WO2002055768A1 - Thermoplastic compositions for the preparation of fibers and films - Google Patents

Abstract

Thermoplastic compositions particularly adapted for use in preparing extruded fibers and films for carpets, rugs, woven fabrics, non-woven or spun-bonded fabrics, knit fabrics, garments, laminates, constructions, or other applications and a method for the formation thereof.

Description

  



   THERMOPLASTIC COMPOSITIONS FOR THE PREPARATION OF FIBERS AND FILMS
The subject invention relates to a thermoplastic composition useful for the preparation of filaments, fibers, molded films and/or other shaped compositions as well as to methods for the preparation thereof. The subject invention further relates to articles comprising such filaments, fibers, or films, including but not limited to, yams for use in carpet, fabrics, roving, non-wovens, and other applications, and films for textiles, envelopes, adhesive tapes, wrapping, and other applications.



   Natural fibers, such as wool, cotton, and silk have long found utility in fiber-, filament-, and   yarn-based    applications such as carpet and fabric applications. However, natural fibers are in limited supply. In addition, due to the origin of natural fibers in living animals and plants, the quality and characteristics of natural fibers varies widely. Such irregularities can negatively affect the feel, appearance, and performance of the fiber, and, thus of resultant articles incorporating such fibers.



   Synthetic fibers, such as nylon, polyester, and polypropylene fibers, do not have the supply limitations of natural fibers, and are accordingly less expensive than natural fibers. In addition, given that synthetic fibers result from controlled chemical reactions and physical shaping environments, they are more uniform in quality than natural fibers giving them performance advantages such as improved durability over natural fibers. However, consumers often view synthetic fibers as less desirable than their natural counterparts, as synthetic fibers cannot match the overall performance profile of natural fibers, especially with regard to the softness, warmth, depth of color, and hand of natural fibers.



   Synthetic fibers are known to be prepared by extruding a filament of a synthetic resin and drawing or spinning, crimping, or otherwise forming the same into a product (hereafter"synthetic fiber") having desirable properties. Thermoplastic polymers are desirable for use in such processes due to the fact that they are readily extruded at temperatures above their melting point and may be shaped and formed through later operations before or after cooling. Highly desirably thermoplastics for the foregoing end uses possess sufficient crystallinity at normal use temperatures, especially at   20  C    such that the polymer is not subject to the rules of linear viscoelasticity, as would apply to amorphous polymers.

   More desirably still, such polymers desirably form sufficient crystallinity upon cooling to temperatures below their crystalline melting point to impart sufficient modulus and general mechanical properties to be suitable for use in fiber or film forming processes. That is, suitable thermoplastic polymers should possess a sufficient crystallization rate to be suitably employed in such processes. Finally, it is desirable that the thermoplastic polymer have a melting point, (Tm) sufficiently below the depolymerization, decomposition or auto-ignition temperature that the polymer may be readily extruded without significant polymer degradation, devolatilization or smoke generation if extruded in the presence of oxygen.



   Yarns are generally formed by combining multiple fibers using any suitable gathering technique. Enhanced physical properties are imparted to the yarn by numerous physical treatments, including heating, twisting, or otherwise physically or chemically modifying the fiber or   yarn.    Yarns prepared from thermoplastics are especially useful in the formation of carpeting, fabrics (including woven-, non-woven-or spun-bonded-and knit-fabrics) and other applications.



   Films are also formed from thermoplastic polymers by extrusion through a die or orifice, and thereafter uniaxially or biaxially orienting the same by use of a tentering frame or expansion bubble using pressurized gas. Such films are adaptable for a number of end uses, including packaging, textiles, adhesive tapes and construction laminates. In certain of these applications, a roughened surface is desired to reduce frictional forces and dust generation during manufacture and to reduce blocking while in storage and use.



   Suitable thermoplastic resins for forming filaments, fibers, films and other compositions, include polyamides, polyesters, polyolefins, and polyurethanes, among others. Polyamides, especially nylon 6 and nylon 6,6, are highly desirable for use in forming fibers, particular for use in making carpets, upholstery fabrics, and apparel fabrics. Generally, nylon synthetic fibers have significantly higher gloss and less depth of color than natural fibers, especially wool and silk fibers. The carpet industry traditionally imparts a more wool-like luster to nylon fibers by incorporating small amounts (typically from 0.1 to 0.6 percent by weight) of a delustering agent, such as titanium dioxide   (TiO2)    into the molten polymer. However, the use of delustering agents poses several disadvantages.

   First, the presence of the delustering agent in a thermoplastic composition reduces the depth of color in the fiber giving articles made from the fiber a faded or chalky appearance. Addition of additional dye does not improve the depth of color. Second, the delustering agent reduces the UV fastness of the fiber.   Ti02    is known to cause degradation of the nylon.   TiO2    also reflects impinging light, and thus prevents light from penetrating as far into the fiber as would be desired. This causes carpets, fabrics and other articles made from delustered synthetic resins to fade more quickly than desired. In particular, because light is prevented from penetrating deeply into delustered synthetic fibers, the less faded interior of the fiber cannot be seen, and thus cannot compensate for the more faded surface portions.



   Synthetic fibers tend to possess a smooth surface, which causes them to lack the texture or "hand', softness, and warmth of natural fibers. The fiber industry has devised several means of modifying and/or processing fibers made from thermoplastic resins in order to impart a more natural or softer texture or hand. For instance, it is known to utilize special star-or polynodalshaped dies or spinnerettes and special fiber spinning conditions to impart a variegated surface to the fiber resulting in a softer, more"wool-like"feel. Disadvantageously, such fiber designs often reduce the fiber's mechanical properties, leading to loss of durability. It is known that forming a finer denier fiber gives improved softness, but again durability and fiber spinning economics are sacrificed.



   Nylon fibers in particular possess additional disadvantages. For instance, nylon fibers absorb water and are more susceptible to staining by water based stains than other fiber forming materials such as polyesters. Although nylon fibers and yams made therefrom can be readily dyed in an aqueous media due to this water absorption and due to the receptivity of their reactive amine end groups to the most common acid dyes used in the tufted carpet industry, these reactive amine end groups also make the nylon yarn extremely susceptible to staining. Special grades of nylon with modified end group concentrations are made for this reason. For resins still containing too many amine end groups, expensive stain-resist agents are often employed to cap the amine end groups and impart stain resistance. Such additional treatment results in added cost to the resulting product.

   Moreover, resins that are inherently stain resistant or modified to impart stain resistance, often disadvantageously have poor dye properties, especially poor color fastness. In applications calling for repeated washing of the carpet, such as throw rugs or bath mats, improved color fastness is desired by the industry. It would be advantageous to be able to modify the absorption of water and stains of the nylon fiber to improve stain resistance but still allow dyeability.



   In addition, carpets or fabrics made from nylon yams are prone to dye or optical streaking.



  Nylon fiber used for warp beams'in woven and knit fabrics are carefully selected for dye uniformity and sold at a higher price than conventional nylon fiber. Synthetic carpet production involves steps during which the fibers are heated and cooled, for instance, when the fibers or yams are crimped or twisted. Even with extensive quality control efforts, the fibers making up a given nylon carpet may have undergone inconsistent heat treatments. Because dye penetration and uptake are influenced by the morphology and crystallinity of the nylon fiber, non-uniform heat treatments can lead to carpet fibers with different levels of dye penetration and uptake, which can, in turn, lead to the formation of unacceptable color streaks of lighter or darker color in the finished carpet.

   In addition, yams used in carpet production may have variable crimp recovery leading to differences in tuft width and height in the carpet which gives an optical streak versus the color streak. It would be advantageous to be able to better control the dye strike rate and shrinkage of the nylon fiber during processing to reduce dye streaks and optical streaks.



   In addition, current grades of nylon are difficult to use in commercial production of partially oriented yams or POY, especially for use in apparel fabric manufacture, due to the fact that if a significant time delay occurs after spinning and drawing, on the one hand, and before drawing and texturizing, on the other, the fiber may undergo relaxation. This is believed to be due to a change in the crystalline type, specifically a change from the gamma to the alpha crystal form of the polymer. In practice, spools of fiber made from resins exhibiting this property are subject to despooling and are unacceptable for commercial use. The ability to spin stable POY is advantageous as it allows the spinning process to be de-coupled from the draw and texture process enabling the use of high spinning speeds for apparel yarns.



   A final known disadvantage of nylon resins is their propensity to absorb unacceptable quantities of moisture, necessitating careful drying by the manufacturer before melting and extruding filaments therefrom. Moreover, this property can also contribute to poor carpet performance in service such as undesired absorption of cleaning solutions or spilled liquids and poor color fastness in the resulting article.



   It is known to add small quantities of a second polymeric substance to fiber forming polymers in order to produce rough surfaced fibers having a natural wool-like appearance and decreased luster. In USP 4,518,744 fiber forming thermoplastic polymer blends comprising a fiber forming polymer such as polyethylene terephthalate, nylon 6,6, or polypropylene containing between 0.1 and 10 weight percent of another polymer which is immiscible in a melt and having domain particle diameters from 0.5 to 3 microns in the melt and forming oriented microfibrils in the fiber were disclosed. While imparting improved surface properties and hand, the foregoing compositions have not demonstrated improved melt spinining properties. This is believed to be due, at least in part, to insufficient compatibility between the respective polymeric components.



   In USP 4,806,299, nylon resin blends having added thereto from 0.1 to 5 percent by weight of low molecular weight (200-40,000) polypropylene having a melting point above   120  C    and a viscosity of 200-10,000 centipoise at   190  C    were employed for this purpose. Similar blends of nylon containing the amorphous polymer, polyethyleneoxide (PEO) or polyethyleneglycol (PEG) have been disclosed as well. Disadvantageously, such blends require fibers to be drawn at spinning temperatures that are less than the softening point of the polypropylene   (50-120  C),    and the quantity of polypropylene cannot exceed the upper limit of 5 weight percent without loss of fiber tenacity.

   Moreover, both polypropylene and polyethylene oxide have melting points   (160  C    Tm or   66  C    Tm) that are less than the melting point (Tm) of polyamides   (220-260 C),    thereby making difficult or impossible the formation of discontinuous occlusions of the minor component in a matrix of the major Component (which is a desirable morphology in order to result in delustered fibers) under typical fiber forming conditions. Finally, the water solubility of polyethylene oxide makes resulting fibers formed from blends containing the same unacceptable for commercial use due to lack of color fastness, lack of stain resistance, and dye variability.



   In USP 5,399,306, nylon carpet or textile yarn prepared at increased rate of throughput containing a secondary component such as a co-monomer, a metal salt, or a molecularly dispersed polymer (for example nylon 6 dispersed in nylon 66 or PEG dispersed in nylon 66) were disclosed.



   USP 6,024,556 disclosed a mechanical process for forming a multilayered, colaminar, composite polymer fiber having improved optical properties, especially increased gloss and depth of color, by forming a multilayered, fiber structure with controlled layer optical accuracy.



   Certain references have proposed compositions comprising syndiotactic polystyrene (SPS) and nylon, or other polymeric compounds. In USP 5,914,370, low water absorbing blends of nylon, SPS and various polar group containing compounds, including a maleated syndiotactic copolymer of styrene and p-methylstyrene were prepared and tested for molding applications.



  Various ratios of ingredients down to 25 percent SPS and 5 percent of the maleated copolymer (see Example 8) were tested. In USP 5,270,353 blends of SPS and various polar functional polymers, including nylon, and a polar group containing compatibilizing compound, including a maleated polyphenylene ether and styrene/maleic anhydride copolymers, were disclosed.



  Example 5 in particular, contained polyamide and syndiotactic polystyrene in an 85/15 weight ratio along with 5 percent of a styrene/maleic anhydride copolymer containing 1 percent maleic anhydride. The amount of compatibilizer in this blend and the quantity of polar groups therein is believed to be insufficient to achieve adequate dispersion of dispersed phase particles in the polyamide matrix for use in fibers or films.



   In Research Disclosures, 40258, published Sept. 20,1997, yams prepared from syndiotactic polystyrene or blends thereof with nylon or other polymers for use as industrial textiles, especially paper machine fabric or other high temperature applications, were disclosed.



  In TW 404965 A, published February 8,1999, an impact-resistant polystyrene/polyamide composition, comprising: (a) 50-100 parts by weight of a syndiotactic styrene-based polymer; (b) 1-50 parts by weight of a polyamide; and (c) 0.01-20 parts by weight of a styrene-maleic anhydride compatibilizer having improved toughness and flexural strength was disclosed. Finally, in USP 6,093,771, blends of thermoplastic polymers for use in fiber, film and molding applications were disclosed.



