or more. These properties can be very useful for example if manufacturing high bulk spun yarns, where say 20% of the blend is a higher shrink fibre.
  • shrinkage of the whole yarn is made possible by these high shrinkage fibres.
  • the cross- section of the yarn increases as the majority lower shrink fibres concertina outwards as the high shrinkage contraction forces dominate during the heat setting process .
  • shrink fibres do not undergo any useful or controllable bonding to themselves either because the heat setting temperature is too low or because they may suddenly melt if the temperature is taken above their melting point. This is especially true in thicker fabrics where no mechanical pressure can be applied so as to avoid distorting or flattening the fabric.
  • a heat-bondable polyolefin fibre comprising a blend of an amount of 70 to 90 % inclusive by weight of polyethylene, and an amount of 10 to 30 % inclusive by weight of polypropylene, the fibre optionally further including one or more polyolefin copolymers in an amount of not more than 10% by weight, the fibre having a degree of shrinkage of between 20 and 50%, inclusive, when measured at 120°C and a shrink tension of not more than 0.015g per denier when measured in the range 90 to 120°C.
  • the polyethylene is a low density polyethylene (LDPE ) or linear low density polyethylene ( LLDPE ) .
  • Low density means a polyethylene having a density of not more than 0.925g/cm 3 .
  • polypropylene it is important to have sufficient of the high melting point polymer present to ensure adequate mechanical properties of the fibre hence the requirement for an amount of polypropylene of 30 to 10% by weight inclusive. Preferably, there is 15 to 10% by weight of polypropylene in the fibre, and most preferably 10%. This also helps to ensure there is retention of a fibre shape and an interconnected fibrous structure in place in the fabric after heat- setting and subsequent cooling of these heat-sensitive fibres.
  • the polyethylene contributes to the stickiness of the fibre over a broad range of temperature.
  • the fibre there is 85 to 90% by weight of polyethylene in the fibre, and most preferably 90%.
  • the nature of the polymeric components in the extruded fibre is not certain. It is believed that the fibre contains a dispersion of discrete strands or regions of one component surrounded by regions or strands of another component. The important feature is that there is sufficient of the low melting point component present in the region of the surface of the fibre to assist bonding. Also, there must be sufficient of the higher melting point component present in the body of the fibre to provide adequate strength during heat setting.
  • the fibres bond together at their points of surface contact when at the heat setting temperature. When the fabric is subsequently cooled, a fibrous bonded and interconnected structure within the cross-section of the fabric is produced thereby providing the necessary binding and stabilisation of the fabric structure.
  • the fibres take up the shape of the fabric construction without distorting it and create an intimate network of heat-bonded fibres.
  • the heat sensitive fibres have a high potential shrinkage (typically in the range of 20 - 50% inclusive depending on the temperature and heat applied) even though the shrink force is low.
  • the design and method of manufacture of the fibres lends itself easily to melt colouration of the fibre by adding colour to one or more of the major polymer elements in its composition before extrusion. Heat- sensitive fibres in a variety of colours can therefore be readily produced. This may be useful in fabrics and designs where colour is critical or when the chosen concentration of the heat-sensitive fibres is relatively high and/or they are placed near to the surface of the fabric.
  • the fibres of the present invention can play a useful role in locking, bonding and setting the final fabric construction and shape, for example, in the production of non-woven or needle punch fabrics.
  • fibres of one or more type and of various colours and deniers can be blended together.
  • This blend of fibres is then carded into a web, which can be useful in its own right.
  • the web is usually folded and cross layered to provide an assembled uniform web of fibres, having strength in machine and transverse directions, of the required weight and thickness.
  • the resulting web can then be fed into a needling process in which barbed or forked needles penetrate the web providing fibre interlocking and fabric compaction. Additional needling processes can be applied as required to move and place the different fibre deniers in the cross-section of the web's thickness.
  • the thicker fibres e.g., 65 - 110 deniers
  • the finer fibres e.g., 10 - 20 denier
  • the layout and type of needles can also be varied to control the pattern of the surface of this type of fabric (e.g., ribbed patterns ) .
  • the fibres of the present invention When blending the fibres of the present invention with a conventional blend used for this type of construction, the fibres of the present invention can be positioned as a result of the process of needling largely in the base or back of the fabric construction, as required.
  • the fibres of the invention are sufficiently fine and easily deflected by these needles, and so do not readily move into the pile (or surface) of the fabric.
  • the heat-sensitive fibres of the present invention are produced by using at least two polyolefin polymers of notably different melting points. It is desirable the melting point of one of the components is at least similar to the dominant fibre in the fabric composition or at least is above the heat setting temperatures employed when finishing the fabric.
  • one polymer would ideally be a polypropylene homopolymer (e.g., melting point 160 - 165°C, inclusive).
  • the other polymer component in the fibre ideally has a melting point in the region of the operating temperatures conventionally used on heat-setting.
  • a low density (i.e. 0.925g/cm 3 or less) polyethylene (LDPE) polymer of melting point 118°C is one suitable choice.
  • Linear low density polyethylene (LLDPE) is also highly suitable for use as the low melting point component in the fibre of the present invention.
  • polystyrene resin in certain cases, it may be desirable to include one or more further polyolefin components in the fibre in order to modify the melting point, stickiness of the fibre or the tensile strength.
  • suitable polyolefins include homopolymers or copolymers of polyolefins including butylene or copolymers of ethylene and propylene.
  • Such optional ingredients when present account for not more than 10% by weight of the fibre content. An amount in excess of this leads to a deterioration in the melting and heat-bonding properties of the fibre.
  • a process for producing a heat-bondable polyolefin fibre comprising the steps: (a) extruding a polymer mixture comprising polyethylene in an amount of from 70 to 90% by weight inclusive, polypropylene in an amount of from 30 to 10% by weight inclusive, and optionally not more than 10% by weight of a further polyolefin component;
  • the air cooling serves to quench the extruded material and is preferably effected by an air knife which provides a concentrated blast of cooling air.
  • the air knife thus serves to ensure adequate cooling of the extruded material which is usually in the form of several filaments.
  • the air cooling stiffens the polymer melt at the point it flows from the die into the air cooling zone. Not only does the extrusion process become more stable and easier to operate, but we also unexpectedly found that the bonding and shrinking properties are improved.
  • the cooling air ideally has a temperature of from 5 to 20°C inclusive, and more preferably 8 to 10°C.
  • the drawing of the extruded polymer to produce fibre is effected at a ratio of between 10 and 100 times.
  • the fibre cools naturally during the drawing and it is not necessary to provide any additional cooling, although further cooling may optionally be provided.
  • the fibre is then fed to an oven to heat the fibre to a temperature at which the fibre can be stretched uniformly and in a controlled manner.
  • the fibre is heated by means of warm air in the oven with the oven temperature ideally being in the range of 90 to 120°C inclusive, with a temperature in the range 100 to 110°C inclusive being preferable in view of ease of control and ensuring uniformity during stretching. It is preferable that the stretching, which is performed in the oven during the heating step, is effected at a stretching ratio of 1.5 to 2.5 inclusive since this leads to finished fibres which have both a particularly low shrink tension and a good degree of shrinkage.
  • the stretched fibres are then fed to the crimper under slight tension so that no shrinkage of the fibre occurs before the crimping process.
  • the crimping process is a conventional process and may be effected, for example, using a stiffer box crimper.
  • the crimped fibres are then cooled and cut in a conventional manner.
  • Figure 1 is a schematic diagram of the process of the present invention and is described in detail in conjunction with Example 1.
  • the conditions extrusion and drawing of the polymer are such as to produce the desired properties in the fibre. Stretching of the drawn fibre results in stresses being set into the fibre which is then cooled and packaged.
  • the advantageous properties of the fibres of the present invention are believed to result from the thermal history of the fibre as a result of its processing.