   It has now been discovered that blends of syndiotactic polyvinylidene aromatic polymers and polyamide polymers or copolymers, even such blends that include a compatibilizer, do not possess good fiber forming properties if the quantity of the syndiotactic polyvinylidene aromatic polymer therein is excessive. In particular, such resins possess insufficient fiber strength to permit formation of fibers using high speed fiber forming equipment. Moreover, such polymer blends that contain a polar group modified polyphenylene ether as a compatibilizer are generally slightly yellow in color. For many applications where light colored or white fibers are desired, such polymers have not been found to be acceptable.

   In addition, blends of the prior art containing polyethylene terephthalate, polypropylene or polyethylene oxide in a nylon matrix, although delustered, generally possessed unacceptable spinnability, colorability, and crush resistance properties, making the same unacceptable for commercial usage.



   Accordingly, there is a need for supplying a fiber comprising a syndiotactic polyvinylidene aromatic polymer that can be prepared using high speed fiber forming equipment.



  Moreover, the industry would find great advantage in synthetic fibers that enjoy the attributes of natural fibers. In particular, the industry would find great advantage in synthetic fibers that exhibit the characteristics of high quality wool fibers--particularly low luster, good hand and softness, low yellowness, and good depth of color. The industry would find particular advantage in synthetic fibers that enjoy one or more further attributes, such as high speed spinnability, stainresistance, colorfastness, low color-streaking, low optical-streaking, reduced soiling, improved crush resistance or durability, and low moisture uptake. Finally, the industry would find particular advantage in solutions to the foregoing problems that do not require costly specialized equipment designs or operating procedures (such as use of reduced drawing temperatures) and finishing technologies.



   A. Accordingly, the subject invention provides a composition comprising:  (a) from 76 to 97, more preferably from 80 to 95, and most preferably from 86 to 92 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc greater than   160  C,    preferably greater than   165  C,    most preferably greater than   170  C    ;

    (b) from 24 to 3, more preferably from 20 to 5, and most preferably from 14 to 8 percent by weight of a second thermoplastic polymer chemically different from component (a) having a crystallization temperature, Tc', and  (c) optionally a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least   5  C,    preferably at least   10 C,    most preferably at least   20 C    less than   Tc'.   



   Preferably the foregoing composition has a yellowness index, YI, of less than 10.



   B. In another embodiment, the invention provides a composition comprising:  (a) from 76 to 97, more preferably from 80 to 95, and most preferably from 86 to 92 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc greater than   160  C,    preferably greater than   165  C,    most preferably greater than   170  C    ;

     (b) from 24 to 3, more preferably from 20 to 5, and most preferably from 14 to 8 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', wherein said percentages are based on the weight of (a) and (b); and  (c) optionally a compatibilizer for (a) and (b), and  (d) from 0.1 to 10.0, preferably from 0.1 to 7.0, more preferably from 0.2 to   5.    0 percent based on total composition weight of a delustering agent, and wherein Tc is at least   5  C,    preferably at least   10 C,    most preferably at least   20 C    less than Tc'.



   Preferably the foregoing composition B, also has a yellowness index, YI, of less than 10.



   C. In another embodiment, the invention provides a composition comprising the foregoing compositions A or B, or a preferred embodiment thereof, wherein the first thermoplastic polymer is a polyamide, preferably a polyamide having a relative viscosity from 25 to 250, and more preferably the polyamide is nylon 6.



   D. In yet another embodiment of the invention there is provided a composition comprising the foregoing compositions A, B or C, wherein the second thermoplastic polymer is a vinylidene aromatic homopolymer or copolymer having a tactic stereostructure, preferably a homopolymer of a vinylidene aromatic monomer, a copolymer of more than one vinylidene aromatic monomer, or a polar group modified derivative thereof, said second thermoplastic polymer having a syndiotactic stereostructure, most preferably a stereostructure of greater than 95 percent syndiotacticity.



   E. In another embodiment, the subject invention provides an extruded and drawn fiber, or an extruded and stretched film comprising the foregoing thermoplastic compositions A, B, C, or
D, preferably a drawn fiber or oriented film, or a yarn comprising such a drawn fiber, preferably such filament, fiber or film has a rough surface or comprising occlusions of Component (b) within a matrix of Component (a), said occlusions having a volume average minor axis size greater than 0.2cm, preferably from 0.3 to 2.0   Am,    or having a D99 minor axis size less than 3.0   pm,    or having laser light scattering ratio (defined hereafter) greater than 0.29, or having luster panel rating of 4.0 or less.



   F. In another embodiment, the subject invention provides a process for preparing a fiber or film, the steps of the process comprising:  (1) extruding a thermoplastic composition according to A, B, C, or D herein in the form of a fiber or film comprising a continuous matrix of the first thermoplastic polymer and containing occlusions of the second thermoplastic polymer,  (2) drawing the filament or orienting the film of step (1) into a drawn fiber or oriented film, characterized in that the occlusions of the second thermoplastic polymer partially extend beyond the surface of the fiber or oriented film or cause perturbations in the surface of the fiber or film.



   G. In another embodiment, the subject invention provides a carpet, rug, woven fabric, non-woven or spun-bonded fabric, knit fabric, garment, laminate, construction, or other article of commerce prepared from any of the foregoing filaments, fibers, yarns, or extruded films, E or F.



   H. In another embodiment, the subject invention provides a process for preparing a fiber or film, the steps of the process comprising:  (1) extruding in the form of a fiber or film a thermoplastic composition according to A, B,
C, or D, the temperature at which the thermoplastic composition is extruded being above the melting point (Tm) of both Component (a) and Component (b),  (2) cooling the extrudate to a temperature between the crystallization temperatures of
Component (a) and Component (b); or cooling the extrudate to a temperature below the crystallization temperatures of Component (a) and Component (b) and subsequently reheating the extrudate to a temperature between the crystallization temperatures Component (a) and
Component (b), and  (3) drawing the filament or film of step (1) into a drawn fiber or oriented film.



     1.    In yet another embodiment of the present invention there is provided a process for preparing a rug or carpet, the steps of the process comprising:  (1) extruding a thermoplastic composition according to A, B, C or D into a multitude of fibers,  (2) drawing the fibers,  (3) optionally texturing, crimping, dying, or partially or fully heat setting the fibers,  (4) combining the fibers of (3) into one or more yarns, optionally with twisting, dying, carding, or bulking processes or further heat setting;  (5) inserting the yarn or yams into a backing and fixing the same thereto; optionally with cutting or shaping of the yarn, to thereby form a rug or carpet, and  (6) optionally, dyeing or finishing the rug or carpet, wherein the finishing comprises applying one or more stain-resist or soil-resist treatments, rinses, drying, or other steps.



   J. In another embodiment of the present invention there is provided a process for delustering a fiber of a first thermoplastic polymer (a) having a crystallization temperature, Tc, greater than   160  C,    preferably greater than   165  C,    most preferably greater than   170  C    ; comprising adding to the thermoplastic polymer from 24 to 3, more preferably from 20 to 5, and most preferably from 14 to 8 percent by weight of a second thermoplastic polymer (b) different from (a) and having a crystallization temperature, Tc', and (c) optionally a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein:

   1) Tc is at   least 5'C,    preferably at least   10 C,    most preferably at least   20 C    less than Tc', to thereby form a polymer mixture, and forming and drawing a fiber from the polymer mixture.



   K. In yet another embodiment of the invention, explained in greater detail here-inafter, there is provided a thermoplastic polymeric composition in the form of an extruded and drawn, multicomponent fiber or an extruded and oriented, multilayer film, or one or more components or layers of such a multi-component fiber or a multi-component film, said composition comprising any of compositions A, B, C or D, or comprising:  (a) from 99 to   51,    preferably from 97 to 76, more preferably from 96 to 80, and most preferably from 92 to 86 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ;

    (b) from 1 to 49, preferably from 3 to 24, more preferably from 4 to 20, and most preferably from 8 to 14 percent by weight of a second thermoplastic polymer different from (a) having a crystallization temperature (Tc'), and  (c) optionally, a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least   5  C,    preferably at least   10 C,    most preferably at least   20 C    less than Tc'.



   L. Another aspect of the present invention is a thermoplastic polymeric composition that is useful for preparing extruded fibers and films, said composition consisting essentially of :  (a) from 65 to 97 percent by weight of one or more first thermoplastic polymer (s) having crystallization temperatures, Tc, greater than   160  C    ; and  (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups, and optionally one or more non-polymeric additives.



   M. In a final embodiment, there is provided any of the foregoing articles, wherein the polymer composition is prepared by melting a base resin comprising primarily Component (a) and mixing the same either simultaneously or subsequently with a concentrate resin comprising primarily Component (b) and optionally Component (c) and or (d), and further optionally, a minor amount of Component (a); and extruding and optionally drawing the resulting molten thermoplastic polymeric composition in the form of a drawn fiber or optionally extruding and stretching the resulting thermoplastic polymeric composition in the form of a stretched film. A preferred manner of obtaining the foregoing well mixed polymeric composition is to incorporate a mixing device or element that provides static mixing or extensional mixing to the polymer melt during or after a melt mixing or extruding process step.



   Figure   l    (a) is a scanning electron micrograph of a fiber prepared from a thermoplastic composition comprising 93.1 weight percent Nylon-6,5 weight percent syndiotactic polystyrene, and 1.9 weight percent compatibilizer according to Example   51.   



   Figure   l    (b) is a scanning electron micrograph of a fiber prepared from a thermoplastic composition comprising 87.3 weight percent Nylon-6,10 weight percent syndiotactic polystyrene, and 2.7 weight percent compatibilizer according to Example 52.



   Figure   l    (c) is a scanning electron micrograph of a fiber prepared from a thermoplastic composition comprising 81.9 weight percent Nylon-6,15 weight percent syndiotactic polystyrene, and 3.1 weight percent compatibilizer according to Example 53.



   Figure 2 (a) is a scanning electron micrograph of a fiber prepared from a thermoplastic composition comprising Nylon-6 and 0.2 weight percent   Ti02    delustering agent according to
Comparative K.



   Figure 2 (b) is a scanning electron micrograph of a fiber made from the thermoplastic composition comprising Nylon-6 and 0.4 weight percent   TiO2    delustering agent according to
Comparative L.



   Figure 2 (c) is a scanning electron micrograph of a fiber made from a thermoplastic composition comprising 89 weight percent Nylon-6,10 weight percent atactic polystyrene, and 1 weight percent compatibilizer according to Comparative M.



   Figure 3 is a plot of a typical multilobal fiber for purposes of calculating modification ratio (Mod ratio).



   Figure 4 is a plot of the appearance retention ratings for sample carpets of Examples   51 c-    53c, Kc and Lc.



   Figure 5 contains stain ratings for sample carpets made from the yams of Examples 54, 55, and Mc.



   Figure 6 is a diagram of an extensional flow mixer incorporated as one element of a melt mixing and extruding device such as is used in Example 48.



   Figure 7 is a novel die design adapted for use with polymer blend compositions according to the invention which possess high die swell.



   Figure 8 is a schematic illustration showing the relationship of instruments used to measure laser light scattering ratios for fibers.



   Figure 9 is an   isometric    view of a single fiber mount used for measuring laser light scattering ratios. 



   Figure 10 is a side view of the single fiber mount used for measuring laser light scattering ratio.



   Figure 11 is a cross-section from line 11 of Fig. 10 in the direction indicated of a mount used for measuring single fiber laser light scattering ratio.



   Figure 12 is a plot of luster as a function of scattering ratio, Rs, as determined by laser light back scatter measurement of fibers in Examples 1-3, A, B and   C 1-C5.   



   Figure 13 is a plot of scattering ratio,   Rs,    as a function   of Ti02    content for various fibers in Examples   D 1-D6,    as determined by laser light back scatter measurement.



   Figure 14 is a plot of volume average particle diameter, as a function of panel luster for fibers in Examples 16-27.



   Figure 15 is a plot of volume average particle diameter, as a function of scattering ratio for fibers in Examples 16-27.



   Figure 16 is a plot of 99"'percentile by volume D99 of occluded particles, as a function of tenacity for fibers in Examples 16-27.



   Figure 17 is a scanning electron micrograph (SEM) of occluded particles of Component (b) from fibers produced in Example 25.



   Figure 18 is a plot of D65, 10 degree color ratings   of undyed    fibers, after exposure to UV light as determined in Examples F,   39a, 41a, 43a,    and 44a.



   Figure 19 is a scanning electron micrograph (SEM) of the surface of a fiber of
Example 48.



   For purposes of United States patent practice, the contents of any patent, patent application or publication referenced herein is hereby incorporated by reference in its entirety, especially with respect to the disclosure of analytical or synthetic techniques and general knowledge in the art. The term"comprising"and derivatives thereof is not intended to exclude the presence of any additional component, step or procedure, whether or not the same is disclosed herein. In order to avoid any doubt, all compositions claimed herein through use of the term   "comprising"may    include any additional additive, adjuvant, or compound whether polymeric or otherwise, unless stated to the contrary.