  • the fibre begins to melt and deform (if there is any contact pressure) over a broad temperature range which is dictated by the proportion of the components in the polymer. This is typically in the range of 105 to 155°C.
  • the polymeric components are metered as a blend in proportion into the extruder and are melted and mixed in a conventional extruder. Blending in the extruder is carried out in the temperature range of 220 to 280°C, inclusive, with a temperature in the range 230 to 250°C, inclusive, being preferred. The exact temperature will, of course, depend on the nature of the components to be blended. Alternatively, the separate components may be fed directly to the extruder throat and co-extruded.
  • a 15 denier fibre was made by feeding the following component polymers directly into the throat of a 115mm extruder and coextruded: a) 90% Linear low density polyethylene - LLDPE (e.g. grade 18QFA from Mariac; density 0.919g/cm 3 and MFR 2.8 for 190°C 2.16kg; melting point 126°C) b) 10% polypropylene homopolymer - PP (e.g. grade 1101M from Targor with MFR 9.0 for 230°C 2.16kg; melting point 163°C)
  • the molten flow of extrudate was fed into a spinning beam and filtration system via metering pumps to the die plates in the die block ( 1 ) .
  • this extrusion process there were 8 stainless steel die plates in the die block ( 1 ) , each with 11,232 holes with each hole having a diameter of 0.5mm.
  • the resulting extruded polymer was discharged from the die holes through a concentrated air cooling zone with input air temperature measured at 8°C.
  • the draw down from these die holes was achieved by first haul- off rollers (2) operating at a surface speed of lOm/min to produce a bundle of fibres.
  • the bundle of fibres (89,856 in total) then passed to second haul-off rollers (3) at a surface speed of 11 m/mins (3) (i.e. a higher speed than the first haul-off rollers ( 2 ) to maintain sufficient tension in the fibres to stop shrinkage taking place ) .
  • No additional heating was applied to the fibres after leaving the die holes and before the second haul- off roller ( 3 ) and the fibres travelled a distance of about 8m. During this time the fibres cooled but were not allowed to shrink. These cooled fibres were pulled through an oven
  • the fibres were then passed to the nip rollers ( 6 ) of a stuffer box crimping machine ( 7 ) . These rollers were operated at 22m/min to ensure the filaments did not shrink as they cooled and travelled from the third haul-off rollers (5). The crimped cooled fibres were then taken through a guiding system into a cutter before being conveyed by air into a bale press.
  • the extrusion process had the following temperature profile: Barrel zones profile 235, 235, 245, 245, 250, 250°C Adapter, filters etc. 240°C Feed/pump/beam centre 235°C Die head 240°C
  • the outputs of extruder and metering pumps were set to give individual fibres at the end of the process of 15 denier (50 micron diameter).
  • the shrinkage of the fibres was measured as follows:
  • Example 1 The extrusion and process conditions of Example 1 were used in this Example. However, the proportion of the two same polymers fed into the extruder was varied as follows:
  • LLDPE in fibre polymer composition are as follows:
  • Example 3 First and second comparative fibres comprising
  • the first comparative fibre comprising 100% polypropylene fibres remained fibrous up to the melting point of 165°C. At this temperature the fibres became a viscous liquid. At above 155°C they began to become slightly sticky.
  • Example 4 As the proportion of polypropylene in the fibre was increased, the degree of softening of the fibres reduced and the degree of stickiness of the fibres also reduced. Accordingly, an LLDPE content of 85 to 90% inclusive is preferred in view of the intended end use because the stickiness ( as a measure of the efficacy of the bond) is important. At the same time, it is important that the fibrous nature of the material remains .
  • Example 4 As the proportion of polypropylene in the fibre was increased, the degree of softening of the fibres reduced and the degree of stickiness of the fibres also reduced. Accordingly, an LLDPE content of 85 to 90% inclusive is preferred in view of the intended end use because the stickiness ( as a measure of the efficacy of the bond) is important. At the same time, it is important that the fibrous nature of the material remains . Example 4
  • fibres in the range of 5 to 25 denier are preferred. More particularly, fibres in the range 10 to 20 denier are more preferred with 13 to 17 denier being most preferable.
  • the shrinkage without applied tension of the fibres of Example 1 is notably higher than the shrinkage when even only a small tension is applied.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
  • Artificial Filaments (AREA)