   In particular, the blends of the present invention characterized in the use of the term"comprising"may include in components (a), (b) and (c) more than one thermoplastic polymer meeting the claim requirements. In contrast, the term,"consisting essentially of'excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. Finally, the term"consisting of' excludes any component, step or procedure not specifically delineated or listed.



   The term"polymer", as used herein, includes both homopolymers, that is, polymers prepared from a single reactive compound, and copolymers, that is, polymers prepared by reaction of at least two polymer forming reactive, monomeric compounds. The term"crystalline"refers to a polymer that exhibits an X-ray diffraction pattern at   25  C    and possesses a first order transition or crystalline melting point (Tm). The term may be used interchangeably with the term "semicrystalline". The term"chemically different"refers to the primary repeat groups of two polymers differing functionally rather than by difference of repeat unit size.



   The term"fiber"refers to a strand of a thermoplastic material having a relatively large length/thickness ratio, including continuous fibers. The fiber's cross-section may have any desired closed shape, including rounded or curved, polygonal or polynodal shapes. In addition, the cross-section may include continuous or discontinuous voids of any shape, thereby resulting in a hollow, partially hollow or cell containing fiber. Included are continuous and discontinuous single fibers or yams produced therefrom. Preferably, the fiber has a maximum cross-sectional dimension of 2.0 mm, more preferably 1.0 mm, most preferably 0.5 mm. Preferably, a fiber is characterized by having a length at least 100 times its diameter or maximum cross-sectional dimension.

   For use in preparing yarns, fibers should have a length of at least 5 mm, and sufficient strength and flexibility to be useful in this application. Drawn fibers are articles formed by drawing or spinning the foregoing fibers, thereby elongating the same, and imparting improved tensile strength or other physical properties thereto. Generally, drawing imparts greater orientation to the crystal structure of one or more polymer components of the fiber. Preferred drawn fibers are those that are drawn at a ratio of at least 2/1, preferably at least 2.3/1 and most preferably at least 2.6/1. In the foregoing definition, the draw ratio refers to the ratio of the respective linear velocities of the fiber as measured at the end point and at the initiation of the drawing process.

   Fibers may be crimped, dyed or otherwise physically or chemically modified before or after combining with other fibers to form yams or tow.



   The term"filament"as used herein, generally refers to a fiber of an indefinite or extreme length. Fibers of relative short length are referred to as"staple"."Tow"refers to a combination of several fibers without definite twist or other physical modification. The individual fibers may be held together by entanglement or by crimping of the fibers. The   term"yarn"refers    to any combination of one or more fibers or filaments including further physically or chemically modified derivatives thereof, such as interlaced, dyed or heat set derivatives of such fibers or filaments. Included are tows, which are referred to as zero-twist   yarn.    Twisting generally imparts improved strength, cohesiveness and uniformity to the yarn, generally due to improved entanglement.



   The term"film"refers to a solid, self-supporting, generally planar, structure having average thickness less than or equal to 50 percent of its average width and average thickness less than or equal to 1.0 mm. 



   A"compatibilizer"is a polymer or other compound that increases the interfacial adhesion, reduces interfacial tension, or both increases interfacial adhesion and reduces interfacial tension between differing phases of a multi-component mixture. Polymeric compatibilizers may be one of several types : a.) The compatibilizer may comprise separate regions or"blocks"having different physical and chemical properties. The polymer may either be linear block copolymer having two or more blocks, a radial copolymer containing multiple arms eminating from a central core, or a   "star"or    dendimer geometry containing separate regions of similar chemical structure. One block, arm or region is miscible or has an affinity for one or more of the mixture's components.

   One or more other blocks, arms or regions are miscible or have an affinity for one or more of the remaining components of the mixture. b.) The compatibilizer is miscible or has an affinity for one of the components in the mixture and contains functionality that is capable of reacting with and binding to one or more of the remaining components. c.) The compatibilizer contains at least two types of functionality. One type is capable of reacting with and binding to at least one of the components of the mixture, and one or more types of remaining functionality are capable of reacting with and binding to at least one of the remaining components of the mixture.



   Increased interfacial adhesion is evidenced by an increase in tensile strength of a sample containing the compatibilizer, as determined according to ASTM D 638 and after conditioning according to ASTM D 618 A. Domains are identifiable regions of individual polymers determined through microscopic examination, optionally using a stain, or evidenced by some other morphological analysis technique. The separate domains result from incomplete or inhomogeneous mixing of the respective polymers. The domains may be in the form of occlusions of one polymer in a matrix of the other polymer, or an interpenetrating network wherein each polymer remains continuous or semicontinuous.

   For use herein, thermoplastic polymers are considered immiscible if a blend formed by thorough mixing of two such polymers at a temperature above the melting points of both polymers, results in a non-homogeneous material, that is, a material characterized by separate domains of one or all of the polymers that are identifiable by microscopic examination or other morphological analysis technique. Preferably, the composition of the invention results in the formation of occlusions of Component (b) within a continuous matrix of Component (a) and the filaments and fibers of the invention are characterized by the presence of occlusions of Component (b) within a continuous matrix of
Component (a). 



   Preferred compatibilizers (component (c)) for use herein are thermoplastic polymers containing both an oleophilic functionality, preferably an organic, aromatic functionality, and a relatively polar functionally. Illustrative thermoplastic compatibilizers for use herein include polar-group-modified polyphenylene ethers, polar group modified vinylidenearomatic polymers, polar group modified block copolymers of one or more vinylidenearomatic monomers and one or more conjugated dienes, including partially or fully hydrogenated derivatives of such polymers or block copolymers and mixtures of the foregoing. Suitable vinyl aromatic monomers include styrene,   C,    ring alkyl-or halo-substituted styrenes (especially all isomeric forms of vinyl toluene, including mixtures of such isomers) and a-methylstyrene.

   Preferred compatibilizers include graft copolymers of an ethylenically unsaturated, polar group containing compound, especially maleic anhydride or fumaric acid, with a preformed polyphenylene ether; graft copolymers of a polar comonomer, especially maleic anhydride, fumaric acid, Nmethylmaleimide, methylmethacrylate, acrylonitrile or acrylamide and a vinyl aromatic polymer or copolymer, especially atactic or syndiotactic polystyrene, a copolymer including syndiotactic copolymers of styrene and one or more ring-alkyl substituted styrenes, especially a syndiotactic copolymer of styrene and p-methyl styrene, o-methylstyrene, m-methylstyrene or mixtures thereof ; or a block copolymer of styrene and a conjugated diene, and copolymers of the foregoing polar comonomers with a vinyl aromatic monomer, especially styrene.



   It is hereby reiterated for purposes of clarity, that in the previously noted embodiments of the invention A-M, Component (b) may likewise be a polar group modified crystalline polymer, such as those of the foregoing list of suitable components for Component (c), especially a reactive polar group modified syndiotactic vinylidene aromatic homopolymer or copolymer. In such embodiments of the present invention, a separate compatibilizer (component (c)) need not necessarily be included in the composition. As an example of such an embodiment, a composition comprising as the sole polymeric components from 97 to 76 percent Component (a) and 3 to 24 percent of such a polar group modified syndiotactic vinylidene aromatic homopolymer or copolymer is particularly preferred according to the invention.

   More preferably still, such compositions comprise a polar group graft modified syndiotactic copolymer of styrene and one or more ring methylated styrenes, especially p-methylstyrene, said copolymer containing from 99.5 to 95.0 percent styrene and from 0.01 to 5.0 percent of said ring methylated styrene, based on the combined weight of the polymerized styrene and methylstryene components; and from 0.01 to 3 weight percent, based on total graft polymer weight, of a grafted, polar comonomer residue.



   As used herein, the term"tactic"refers to polymers having a stereoregular structure of greater than 90 percent isotactic or syndiotactic, preferably greater than 95 percent isotactic or syndiotactic, of a racemic triad as determined   by'3C    nuclear magnetic resonance spectroscopy. 



  The term"isotactic"and"syndiotactic"refer to such tactic polymers which having isotactic or syndiotactic stereostructures, respectively."Relative viscosity"values, RV, unless stated to the contrary, are unitless values and are based on viscosity measurements of an 8.5 weight percent solution of the polymer in formic acid for nylon, or in another suitable solvent for other polymers, at   25  C,    otherwise measured according to ASTM D 2857.



   Yellowness Index, YI, is determined on both polymer samples and article samples (fibers) are unitless numbers determined according to ASTM E-313-00. Preferred YI ratings for compositions and fibers according to the invention are less than 8, and most preferably less than 6.



   Luster in fibers has long been tested qualitatively, especially in the textile industry, using a panel of experts comparing samples to known standards made from wool for a dull or delustered fiber and from pure nylon fiber for a bright or high luster standard. A similar luster panel approach is used in this patent where fibers are graded from 1 (dull, wool) to 5 (bright, not delustered). Disadvantageously, while the test reflects the luster as determined by the human eye, the test is subjective. In order to provide a luster test that may be applied to the fiber itself, and which is more quantifiable than the panel test, the present inventors have developed a laser light back-scatter analysis technique based on the published technique   of C.    Luo and R. R.

   Bresee, published as,"Experimental Studies of Fiber Surface Roughness by Laser   Backscattering"J.   



  Polym. Sci. Phys.   Ed.,    28,1771 (1990) and"Computer Simulation of Laser Backscattering from
Fiber Surfaces"J.   Polvm.    Sci.   Phys.    Ed., 28,1755, developed for determining the surface structure of textile fibers.



   The above technique takes advantage of the fact that fibers which have high luster exhibit emanating radiation which is highly directional (anisotropic, low solid angle) while those with low luster emanate radiation that is less directional (more isotropic, higher solid angle). By using fixed solid angle detection optics and image analysis, the degree of scattered radiation can be measured and quantified. One known way to optically de-luster fiber is to impart surface roughness on the fiber. (Other means include adding internal means such as scattering bodies or refractive index boundaries within the fiber.) Regardless of the mechanism for de-luster, collimated incident light emits from the fiber in a greatly enhanced solid angle. Images resulting from the emission are converted into a spatial frequency domain for subsequent analysis using a
Fourier transform method.

   In the aforementioned technique, a roughness coefficient, RC, was then obtained from this analysis and used to quantify luster of various fibers.



   In order to quantify luster on individual fiber samples according to the present invention, the following procedure and technique (referred to herein as laser light back scatter technique) was developed based on the foregoing prior art teachings. An apparatus adapted to measure scattered laser radiation from a single fiber according to the present technique is depicted in 
Figure 8. It includes four major components: a laser light source, 10, emitting a light beam, 2, a fiber mounting and orienting means, 20, a recording/analyzing means, 30, such as a digital camera coupled to a digital processor or computer, and a back lighting strobe unit, 40, for synchronizing the measurement of scattered laser light by means of light beam, 4.

   A preferred laser light source is a helium-neon gas laser emiting TEMoo, random polarized light, at a wavelength of 632.8 nm, with a   1/e2 beam    diameter of approximately 0.78 mm (model LSR2P laser, available from
Aerotech Inc.). The laser is mounted on a vibration dampening, adjustable stage, such as a 433 translation stage, available from Newport, Inc., Irvine, CA) which allows fine adjustment of height and course adjustment in the angle of the incident radiation,   0.    Fine adjustment of the angle of the incident radiation is provided by adjusting the amount of travel using a precision rail system (PRC-3 carrier and PRL-36 rail, available from Newport Inc., Irvine, CA).

   A linear, variable neutral density filter   (3 1WOOML. 1,    Newport, Inc.) may be fitted to the laser to adjust the power of the incident laser beam, 2.



   The fiber mount, shown in isometric view in Figure 9, end view in Figure 10, and crosssection from line A, in Figure 11, allows flexibility in fiber orientation and conformation. The mount includes a yoke   21,    comprising holders,   21a    and   21b    attached to base   21c    by fasteners   21d,    and containing circular openings that accept thimbles 22a and 22b. Thimbles 22a and 22b are held in position in the holders   21a    and   21b    respectively by means of locking devices 23a and 23b, respectively. Fiber locking clamps 24a and 24b for mounting the respective ends of the fiber, 1 are located on the outside face of thimbles 22a and 22b.

   Thimbles 22a and 22b can be rotated around the major axis of the fiber in unison or independently. With locking devices 23a and 23b loosened, the thimbles rotate together due to an interconnection with thimble strut 24. Thimble 22a is further comprised of an inner thimble 28 comprising a central axial portion, 29, concentrically fitted to thimble holder 27 and rotatable along the fiber axis with respect to thimble holder 27. Inner thimble 28 is held in axial relation to thimble holder 27 by means of independent locking means 23c such as a set screw. The fiber is twisted multiple times to randomize surface features before measurements are made, by unlocking independent locking means 23c, and rotating inner thimble 28, while preventing motion of thimble holder 27 by locking thimble screw 23a.

   The fiber mount yoke is removably connected to a height adjustable positioning means, not shown, such as a post, that engages connecting port, 26.



   Further regarding figure 8, the detector, 30, comprises a video camera, such as a model
XC-55/55BB video camera, available from Sony Corporation, Japan. This camera contains a sensor array of 659 X 494 (horizontal/vertical) pixels operated with an 8-bit gray scale, and a zoom lens set at a magnification of 4, yielding a spatial resolution of 4.022   vum/pixel.    To provide backside illumination and to synchronize the camera exposure, a fiber optically coupled flashlamp, 40, such as a LS-1102 flashlamp, available from EG & G Optoelectronics, Salem, MA, is positioned on the opposite side of the fiber from the camera.



   The fiber to be analyzed is carefully washed in hot, deionized water, to remove finishing coatings and dust, dried, and maintained in a dust free environment before and during analysis.



  The fiber is twisted to randomize surface features and placed under tension for analysis. Image acquisition and analysis may be performed using an IBM personal computer equipped with an
Intel, Pentium (III)   TM    microprocessor, a video capture board, and image analysis software (Speedview 850, Greenfield Instruments, Greenfield, MA).



   Images of the fiber collected with and without incident laser light are processed to yield a measure of scattered laser intensity emitting from the fiber. Quantification of the amount of scattered light was accomplished by analyzing the gray scale images in a histogram format, whereby peaks attributable to the reflected fiber-, background-and scattered-radiation are recorded. The integrated intensity of these peaks, in pixels (area), gives the fiber area and the intensity of scattered radiation. Since the fiber diameter is known to affect scattering intensity and the fibers analyzed are of different diameters, the measure of scattered intensity is normalized to fiber diameter through the equation:
Rs= s (1)
Af
Where   Rs    is the scattering ratio, Is is the intensity of scattered light collected and Af is the area of the fiber.

   It has been found that the scattering ratio, also referred to as laser light back scattering ratio, is a quantifiable number that is inversely related to the appearance attribute of luster. As disclosed with respect to Examples 1-3, A, B,   C1-C5    and   D1-D6,    this laser light scattering technique for luster measurement has been shown empirically to closely correlate to luster panel results and to luster values produced through addition of known quantities of a delustering agent   (TiO2).    Highly desirably according to the present invention, the fibers as measured by this technique of laser light back scattering, have a scattering ratio,   Rs,    of at least 0.29, preferably at least   0.

   33.    Alternatively, or in addition, the fibers possess a corresponding luster panel value less than or equal to 4, more preferably, less than or equal to 3.5.



   The term"occlusions"refers to discontinuous or substantially discontinuous regions of
Component (b) surrounded or partially surrounded by Component (a), referred to as the matrix.



  The size and distribution of the solid occlusions of Component (b) determine the ultimate fiber properties, especially luster and spinnability. A good correlation between luster and volume average minor axis diameter has been determined to exist. Preferred are fibers having volume average, minor axis diameters, Dv, of Component (b) occlusions, greater than 0.2   Hm,    preferably of from 0.25 to 3.0   pm,    more preferably from 0.3 to 2.0   um,    and most preferably from 0.4 to 1.6   pm.    In addition, the absence of large occlusion particles is highly desired in order to improve fiber tenacity and avoid fiber breakage, which properties jointly are indicative of spinnability.

   In particular, highly preferred are fibers having a 99 percentile minor axis diameter, D99, of
Component (b) occlusions of less than 3.0   m.    Having a narrow particle diameter distribution is highly preferred as the minimum luster and maximum tenacity can be achieved for the volume average particle diameter.



   A particle diameter dispersity, P, can be calculated using these two measures of diameter for occluded particles of Component (b) using the formula:   
D 99
P =-=-,   
Dv
Preferred fibers have Component (b) particle diameter dispersities of less than 2.7, most preferably less than 2.3.



   The foregoing Dv and D99 measurements are determined by dissolving fiber or film samples in a solvent for the matrix which is not a solvent or swelling agent for the occlusions. A suitable solvent for polyamide matrices and, which is not a solvent or swelling agent for syndiotactic vinylaromatic polymer occlusions is formic acid or aqueous solutions of formic acid.



  After dissolving the matrix, the resulting separated particles of occluded material are recovered by filtration, surface coated with chromium, and photographed by scanning electron microscopy.



  Standard, computer assisted particle size analysis techniques are used to measure particle diameters.



   Techniques to control the particle size of Component (b) occlusions and thus the properties of the resulting fiber, include the type and quantity, if any, of compatibilizer,
Component (c) employed; the degree of mixing achieved while in the molten state prior to extrusion; the amount of delay time between the completion of mixing of the molten thermoplastic blend and extrusion of the fiber under conditions allowing coalescence of Component (b); the amount and type, if any of any nucleator present in the formulation, the relative viscosities and melt viscosities of the respective components (a) and (b), and other processing variables.



   The benefits of the present invention are believed to be due to the fact that upon drawing or spinning of the fibers while simultaneously cooling the extrudate or filament, occlusions of
Component (b) are less affected by the drawing forces compared to Component (a). This is referred to as differential drawability for the purposes of this patent. Preferably according to the invention, Component (a) is drawn more than occlusions of Component (b) under extrusion and fiber forming conditions. More preferably, the matrix polymer (component (a)) is drawn at least 2, most preferably at least 3 times greater than are occlusions of polymer Component (b).



  Differential drawability is determined by taking the ratio of the draw of the whole fiber or film to the draw of the dispersed phase. The draw of the whole fiber or film is defined as the ratio of the cross-sectional area of an undrawn fiber or unstretched film and a fully drawn fiber or fully stretched film, assuming conservation of particle mass. The draw of the dispersed phase is defined as the ratio of the average cross sectional area of the dispersed phase in an undrawn fiber or unstretched film and that of a fully drawn fiber or fully stretched film.

   As a result of the foregoing differential drawability, portions of such occlusions are left projecting from the surface of the resulting fiber or film, or, due to the close proximity of such occlusions to the surface of the fiber or film, cause protuberances, crevasses, or other discontinuities or irregularities in the surface, due to greater draw-down of the matrix (component (a)) as it is drawn to a greater degree than are the occlusions. Such rough surface fibers have a desirable low luster, hand, and softness; similar to a natural fiber; and still possess improved spinnability and drawing properties, allowing high speed commercial fiber forming and reduced frictional forces or drag during the fiber forming process. The reduced fiber to metal frictional forces additionally allow use of lower amounts of spin finish lubricant to be employed.

   Rough surfaced films possess similarly desirable properties such as anti-block, less dust formation, and reduced friction during manufacture.



   Differential drawability, as demonstrated in the invention, is affected by many variables.



  The domain size of the dispersed phase must be large enough to be able to create an effective rough surface but not so large as to reduce the tenacity of the fiber to a level where fiber spinning is difficult. The domain size of the dispersed phase must be stable in the melt phase to accommodate the residence time found in the extruder and manifold of the fiber spinning line without excessive coalescence. Compatibilization of the interface between the dispersed phase and the continuous phase helps to prevent tears or ruptures that would dramatically reduce the fiber's spinnability. The melting points of the dispersed phase and continuous phase must be close enough that both phases are melted yet not too hot for decomposition or fiber spinning.

   The rheology of the dispersed phase and the continuous phase must be similar enough to allow the desired particle diameter to be formed during melt mixing but dissimilar enough to allow differential drawability during fiber spinning. The drawability of the dispersed phase and the continuous phase is dependent on the viscosity and crystallization kinetics of the respective phases. The development of a small amount of crystallization can dramatically increase the viscosity of either phase. Crystallization kinetics can be quantified by the temperature at which crystallization begins, the temperature of maximum crystallinity development, or the rate of crystallization versus temperature. Nucleators or crystallization inhibitors can be used to modify the crystallization kinetics.

   The viscosity of either phase can also be increased or decreased by changing the molecular weight of the polymer or by adding substances that affect the flow properties (for example, plasticizers or flow enhancing materials).



   The molecular weight of the continuous phase can also be changed to impact the drawability of the dispersed phase. Similarly, additives to affect the flow properties may be added to the continuous phase. The drawing forces in fiber spinning are imparted onto the continuous phase by the draw godets of the fiber spinning equipment. The drawing forces are imparted onto the dispersed phase via the continuous phase. As the molecular weight of the the continuous phase is lowered, it is drawn more easily and imparts less drawing force on the dispersed phase.



   In the formation of extruded films and uniaxial or biaxial orienting or tentering of the same, a similar phenomena results in formation of irregularities in the surface of the resulting film.



  Such films possess less cling and are more readily handled by high speed film forming equipment without the required additional presence of a blocking agent. In addition, such films are less prone to formation of dust during high speed handling and conveying processes.



   Although the foregoing benefits in fiber properties are achieved without the need to include a delustering agent, especially titanium dioxide, in the thermoplastic composition, it is understood that addition of such an additive is not precluded. If present, the quantity used may be significantly reduced, compared to prior art nylon based formulations. Where employed, the quantity of delustering agent may be from 0.01 to 0.3 weight percent and preferably less than 0.1 weight percent. Most preferably no delustering agent is employed, thereby advantageously improving the ability to recycle fibers, film, and articles incorporating the same according to the invention, especially into articles such as injection molded, glass fiber reinforced articles, as to which delustering agents such as   TiO2    detrimentally affect physical properties.



   Furthermore, custom die or spinnerette designs may be employed, if desired, to produce a polynodal filament shape thereby resulting in production of fibers possessing improved bulk. Due to die swell differences compared to pure nylon resins, a special die design is preferably employed in order to best utilize the present polymer blend composition.

   This die geometry is illustrated in
Figure 7, where an elongated trilobal die opening design, 70, having three equal length slots,   71,    having generally parallel (illustrated) or slightly converging sides which terminate in half-circular or arcurate ends, 72, with a total slot length (measured along a central axis, 73, of the slot from the point where each central axis of the three lobes intersects) of 0.045 inches (1.143 mm), slot width of 0.007 inches (0.178 mm), a capillary length of 0.040 inches (1.02 mm), having a Mod ratio   (MR)    of 11.2. Preferred die have Mod ratios from 9 to 12.



   Mod Ratio as used herein refers to the ratio of two measures of the cross-sectional shape of a polynodal fiber or die. Specifically, it is the ratio of the radii of two circles, the larger of which (numerator) is centered on the center of the cross-sectional shape and circumscribes the entire polynodal shape and the smaller of which (denominator) inscribes the inner area of the polynodal shape. This is illustrated by reference to Figure 3 where a polynodal shape, 30, having three nodes,   31,    a circumscribing circle, 32, having radius   R1    and an inner inscribing circle, 33, having radius, R2. Mod ratio is defined as   R1/R2.    Preferred Mod ratios of fibers according to the invention are from 2.5 to 4.



   It has further been found that yams comprising fibers and filaments according to the present invention generally demonstrate enhanced color penetration and fade resistance, enhanced dye retention, improved stain resistance, improved soiling resistance, improved dimensional stability, improved dye leveling, and decreased moisture uptake relative to yams made from polymer compositions containing Component (a) as the sole thermoplastic polymer component or blends of polymers not meeting the foregoing requirements.

   This is believed to result from the fact that the occlusions of Component (b) lower the fiber or film surface energy and reduce wetting of the surface with aqueous stains, and the occlusions are not as affected by moisture as is
Component (a), thereby providing a more tortuous path for penetration of foreign substances such as aqueous fluids, resulting in greater stain resistance and dye retention.



   It has further been found that yams formed from fibers of thermoplastic compositions in which the first and second thermoplastic polymer components differ in terms of crystallization temperature according to the invention, exhibit both good bulk and good durability, which properties are typically viewed in the industry as being mutually exclusive. The differential in crystallization temperature between the polymer alloy components provides an easy means of controlling the development of crystallinity in the fiber.

   For example, the crystallinity of one phase could be used to set the crimp while the crystallinity of the other phase could be used to set the twist in a twisted heat set BCF   yarn..    An added benefit of yams made from the present thermoplastic composition, especially those wherein thermoplastic Component (a) is a polyamide, is that the morphology and crystallinity of the composition may be made more consistent throughout the fiber, since the crystallinity of one of the components, especially Component (b) may be set in one or some of the process steps, such as during drawing or during drawing and crimping, while reserving crystallinity in the matrix for use in setting of yarn twists. This results in an ability for the skilled artisan to minimize or eliminate problems with differential dye uptake and concomitant streaking in the finished carpet.

   Moreover, with respect to apparel fiber, sufficient crystallinity may be set in the spinning and drawing steps to reduce or prevent fiber relaxation if the fiber is subjected to separate drawing and texturizing steps.