Abstract

La présente invention concerne des fibres synthétiques prévues pour être utilisées dans la fabrication de tissus, et un procédé de fabrication de ces fibres. Ces fibres sont thermosoudables et peuvent être soudées les unes aux autres sous l'effet de la chaleur. Elles ont également l'avantage de présenter une faible force de rétraction ce qui les rend particulièrement utiles en permettant leur intégration dans des produits non tissés.
PCT/GB1999/000678 1998-10-02 1999-03-08 Fibre thermosoudable WO2000020668A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU32673/99A AU3267399A (en) 1998-10-02 1999-03-08 Heat-bondable fibre
EP99970133A EP1149194A1 (fr) 1998-10-02 1999-03-08 Fibre thermosoudable

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9821369.7 1998-10-02
GB9821369A GB2342355B (en) 1998-10-02 1998-10-02 Heat-bondable fibre

Publications (1)

Publication Number Publication Date
WO2000020668A1 true WO2000020668A1 (fr) 2000-04-13

Family

ID=10839798

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1999/000678 WO2000020668A1 (fr) 1998-10-02 1999-03-08 Fibre thermosoudable

Country Status (4)

Country Link
EP (1) EP1149194A1 (fr)
AU (1) AU3267399A (fr)
GB (1) GB2342355B (fr)
WO (1) WO2000020668A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8076417B2 (en) 2006-02-15 2011-12-13 Dow Global Technologies Llc Crosslinked polyethylene elastic fibers

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0192897A2 (fr) * 1984-12-27 1986-09-03 E.I. Du Pont De Nemours And Company Mélange de polyéthylène et de polypropylène
EP0277707A2 (fr) * 1987-01-12 1988-08-10 Unitika Ltd. Fibre de polyoléfine à deux composants et étoffe non tissée fabriquée à partir de cette fibre
EP0621356A2 (fr) * 1993-04-19 1994-10-26 Hercules Incorporated Fibres à composants multiples et non-tissées réalisées avec celles-ci

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4632861A (en) * 1985-10-22 1986-12-30 E. I. Du Pont De Nemours And Company Blend of polyethylene and polypropylene
US5112686A (en) * 1987-10-27 1992-05-12 The Dow Chemical Company Linear ethylene polymer staple fibers
EP0604576A1 (fr) * 1991-09-16 1994-07-06 Exxon Chemical Patents Inc. Melanges de polyethylene et de polypropylene compatibilises par un plastomere
CZ5693A3 (en) * 1992-01-23 1993-10-13 Himont Inc Elastic yarn of polypropylene polymer and articles made therefrom
DE19540129A1 (de) * 1995-10-27 1997-04-30 Dlw Ag Verfahren zur Herstellung von gefärbten Fasern und zum Bedrucken von Kunstrasen

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0192897A2 (fr) * 1984-12-27 1986-09-03 E.I. Du Pont De Nemours And Company Mélange de polyéthylène et de polypropylène
EP0277707A2 (fr) * 1987-01-12 1988-08-10 Unitika Ltd. Fibre de polyoléfine à deux composants et étoffe non tissée fabriquée à partir de cette fibre
EP0621356A2 (fr) * 1993-04-19 1994-10-26 Hercules Incorporated Fibres à composants multiples et non-tissées réalisées avec celles-ci

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8076417B2 (en) 2006-02-15 2011-12-13 Dow Global Technologies Llc Crosslinked polyethylene elastic fibers

Also Published As

Publication number Publication date
GB9821369D0 (en) 1998-11-25
GB2342355B (en) 2002-05-15
GB2342355A (en) 2000-04-12
EP1149194A1 (fr) 2001-10-31
AU3267399A (en) 2000-04-26

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