   In accordance with the foregoing benefits, advantage has therefor been found in selecting thermoplastic polymer (a) and thermoplastic polymer (b) based upon a differential between the crystallization temperature (Tc) of such components, as measured by differential scanning calorimetry. Preferably, thermoplastic polymer (a) will have a crystallization temperature at least   10 C    less than the crystallization temperature of thermoplastic polymer (b), more preferably at least   20 C    less than the crystallization temperature of thermoplastic polymer (b), and most preferably at least   40 C    less than the crystallization temperature of thermoplastic polymer (b).

   In a particularly preferred embodiment, thermoplastic polymer (a) will have a crystallization temperature of preferably no more than   250 C,    more preferably no more than   240 C,    and most preferably no more than   230 C.    In a particularly preferred embodiment, thermoplastic polymer (b) will have a crystallization temperature of at least   170 C,    more preferably at least   200 C,    most preferably at least   215 C    ; preferably no more than   285 C,    more preferably no more than   280 C,    and most preferably no more than   275 C.   



  Concerning the Thermoplastic Polymer (a)
Highly desirably, thermoplastic polymer (a) is a non-tactic polymer capable of being extruded and drawn, also referred to as spun, into a fiber. Exemplary polymers for use as thermoplastic polymer (a) include polyamides, polyesters, polylactic acid, polyvinylcyclohexane homopolymers and copolymers, ethylene/styrene interpolymers, and mixtures thereof.



   Suitable polyesters include condensation copolymers of ethylene glycol, polyethylene glycol or polypropylene glycol with an aromatic dicarboxylic acid, especially terephthalic acid, phthalic acid, or mixtures thereof. A preferred polyester is polyethylene terephthalate (PET) or polyethyleneglycol terephthalate (PEGT).



   A preferred polymer for use as thermoplastic polymer (a) is a polyamide or copolyamide, also referred to as nylon, including mixtures of nylons. Suitable polyamides include aliphatic and aromatic polyamides prepared, for example, by condensing an aliphatic or aromatic dicarboxylic acid having 4 to 12 carbon atoms and an aliphatic or aromatic diamine having 2 to 12 carbon atoms. A representative but non-exhaustive list of aliphatic dicarboxylic acids suitable for use in the synthesis of polyamides for use herein includes adipic acid, pimelic acid, azelaic acid, suberic acid, sebacic acid and dodecane dioic acid. Representative aromatic dicarboxylic acids include: phthalic acid, isophthalic acid, terephthalic acid, and naphthalene dicarboxylic acid.



  Representative aliphatic diamines include, by way of example, alkylenediamines, such as hexamethylenediamine and octamethylenediamine. Suitable aromatic diamines are the following: diaminobenzenes, such as 1,4-diaminobenzene,   1,    3-diaminobenzene, and 1,2-diaminobenzene; diaminotoluenes, such as 2,4-diaminotoluene, 2,3-diaminotoluene, 2,5-diaminotoluene, and 2,6diaminotoluene; ortho-, meta-, and para-xylene diamines; ortho-, meta-, and para-2,2'diaminodiethyl benzene; 4,4'-diaminobiphenyl; 4,4'-diaminodiphenyl methane; 4,4'diaminodiphenyl ether; 4,4'-diaminodiphenyl thioether; 4,4'-diaminodiphenyl ketone; and 4,4' diaminodiphenyl sulfone. Mixtures of the foregoing aliphatic and aromatic dicarboxylic acids and diamines may be used as well.

   It is also possible to produce the polyamide from acid derivatives and amine derivatives, such as an acid chloride and an amine salt, as well as by self-condensation of a lactam or a   m-aminocarboxylic    acid. Examples of such lactams include ±-caprolactam and   m-    laurolactam. Examples   of such w-amino    acids include 11-aminoundecanoic acid, 12aminododecanoic acid, 4-aminophenylcarboxyl methane,   1- (4-aminophenyl)-2-carboxyl    ethane,   3- (4-aminophenyl)-1-carboxyl    propane, and   para- (3-amino-3'-hydroxy)    dipropyl benzene.



   Representative aromatic polyamides suitable as Component (a) include polyxyleneadipamide; polyhexamethyleneterephthalamide; polyphenylenephthalamide; polyxyleneadipamide/hexamethyleneadipamide; polyesteramide elastomer; polyetheramide elastomer; polyetheresteramide elastomer; and dimeric acid copolymerized amide.



   Representative aliphatic polyamides for use as thermoplastic polymer (a) include: polycaprolactam (nylon-6); poly (hexamethylene adipamide) (nylon-6,6): nylon-3,4; nylon-4; nylon-4,6; nylon-5,10; nylon-6; nylon-6,6; nylon-6,9; nylon-6,10; nylon-6,12; nylon-11; and nylon-12. Preferred Component (a) polymers are the aliphatic polyamides, especially nylon 6 or nylon 6,6, most preferably nylon 6.



   Thermoplastic polymer (a) is suitably of any molecular weight and molecular weight distribution (MWD). MWD is calculated as the ratio   MW/Mn,    where Mw is the weight average molecular weight and Mn is the number average molecular weight. Preferred materials have
MWD from 1 to 20, preferably from 1.5 to 10. The melt flow rate, measured by ASTM   D1238    at   230 C/2.    16 kg, of nylon-6 thermoplastic polymer (a) is desirably from 0.1 to 100 g/10 min., more preferably from 0.2 to 50 g/10 min., and most preferably from 0. 3 to 10 g/10 min. in order to achieve good processability of fibers and films made therefrom, as evidenced by high output rates, and good mechanical properties, as measured by tensile strength.

   Many suitable polymers for
Component (a), especially polyamides, use relative viscosity as a measure of molecular weight.



  Utilizing this method of measure, suitable polymers possess RV's from 25 to 250, preferably from 30 to 180, more preferably from 35 to 160. Preferably, the thermoplastic polymer (a) will have 10 percent crystallinity, preferably at least 15 percent crystallinity, more preferably at least 20 percent crystallinity, at maximum crystallinity, as determined by wide angle x-ray diffraction at   25  C.   



  Equally desirably, the thermoplastic Component (a) will have a rate of crystallization such that fibers and films having suitable degree of crystallization may be formed by use of typical forming and drawing or forming and orienting process conditions. An additive to increase or decrease the rate of crystal formation (crystallization promoter) may be incorporated into Component (a) if desired. 



   As previously disclosed, a preferred polymer for use as Component (a) is nylon 6, which is surprising in view of the fact that without the present improvement, nylon 6 is generally inferior for fiber formation compared to nylon 6,6. As is previously known in the art, the polyamide employed may possess a disproportionate quantity of amine end groups thereby producing polymers that are more readily dyed and possess increased color fastness. Such polyamide compounds are characterized by the fact that the ratio of amine end-groups to carboxylic acid end groups in the polyamide is greater than 1. If desired, the quantity of amine end groups can be modified, in known manner, by reaction with a compound containing carboxylic acid functionality or other functionality that is reactive with primary amine end groups.



   Preferred polyamides for use herein furthermore may depend on the desired fiber end use properties. For highly delustered fibers a low viscosity polyamide is preferred, for example a nylon 6 resin having RV from 25 to 75, more preferably from 30 to 60. For fibers having increased ease in spinning (less fiber breaks) a higher viscosity nylon 6 or nylon 6,6 is preferred, for example a resin having RV from 120 to 250, more preferably from 150 to 180.



  Concerning Thermoplastic Polymer (b)
Polymers suited for use as thermoplastic polymer (b) are suitably selected from tactic polymers of vinylidenearomatic monomers (including but not limited to isotactic or syndiotactic polystyrene and isotactic or syndiotactic copolymers of styrene and one or more comonomers (such as halo-,   C14    alkoxy-,   Cl 4 alkyl-or Cl 4 haloalkyl-ring    substituted styrene, or polar group substituted styrene), high temperature polyesters, such as polycyclohexene terephthalate, polyimides, liquid crystal polymers; polar comonomer grafted derivatives of the foregoing, espccially maleic anhydride, fumaric acid, or maleimide grafted derivatives of isotactic or syndiotactic copolymers of styrene and ring-alkyl substituted styrene compounds;

   and mixtures of the foregoing, provided that the objects of the invention are obtained.



   Preferably, the thermoplastic polymer (b) will have   5,    preferably at least 10, more preferably at least 15 percent crystallinity, as determined by wide angle x-ray diffraction at   25  C.   



  An additive to increase the rate of crystal formation (crystallization promoter) may be incorporated into Component (b) if desired. This material may be the same as or different from the crystallization promoter incorporated into Component (a).



   More preferably, thermoplastic polymer (b) is a syndiotactic homopolymer of a vinylidenearomatic monomer or a syndiotactic copolymer, including stereo-block copolymers, of more than one vinylidenearomatic monomer, or one or more of the foregoing polymers that are copolymerized, including graft copolymerized, with a polar functional group containing monomer (herein after referred to as"polar group modified"polymer). A"polar group"or"polar functional group"for use herein is defined as any group or substituent which imparts a greater polar moment to a compound compared to such compound lacking such moiety.

   Preferred polar groups include carboxylic acids and carboxylic acid derivatives (for example, acid amides, acid anhydrides, acid azides, acid esters, acid halides, and acid salts, which result from substitution of a hydrogen atom or a hydroxyl group of a carboxylic acid group), sulfonic acids and sulfonic acid derivatives (for example, sulfonic acid esters, sulfonic acid chlorides, sulfonic acid amides, and sulfonic acid salts), epoxy groups, carbonate groups, amino groups, imido groups, and oxazoline groups.



   Suitable vinylidenearomatic monomers are compounds of the formula:   H2C=CR-Ar,    wherein R is hydrogen or an alkyl group having from 1 to 4 carbon atoms, and Ar is an aromatic radical or an alkyl-, haloalkyl-, alkoxy-or halo substituted aromatic radical of from 6 to 18 carbon atoms. Preferred polar functional groups are polar remnants resulting from reaction with maleic anhydride or fumaric acid. Preferred vinylidene aromatic monomers are styrene and   Cl 4 alkyl-,      Cul      4    alkoxy-, or halo-, ring substituted styrene derivatives.



   Representative vinylidenearomatic polymers include: polystyrene, poly (methylstyrene), poly (ethylstyrene), poly (isopropylstyrene), and poly (p-tert-butylstyrene); poly (methoxystyrene), poly (vinyl naphthalene), poly (bromostyrene), poly (dibromostyrene), poly (chlorostyrene), poly (fluorostyrene), mixtures of the foregoing polymers including those prepared by polymerizing mixtures of monomers including mixtures of monomer isomers (for example, styrene/pmethylstyrene copolymers), and hydrogenated or polar group modified derivatives thereof. Most preferred are forms of the foregoing polymers having a syndiotactic stereoisomer structure.



   Most preferred thermoplastics for use as thermoplastic polymer (b) are syndiotactic vinylidenearomatic polymers and polar group functionalized derivatives thereof. Polymerization processes for synthesizing syndiotactic vinylidenearomatic polymers are described in   US-A4,    680,353; US-A-5,066,741; US-A-5,206,197; US-A-5,294,685; US-A-5,990,217; and elsewhere.

   Syndiotactic vinyl aromatic polymers are also readily available commercially from
The Dow Chemical Company under the trade designation Questra   TM.    Most preferred polymers for thermoplastic polymer (b) are syndiotactic polystyrene, syndiotactic styrene/p-,   m-,    or omethylstyrene copolymers containing from 0.005 to 15 weight percent, preferably 0.01 to 10 weight percent p-,   m-,    or o-methylstyrene comonomer, especially p-methylstyrene, and polar group functionalized derivatives of the foregoing, containing from 0.005 to 5 weight percent polar group functionality.

   A most highly preferred polymer is syndiotactic polystyrene or a maleic anhydride or fumaric acid grafted or copolymerized styrene/p-methylstyrene copolymer, containing from 0.1 to 10 weight percent p-methylstyrene and 0.01 to 1.5 weight percent maleic anhydride or fumaric acid. The latter graft copolymer may be combined with thermoplastic polymer (a) and achieve good polymer morphology for fiber preparation without the additional presence of a separate compatibilizer (c). 



   The weight average molecular weight, Mw, determined by gel permeation chromatography, of thermoplastic polymer (b) is not critical, but is typically from 5000 to 5,000,000, more typically from 10,000 to 1,000,000, and preferably from 20,000 to 500,000.



  Moreover, the molecular weight distribution of Component (b) may vary over a wide range, but suitably is from 1.0 to 20, preferably from 1.5 to 10.



   When the quantity of thermoplastic polymer (b) in the composition is less than a desirable amount, fibers prepared therefrom do not demonstrate the desired hand or softness. When the quantity of thermoplastic polymer (b) is greater than desired, the filament or fiber may be subject to a higher incidence of breakage upon drawing or spinning. When used herein, the term"domain forming"refers specifically to components (a) and (b), that form identifiable regions or domains in the resulting composition, although it is to be understood that the respective polymers may be at least partially compatible with each other and capable of forming homogeneous blends.



  Preferably however, the two polymers are substantially incompatible with each other such that a homogeneous blend of the two components does not form despite significant mixing in a shear generating, melt mixing device.



  Concerning Component   (c)   
Component (c) is utilized where improved interfacial adhesion and/or decreased interfacial tension between the resulting polymer domains of the present composition is desired.



  In addition, the type and amount of compatibilizer helps in the formation of small sized particles, well dispersed, occlusions of Component (b) in the polymer matrix, leading to compositions having improved melt strength and spinnability as well as increased fiber tenacity. Suitably small sized domains of occluded polymer (b) give improved optical properties and surface roughness of the resulting fiber or film. Preferred compatabilizers are polymers having both aromatic functionality and polar groups therein, either physically mixed into the composition or reacted with one or more of the thermoplastic components (a) or (b), such as by grafting or interpolymerizing, but which do not contribute to yellowness of the resulting blend.



   Suitable compatibilizers include grafted or otherwise functionalized derivatives of polymers such as vinylidenearomatic homopolymers and copolymers (including atactic, syndiotactic and isotactic homopolymers and copolymers of vinylidenearomatic monomers, as well as copolymers of a vinylidenearomatic monomer with acrylonitrile, maleic anhydride, or a maleimide), polyphenylene ethers, poly (vinylethers), poly (vinylmethacrylate), polyolefins, poly (dienes), and any polymer which has miscibility, partial solubility, or preferential affinity with
Component (b) over Component (c). Also included in these materials are block copolymers (that is polymers which are constructed of two or more different repeat unit segments). Suitable block copolymers contain segments which have has miscibility, partial solubility, or preferential affinity with component b over component c.

   The additional segments may or may not meet the criteria of miscibility, solubility or affinity with component c. Examples of these materials are grafted or otherwise functionalized derivatives of polymer such as block copolymers of vinylidenearomatic polymer with any other repeat unit (for example hydrogenated poly (styrene-block-ethylenebutadiene-block-styrene)-graft-maleic anhydride) and block copolymers of any of the following: atactic, syndiotactic and isotactic homopolymers and copolymers of vinylidenearomatic monomers, as well as copolymers of a vinylidenearomatic monomer with acrylonitrile, maleic anhydride, or a maleimide), polyphenylene ethers, poly (vinylethers), poly (vinylmethacrylate), polyolefins, and poly (dienes).



   The polymer chain structure of the compatibilizer (c) will preferably be modified with a reactive polar group capable of reacting with a functional group of the first thermoplastic polymer (a). Preferred reactive polar group-containing reactants are compounds containing unsaturation, such as an ethylenic unsaturation, along with the desired polar group functionality, as previously defined.

   Examples of suitable reactive polar groups include carboxylic acids, dicarboxylic acids and dicarboxylic acid derivatives (for example, acid amides, acid anhydrides, acid azides, acid halides, and acid salts, which result from substitution of a hydrogen atom or a hydroxyl group of a carboxylic group), sulfonic acids and sulfonic acid derivatives (for example, sulfonic acid esters, sulfonic acid chlorides, sulfonic acid amides, and sulfonic acid salts), epoxy groups, carbonate groups, amino groups, imido groups, and oxazoline groups.



   Preferred reactive polar group containing unsaturated reactants are those containing unsaturated carboxylic and dicarboxylic acids, unsaturated carboxylic and dicarboxylic acid derivatives, unsaturated epoxy compounds, unsaturated alcohols, unsaturated amines, and unsaturated isocyanates. Specific examples of reactive polar group-containing unsaturated reactants include maleic anhydride, fumaric acid, maleimide, maleic hydrazide, and reaction products of maleic anhydride and diamines, 1-methyl maleic anhydride, dichloromaleic anhydride, maleic acid amide, itaconic acid, itaconic anhydride, acids of natural fats and oils such as soybean oil, tung oil, castor oil, linseed oil, hempseed oil, cotton seed oil, sesame oil, rapeseed oil, peanut oil, camellia oil, olive oil, coconut oil, and sardine oil;

   unsaturated carboxylic acids such as acrylic acid, butenoic acid, crotonic acid, vinyl acetic acid, methacrylic acid, pentenoic acid, angelic acid, 2-pentenoic acid, 3-pentenoic acid,   a-ethylacrylic      acid,-methylcrotonic    acid, 4-pentenoic acid, 2-hexenoic acid, 2-methyl-2-pentenoic acid, 3-methyl-2-pentenoic acid,   a-ethylcrotonic    acid, 2-2dimethyl-3-butenoic acid, 2-heptenoic acid, 2-octenoic acid, 4-decenoic acid, 9-undecenoic acid, 10-undecenoic acid, 4-dodecenoic acid, 5-dodecenoic acid, 4-tetradecenoic acid, 9-tetradecenoic acid, 9-hexadecenoic acid, 2-octadecenoic acid, 9-octadecenoic acid, eicosenoic acid, dococenoic acid, erucic acid, tetracosenoic acid, 2,4-pentadienoic acid, 2,4-hexadienoic acid, diallyl acetate, geraniumic acid, 2,4-decadienoic acid, 2,4-dodecadienoic acid, 9,

  12-hexadecadienoic acid, 9,12octadecadienoic acid, hexadecatrienoic acid, linolic acid, linolenic acid, octadecatrienoic acid, eicosadienoic acid, eicosatrienoic acid, eicosatetraenoic acid, ricinolic acid, eleostearic acid, oleic acid, eicosapentaenoic acid, docosadienoic acid, docosatrienoic acid, docosatetraehoic acid, docosapentaenoic acid, tetracosenoic acid, hexacosenoic acid, hexacodienoic acid, octacosenoic acid, and esters, acid amides and anhydrides of these unsaturated carboxylic acids; unsaturated alcohols such as allyl alcohol, methylvinyl carbinol, allyl carbinol, methylpropenyl carbinol, 4  pentene-l-ol,      10-undecane-1-ol,    propargyl alcohol, 1, 4-pentadiene-3-ol, 1, 4-hexadiene-3-ol, 3,5hexadiene-2-ol, 2,4-hexadiene-1-ol, alcohols represented by the general formulas :

     CnH2n-sOH,      CnH2n-70H, CnH2n-90H    (n is a positive integer),   3-butene-1,    2-diol, 2,5-dimethyl-3-hexene-2,5-diol,   1,    5-hexadiene-3,4-diol, and 2,6-octadiene-4,5-diol, and unsaturated amines which result from substitution   of NH2    for OH group of these unsaturated alcohols.



   Acidic polar groups of the compatibilizer (c) may be fully or partially neutralized with zinc, magnesium, manganese, lithium, or other metal counter ions or combinations of metal counter ions. It is also possible to use neutralized acidic monomers, for instance, zinc acrylate, in a graft polymerization or functionalization to form the compatibilizer (c).



   Examples of the vinyl compounds having epoxy groups are glycidyl methacrylate, glycidyl acrylate, vinyl glycidyl ether, glycidyl ether of hydroxyalkyl (meth) acrylate, glycidyl ether of polyalkyleneglycol (meth) acrylate, and glycidylitaconate, among which glycidyl methacrylate is particularly preferred. The compatibilizer (c) can include two or more of unsaturated groups and two or more of polar groups (the same or different), and two or more of compounds having polar groups or multiple polar groups.



   Among suitable compatibilizers (c) are polyarylene ethers having polar functionality and poly (vinylidenearomatic) homopolymers and copolymers having polar functionality. Also included are block copolymers having polar functionality and containing segments of polyarylene ethers and poly (vinylidenearomatic) homopolymers and copolymers. Such compatibilizers are obtained by modifying a conventional polymer with one of the foregoing polar group containing modifiers. The method of modification is not limited as long as the modified product can be used in accordance with the object of the present invention.

   Suitably the base resin and polar group containing reactant are combined in the melt, in an extruder or similar mixing device, optionally in the presence of a free radical generator or other initiator, such as benzoyl peroxide, di-t-butyl peroxide, dicumyl peroxide, t-butyl peroxybenzoate, azobisisobutyronitrile, azobisisovaleronitrile, or 2,3-diphenyl-2,3-dimethylbutane.



   Polyphenylene ethers can generally be produced by the oxidative coupling of one or more phenols, which are preferably substituted at two or three positions. Preferably, a catalyst, such as a copper-amine complex, especially a copper-amine complex derived from a primary, secondary, or tertiary amine is used.

   Examples of suitable polyphenylene ethers include poly (2,3-dimethyl-6ethyl-1, 4-phenylene ether), poly   (2-methyl-6-chloromethyl-1,    4-phenylene ether), poly (2-methyl-6hydroxyethyl-l, 4-phenylene ether), poly   (2-methyl-6-n-butyl-1,    4-phenylene ether), poly (2-ethyl-6isopropyl-1, 4-phenylene ether), poly   (2-ethyl-6-n-propyl-1,    4-phenylene ether), poly (2,3,6trimethyl-1, 4-phenylene ether), poly   [2- (4'-methylphenyl)-1,    4-phenylene ether], poly (2-bromo-6phenyl-1, 4-phenylene ether), poly   (2-methyl-6-phenyl-1,    4-phenylene ether), poly   (2-phenyl-1,    4phenylene ether), poly   (2-chloro-1,    4-phenylene ether), poly   (2-methyl-1,    4-phenylene ether),

   poly   (2-chloro-6-ethyl-1,    4-phenylene ether), poly (2-chloro-6-bromo- 1, 4-phenylene ether), poly (2,6-di-n-propyl-1,4-phenylene ether), poly (2-methyl-6-isopropyl-1,4-phenylene ether), poly   (2-chloro-6-methyl-1,    4-phenylene ether), poly   (2-methyl-6-ethyl-1,    4-phenylene ether), poly (2,6-dibromo-1,4-phenylene ether), poly (2,6-dichloro-1,4-phenylene ether), poly (2,6-diethyl1,4-phenylene ether), and poly (2,6-dimethyl-1,4-phenylene ether). Suitable methods for manufacture of polyphenylene ethers are disclosed in US-A-3,306,874, US-A-3,306,875,
US-A-3,257,357, US-A-3,257,358, and elsewhere. The polymers are also readily commercially available.



   Typically, the amount of polar group functionality in Component (c) is from 0.01 to 10 weight percent based on the weight of Component (c). Generally, if less than 0.01 percent of polar group functionality is present, the compatibilizer is not as efficient as desired. The amount of compatibilizer (c) employed, if any, is preferably in an amount of at least 0.1, more preferably at least 0.2 weight percent; typically less than 5, preferably less than 4.5, more preferably less than 4.2, and most preferably less than 4.0 weight percent, based on total composition weight.



   Because the quantity of functional groups in Component (c) will vary, because the efficiency of such groups of compounds in compatibilization may vary, because Component (b) may also contain functionality that assists in compatibilization with Component (a), and because additional components may be present in the resin blend that neutralize amine end groups of the polyamide, or otherwise affect the resulting polymer properties, in order to obtain the desired benefits of effective compatibilization of Component (b), it is desirable that the quantity of
Component (c) range from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent, preferably from 0.01 to 0. 24 mol percent.



   Measured in the resulting fiber article, the foregoing ranges are preferably as follows.



   The quantity of Component (c) should range from 0 to less than 24 percent based on combined weight of Component (a) and Component (b) and the total quantity of functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.8 mol percent, preferably from 0.01 to 0.5 mol percent.



   In the following calculations Component (b), when functionalized will be considered as all (if Component (c) is not in the formulation) or part (if the formulation contains both
Component (c) and Component (b)) of the compatibilizer. In making the foregoing measurements the following equations are used:   
100#m(c) 1.) Weight percent functionalized components in blend: w (c) = m(b) + m(a) + m (c) where m (c) = mass of functionalized components (Component (b) if functionalized + Component    (c)),   m (b)    = mass of Component (b),   m (a)    = mass of Component (a).



  2.) Mole percent functionalized components in the blend:   
100#m(c) / MW(c) x(c) = m(b) MW(b) + m(a) / MW(a) + m(c) / MW@    where   MW    = average molecular weight of Component (c) repeat unit,   MW    (b) = molecular weight of Component (b) repeat unit,   MW    = molecular weight of Component (a) repeat unit.



  3.) Weight percent polar group in Component (b) +Component (c):     (m(c)) ( Polar) wPolar,(b)  ) + m (c)    where f   polar-t percent    of Component (c) which is the polar group or functional group remnant (for example, a maleic anhydride remnant in a styrene maleic anhydride copolymer).



  4.) Mole percent polar group in Component (b) +Component (c):     (m(c))(fpolar) / MWpolar xPolar = m(b) / MW(b) + m(@) / MW  (b) (b) (c) (c)    where MWpolar = molecular weight of the polar unit.



     5.)    Weight percent polar group in the blend:     (m(c))(fPolar)
WPolar,Blend m(b) + m(c) + m    6.) Mole percent polar group in blend:     (m(c))(#polar)/ MW polar xPolar,Blend = m(b) / MW(b) + m(c) / MW(c) + m(a) / MW(a)    
Within the foregoing gross amounts of compatibilizer employed, it has been found that ideal levels of compatibilizer may be determined in order to balance the desired properties of the resulting fiber or film product.

   Since the quantity of compatibilizer used ultimately reduces residual amine end groups of polyamide containing blends, which in turn affects dye acceptance by fibers made therefrom, for fiber applications, it is desired to employ sufficient polar group containing compatibilizer to cause improved mechanical properties of the fiber, but less than an amount that would negatively impact dye acceptance of the fiber, through reduction of amine endgroups. The initial molar quantity of amine endgroups (for polyamides formed through ring opening reactions) in turn is dependant on polymer molecular weight. Formulas for estimating available amine end-groups are known.

   For nylon 6 and other polyamides formed through ring opening reactions (and not modified in such a way to affect the end group concentrations), it is:   
I ¯ 106
N = [=] milliequivalents/gram,
Mn    where   M,, =    number average molecular weight of the polyamide.



   Alternatively, the actual quantity (moles) of amine end groups reacted can be calculated for such polymers, assuming complete reaction with polar group functionality of the compatibilizer, by use of the following formula:    mCompatibilizer #Polar
Reacted =
100#MWPolar    where mCompatibilizer = mass of compatibilizer, fPolar = weight percent polar functional groups in the compatibilizer, and   MWpolar =    molecular weight of the polar functional group. For cases where Component (b) and (c) both contain polar functionality, an average weight percent functionality and an average molecular weight, calculated on the combination of the two components in the ratio set by the formulation, is used in the equation above.



   The quantity of amine end groups remaining in the polymeric blend can also be reduced through addition of a reagent containing polar group functionality such as a measured directly by use of analytical techniques such as acid titration or other suitable technique. Particularly, for use with nylon 6,6 and other condensation polyamides, end group content is preferably directly measured, since it is not amenable to calculation by the foregoing method.



   Regardless of the method used for calculating or measuring amine end groups in the blend, the molar ratio of available amine end groups, N, to polar functionality in the compatibilizer is preferably from 70: 30, to 99:   1,    more preferably from 80: 20 to 96: 4, and most preferably from 85: 15 to 93: 7. Alternatively, the final amine end group content of the polymer composition, may be reduced from 5 to 20 percent through reaction with polar functionality of 
Component (c), or by both Component (b) and Component (c) if Component (b) contains polar functionality. Preferred polymers for Component (c) are styrene/maleicanhydride copolymers and maleic anhydride grafted syndiotactic copolymers of styrene and p-methylstyrene.



  Concerning Optional Component   (d)   
Additional additives may be present in the present composition so long as the desired properties or end products are achieved. The type and quantity of any additional additives, if present, are chosen according to known, conventional teachings in the art. Exemplary additional additives include delustering agents, elastomers, flame retardants, antimicrobials, heat stabilizers, light stabilizers, antioxidants, pigments, dyes, lubricants, blowing agents, optical brighteners, and antistatic agents. Such additives may be incorporated into either or both of components (a) or (b) or into the resulting composition after first preparing a blend of components (a) and (b).

   By incorporation of such additives into only Component (b) additives that are detrimental upon addition to Component (a) may be employed according to the present invention.



   Suitable delustering agents are inorganic oxides, titanates, carbonates and silicates, preferably titanium dioxide. Preferred delustering agents are in the form of fine particles or powders, highly preferably those having a volume average particle size less than   100      um,    more preferably less than 50   pm    and most preferably less than 10   jum.   



   Suitable elastomers are those that increase the impact resistance, toughness or elongation of the composition. When employed, the elastomer will typically be provided in an amount from 0.5 to 50, preferably 0.7 to 30 and more preferably 1.0 to 20 weight percent, based on total composition weight.

   Specific examples of elastomers that may be included in the composition include: natural rubber, polybutadiene, polyisoprene, polyisobutylene, neoprene, polysulfide rubber, urethane rubber, silicone rubber, epichlorohydrin rubber, styrene-butadiene block copolymer (SBR), hydrogenated styrene-butadiene block copolymer (SEB), styrene-butadienestyrene block copolymer (SBS), hydrogenated styrene-butadiene-styrene block copolymer (SEBS), styrene-isoprene block copolymer (SIR), hydrogenated styrene-isoprene block copolymer (SEP), styrene-isoprene-styrene block copolymer (SIS), hydrogenated styrene-isoprene-styrene block copolymer (SEPS), styrene-butadiene random copolymer, hydrogenated styrene-butadiene random copolymer, styrene-ethylene-propylene random copolymer, styrene-ethylene-butylene random copolymer, ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM),

   core-shell type particulate elastomers, such as butadiene-acrylonitrile-styrene core-shell rubber (ABS), methyl methacrylate-butadiene-styrene core-shell rubber (MBS), methyl methacrylatebutyl acrylate-styrene core-shell rubber (MAS), octyl acrylate-butadiene-styrene core-shell rubber (MABS), an alkyl acrylate-butadiene-acrylonitrile-styrene core-shell rubber (AABS), butadiene styrene core-shell rubber (SBR), and core-shell rubbers containing siloxane such as methyl methacrylate-butyl acrylate-siloxane, and rubbers obtained by modification of these rubbers.



   Flame retardants also referred to as ignition resistance additives are not intended to reflect performance of the compositions under actual burning conditions. Suitable additives for this purpose include, but are not limited to, brominated polystyrene (including brominated syndiotactic polystyrene),.

   hexabromocyclododecane, decabromodiphenyl oxide, ethylenebis (tetrabromophthalimide), ethylene-bis (dibromonorborane dicarboximide), pentabromodiphenyl oxide, octabromodiphenyl oxide, decabromodiphenoxyethane, poly-dibromophenylene oxide, halogenated phosphate ester, tetrabromophthalic anhydride, bis (tribromophthalic anhydride), tetrabromobisphenol-A bis (2-hydroxyethyl ether), tetrabromobisphenol-A bis (2,3-dibromopropyl ether), dibromo-neopentyl glycol, tetradecabromodiphenoxy benzene, aluminum oxide trihydrated, antimony oxide, sodium antimonate, zinc borate, and di-acrylate ester of tetrabromobisphenol-A.



   Suitable heat and light stabilizers include, but are not limited to, calcium stearate, phenols and hindered phenols, zinc oxide, aryl esters, hydroxybenzophenone, and hydroxybenzotriazole.



   Suitable antioxidants include phosphorus based antioxidants, phenolic antioxidants and sulfur based antioxidants. Examples of phosphorus-based antioxidants including a monophosphites and diphosphates, such as, tris (2,4-di-tert-butylphenyl) phosphite and tris (mono/di-nonylphenyl) phosphite, distearyl pentaerythritol diphosphite; dioctyl pentaerythritol diphosphite; diphenyl pentaerythritol diphosphite; bis (2,4-di-tert-butylphenyl) pentaerythritol diphosphite; bis (2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, dicyclohexy pentaerythritol diphosphite; tris (2,4-di-tert-butylphenyl) phosphite; tetrakis (2,4-di-tertbutylphenyl)-4,4'-biphenylene phosphite.



   Suitable phenolic antioxidants include, 2,2'-methylenebis (6-tert-butyl-4-methylphenol); 1,1-bis (5-tert-butyl-4-hydroxy-2-methylphenyl) butane; 2,2'-methylenebis (4-methyl-6cyclohexylphenol); 4,4'-thiobis (6-tert-butyl-3-methylphenol), 2,2-bis (5-tert-butyl-4-hydroxy-2methylphenol)-4-n-dodecylmercapto-butane, 2,6-di-tert-4-methylphenol; 2,2'-methylenebis (6-tertbutyl-4-ethylphenol); 2,2'-methylene-bis > 4-methyl-6- (. alpha.-methylcyclohexyl) phenol; 2,2'methylenebis (4-methyl-6-nonylphenol); 1,1,3-tris- (5-tert-butyl-4-hydroxy-2methylphenyl) butane; ethyleneglycol-bis > 3,3-bis (3-tert-butyl-4-hydroxyphenyl) butyrate; 1-1bis (3,5-dimethyl-2-hydroxyphenyl)-3- (n-dodecylthio)-butane;   1,    3,5-tris (3,5-di-tert-butyl-4hydroxybenzyl)-2,4,6-trimetylbenzene; 2,2-bis (3,5-di-tert-butyl-4-hydroxybenzyl) dioctadecyl malonate ester;

     n-octadecyl-3- (4-hydroxy-3,    5-di-tert-butylphenyl) propionate, tetrakis) methylene (3,5-di-tert-butyl-4-hydroxyhydrocinnamate) methane, 3,9-bis-1,1-dimetyl-2- (p (3-tert-butyl-4-hydroxy-5-methylphenyl) propi onyloxy) ethyl-2,4,8,10-tetroxaspiro > 5,5-undecane,   tris- (3,    5-di-tert-butyl-4-hydroxylenzyl) isocyanurate, 2,6-diphenyl-4-methoxyphenol, and   tris- (4-    tert-butyl-2,6-di-methyl-3-hydroxybenzyl)-isocyanurate.



   Suitable sulfur-based antioxidants include: dilauryl-3,3'-thiodipropionate; dimyristyl-3,3'thiodipropionate, distearyl-3,3'-thiodipropionate,   pentaerythritol-tetrakis- ( (3-lauryl-    thiopropionate),   bis > 2-methyl-4- (3-n-alkylthiopropionyloxy)-5-tert-butylphenylsulfide,    and 2mercaptobenzimidazole.



   Useful pigments are well known in the art and include, but are not limited to inorganic pigments such as: cadmium mercury orange, cadmium sulfide yellow, cadmium sulfoselenide, titanium dioxide, titanium yellow, titanium green, titanium blue, cobalt aluminate, manganese blue, manganese violet, ultramarine red, ultramarine blue, and ultramarine violet; and organic pigments such as, permanent red 2B, perylene red, quinacridone red, diazo orange, diazo yellow, isoindolinone, hansa yellow, phthalocyanine green, phthalocyanine blue, quinacridone violet, and doxazine violet.



   Suitable anti-microbial additives are antibacterial or other agents normally added to polymers to impart resistance to bacteria, mildew or mold. Suitable antistatic agents include conductive or zwitterionic substances previously know to impart antistatic properties to fibers.



   In one method of operation, a concentrate of the pigment or other additive in a suitable base resin may be added to the extruder along with one or more of the compositions (a) and (b).



  Alternatively, the pigment or other additive may be previously compounded in such resin. Use of a concentrate allows for greater control of the quantity of additive and improves the ability to incorporate the additive evenly in the final composition. It will be appreciated by the skilled artisan that the pigment or other additive may be added primarily to only one of the components of the composition. The advantage of this embodiment is that pigments or additives that may be harmful to one of the components can be incorporated primarily into the opposite component. For instance, certain organic pigments may crosslink a polymer, thereby raising its melt viscosity and form spherulites which weaken the fibers, resulting in increased filament breaks during the spinning process.

   Conversely, some inorganic pigments may catalyze a polymer's depolymerization, raising the number of functional end groups affecting dye susceptibility and reducing melt viscosity. Incorporating such pigments into primarily one phase, at least during the initial stages of the fiber forming process, can reduce or eliminate some or all of the foregoing difficulties. In a preferred embodiment, it may be possible to achieve improved performance by incorporating the additive selectively into the minor component, especially where the substance is more compatible with Component (b) than with Component (a). In addition, by concentrating the additive only in the dispersed phase, equivalent performance may be obtainable, under certain circumstances, while using less total additive.

   For example, this may be possible when employing an anti-microbial substance, due to the fact that it will be more exposed to the surface of the fiber or film and therefor accessible to the environment, due to the protuberance of the occlusions of
Component (b) above the surface of the fiber.



   In a highly preferred embodiment, Component (b) is supplied as an alloy or concentrate, including any additional additives desired in the formulation, especially any compatibilizer (c), delustering aids, colorants, and/or other additives. The concentrate, which may include a minor proportion of Component (a) is then melted and blended into Component (a) in the equipment used in the fiber or film forming process or in a separate extruder or other melt mixing equipment, adequate to supply a fully compounded polymer mixture suitable for fiber or film formation to the dye or spinnerette.

   An example of a suitable mixing device that may be incorporated into a conventional fiber forming extruder to generate sufficient mixing and particle sizing of
Component (b) under such conditions, is an extensional flow mixer, such as disclosed in
US-A-4,334,783   and US-A-5,    451,106.



   In a particularly preferred embodiment the molten polymer blend is passed through a mixing unit which may be either a zone within an extruder or a separately added mixing device, utilizing divergent mixing, extensional flow mixing, or a combination thereof, such that adequate mixing of the polymer melt to achieve the desired dispersed phase particle size described herein is obtained.



   In compounding of polymers, distributive mixing is effected by use of a so-called "motionless mixer"or"static mixer"between a screw feeder and a die. In most cases they consist of a number N of alternating right and left-handed helical elements placed in a tubular housing equipped with a means for temperature control. The energy of mixing is provided by the pressure loss across the mixer. The splitting and recombination of streams results in a predictable number of striations,   2N.    The basic principle behind distributive mixing is the division and recombination of the flow stream. Since the flow division is of the shear type, the dispersive forces are usually weak, and the devices work best where the liquids to be mixed are of similar viscosity.

   For two liquids this relationship can be expressed as:    k =T1d/T1m 1, where    where   tld      and T) m    are shear viscosities of the dispersed phase and the matrix, respectively.



  In contrast, in extensional flow mixers, the mixing action depends only weakly on the viscosity ratio. It has been previously determined that mixing of either Newtonian or non-Newtonian liquids of different viscosities, is more efficient in extensional flow than in shear flow.



   Extensional flow occurs in one instance when a fluid converges from a reservoir to a capillary. Generally, extensional flow tends to deform drops into long prolate ellipsoids that upon cessation of flow disintegrate into a series of micro-drops with diameter twice as large as the smaller diameter of the prolate ellipsoid. By dispersing the minor-phase of a multiphase system into such fine droplets in a system having a series of convergences and divergences with progressively smaller diameter of the restriction a good level of mixing can be obtained. Suitable extensional flow mixers comprise a series of plates placed across the flow channel. In these plates the fluid mixture is forced to pass through a series of convergences and divergences.

   Designs wherein the diameter of these restriction are kept constant or progressively reduced in order to generate a series of convergences and divergences of progressively increasing intensity may be employed. Moreover, designs incorporating regions wherein the fluid mixture is exposed to strong extensional flow fields, each followed by a semi-quiescent zone, the overall direction of flow in such mixer is in the radial direction rather than the axial direction, in the sense of the normal flow in an extruder, or the restrictive openings of such mixer are in the form of slits rather than holes, preferably at least some of which are adjustable to differing width, are highly preferred.



  Concerning the Formation of Filaments, Fibers and Yarns
The composition of the present invention may be formed by combining the various components and additives in a variety of ways, including by dry blending two or more of the constituents, and preferably all of the constituents, prior to feeding the blend into an extruder or other melt mixing device, or by feeding the individual constituents directly to such an extruder or device, in any order, provided there is sufficient mixing thereof while in a substantially molten state to prepare a composition of the desired morphology. Although the composition may be formed into strands and pelletized after preparation, in a desirable embodiment, the composition is formed in an extruder in operative communication with the die (s) or spinnerette assembly used to prepare films or fibers.

   Highly desirably, Component (a) is first added to an extruder and melt plasticized. Thereafter, in one or more addition zones of the extruder, preferably after heating the melt of Component (a) to a temperature above its crystalline melting point, or optionally above the crystalline melting point of Component   (b),    Component (b) is added, either simultaneously with the other constituents of the composition, prior to, or subsequent to their addition. The melt plasticized composition is then passed through the die assembly or spinnerette, optionally after cooling to a temperature between the crystalline melting points of components (a) and (b), and formed into a fiber in one or more unit operations.

   By not reheating and reextruding a prior compounded and pelletized version of the composition, less polymer degradation results, and operational costs are reduced.



   The composition is preferably forced from the extruder through the die or spinnerette at a temperature at which the composition remains readily flowable but retains sufficient melt strength to avoid breaking the film or filament. Desirably, the temperature of the polymer melt is maintained in a range below the decomposition temperatures, Td, of at least components (a) and (b). Td is defined as the temperature at which under a vacuum, the rate of weight loss for a polymer is 1 percent per minute.

   Preferred temperatures for extruding and spinning the composition of the invention are within the range of 170 to   340  C,    more preferably 200 to 320    C,    and most preferably 250 to   300  C.    The extruder temperature is selected based on desired properties in the resulting filament, film or fiber and the desired process rate, among other concerns.



   The spinnerette may be designed to impart to the filaments any desired cross-section shape commonly used in the art, including, by way of example, deltoid, multilobal, pentagonal, etc. The filaments may have one or more axial voids. Further, the filament may be either monocomponent or multi-component, that is, the filament may comprise more than one longitudinally co-extensively bonded strands. Examples of multi-component fibers include those having a sheath-core, side-by-side, or similar strand arrangement. The present composition may be used to form one component of such a multi-component filament or all such components, depending on the desired properties of the filament, fiber or   yarn.    In such process, a multifeed block die is employed according to known procedures, examples of which are disclosed in USP 6,024,556, USP 6,162,382, and elsewhere.



   In manufacturing fibers that are particularly adapted for use in preparing carpets, during the spinning process, a spinnerette plate having a plurality of orifices for forming a multitude of filaments is commonly employed. As the extruded filaments emerge from the spinnerette plate, the filaments are quenched with a cross-flow of gas, typically air. The filaments are then drawn, optionally texturized and/or crimped, optionally with reheating, and finally cooled, gathered into a yarn and wound onto a take-up spool. Crimping imparts greater bulk to the yarn and, hence, greater bulk to the carpet. The crimping process involves putting one or more bends or deformations into the fiber, preferably, in alternating directions.

   Generally, the crimped fiber is then exposed to heat, either in a dry environment or in the presence of steam, to increase the crystallinity of the polymer components and"set"the crimp.



   In further exemplification of the invention herein, particularly where Component (a) is a nylon, the extrusion step may comprise the steps of : (i) conveying the composition through an extruder characterized by heating, mixing and conveying zones, or combinations thereof, in order to raise the composition to an ultimate temperature preferably from   260 C    to   330 C,    more preferably from   285 C    to   295 C    ;

   (ii) passing the composition through a volume controlled melt pump feeding a multitude of spinnerettes comprising a multiplicity of holes configured in the desired filament shape, and wherein the spinnerettes are adjusted to produce a number of extruded fibers; and (iii) cooling the extruded fibers by passing them through a quench zone, preferably operating at a temperature from   10 C    to 20    C.   



   After extrusion, the filaments may be drawn one or more times, preferably two times.



  Post forming treatments such as texturizing, crimping, heat setting, dyeing, bulking, entangling, coating, winding, cutting and carding may be conducted as well. The filaments may also be processed into any previously known form, including bulked continuous filaments, staple fibers, combinations of the foregoing, carded and uncarded yams or threads, and multifilament yarns, with or without twisting. The rough surface of the fibers of the present invention provides higher fiber-fiber interfriction, leading to advantages in processing staple fibers into yarns.



   As previously mentioned, the thermoplastic composition of the invention desirably results in the formation of occlusions of Component (b) in a matrix of Component (a). Upon drawing of fibers of the present invention, or orienting of films according to the present invention, some of the foregoing occlusions uniquely form projections or protuberances on the surface of the fiber or film. In a preferred embodiment, such occlusions have a minor axis, or diameter of from 0.2 to 3.0 um based on a volume average and the particles or occlusions are substantially ellipsoid, spherical, cylindrical, oblate, or"sausage"shaped, having a volume average length to diameter ratio (aspect ratio) of from 1 to 20.

   Such fiber morphology has been discovered to result in a desirable degree of surface roughness on the fiber or film, preferably sufficient to improve one or more fiber or film optical or physical properties, or forming or manufacturing properties.



   While not desiring to be bound by theory, the benefits obtained, especially in formation of fibers from the use of the above-described compositions are believed to be attributable, at least in part, to the ability to form disperse, discontinuous domains of thermoplastic polymer (b) in a continuous matrix of thermoplastic polymer (a) during the fiber forming process. In particular, it is believed that by using quantities of thermoplastic polymer (b) that are low relative to quantity of thermoplastic polymer (a), and that have the requisite thermal properties, such disperse, discontinuous domains are readily formed under typical fiber forming conditions.

   If higher concentrations of thermoplastic polymer (b) are employed, a network of fibrils thereof extending throughout the continuous phase of Component (a) or a structure where Component (a) is dispersed in a matrix of Component (b) is likely to form. In addition, the higher crystallization temperature of polymer (b) assures that the fiber forming operation may take place at a temperature above the temperature of crystallization upon cooling (Tc) of polymer (a) thereby generating relatively crystallized occlusions within a drawable matrix such that draw thinning of the matrix or continuous polymer generates protuberances on the surface of the fiber. A small degree of drawing of the occluded phase particles may occur as well, such that some of the fiber properties such as tenacity and crimp, may be generated due to crystallization of Component (b) rather than Component (a).



   The resultant fiber morphology is also influenced by spinnerette design, spin ratio, the quantity and effectiveness of Component (c), extruder mixing capability and other physical and operational variables. Most desirably, the composition possesses sufficient melt strength after extruding and quenching that fibers may be prepared therefrom at a high linear rate, suitably at a rate after drawing of at least 1000 m/min, preferably at least 1500 m/min, more preferably at least 2000 m/min, and most preferably at least 2500 m/min. Further preferably, the resulting, fully drawn fibers are characterized by tenacity of at least 1.0 g/denier, more preferably at least 1.8 g/denier.



   As previously disclosed in embodiment K of the present invention, it may be beneficial to form a bicomponent or multicomponent fiber or a bilayer or multi-layer film where, for example, a first polymer which may be the same as polymer (a) is employed to form a first polymer region which is encapsulated or coated with one or more layers of one or more second polymers, at least one such layer comprising a composition as previously disclosed. Because the amount of coating composition is reduced compared to the total volume of the fiber, in this embodiment of the invention, the quantity of Component (b) in the composition may be increased up to twice or even three times, or even more, over that which is employed in a single component fiber or film, without loss of film or fiber strength or forming properties.

   That is, the quantity of Component (b) in such a composition may range as high as 99 weight percent, as previously disclosed.



   The fibers or the resulting yarn may be dyed in a post forming operation. Suitable dyes include organic solvent born dyes (disperse dyes) or aqueous dyes, such as acid dyes, premetalized dyes, and cationic dyes. Examples include mono-and disulfonated acid dyes, as well as triphenylmethane, pyrazolone, azine, nitro and quinoline dyes. Preferred dyes are monoand disulfonated acid dyes. More than one dye may be applied if desired, and different fibers within a yarn or strand may be dyed differently, if desired.



  * In an aqueous dying process, the filaments, fibers or yams are preferably first washed with hot water usually containing a base such as   NaOH,    KOH or NH30H. The temperature of the hot water wash ranges from   60 C    to   80 C    and should be hot enough to remove any residual finish oils, such as any lubricants. Next the filaments, fibers or yams are passed through the dye bath, optionally at an elevated temperature, suitably at a bath temperature of   80 C    to   100 C    for a contact time from 0.1 to 30 minutes, optionally followed by heating to set the dye, washing, rinsing and drying. The dye bath is typically operated at atmospheric pressure.



   It is well known to treat synthetic fibers with various agents in order to increase or decrease their affinity for certain dyes. For example the polymer chain may substituted with additional reactive groups or shortened to give more end groups, thereby providing an increased number of dye sites and resultant increase in dyeability. Alternatively to decrease the dyeability of some synthetic fibers, the polymer is reacted with a capping agent to reduce the number and availability of functional end groups. Disadvantageously, such processes may alter the melt properties and crystallinity of the polymer, thereby affecting spinnability of the fiber and ability to later modify fiber properties. The present invention provides a method for reducing the dyeability of fiber formed therefrom without necessarily affecting the resin's spinnability or fiber modifying properties.

   The present invention may be practiced using conventional light dye and deep dye technologies.



   Dye uptake is affected by the crystalline structure of the fiber. Amorphous polymer regions generally accept water based dyes more readily than do crystalline polymer regions. The
Formation of large crystals in the fiber results in a larger proportion of amorphous polymer and relatively more non-occluded amorphous regions. The formation of relatively small crystals generally reduces the number of non-occluded amorphous regions and the total amorphous polymer content.

   In fibers according to the present invention, the additional occluded regions of
Component (b) provides different crystals and an altered crystal morphology (with an inherently different moisture transport rate and equilibrium moisture content) that is independent of the crystalline structure due to Component (a), thereby moderating dye uptake variability resulting from variation in heat history among different fibers. More particularly, fibers of the present invention generally possess a reduced strike rate compared to fibers formed solely or essentially from Component (a). For this same reason, the fibers of the present invention inherently possess an improved stain resistance.



   Desirably, the filaments or fibers are in the range from 0.5 denier to 60 denier, and preferably from 1 denier to 30 denier. The fibers may be staple fibers, continuous fiber, bulked continuous filaments ("BCF"), or a mixture thereof ; but preferably are in the continuous form.



  Yarns are prepared from the foregoing filaments or fibers according to well known techniques.



   A coating may also be applied to the filament before or after drawing. Suitable coatings include lubricants, antistatic agents, sealants, and metallizing coatings. Due to the inherently rough surface of the present fibers and the reduced friction with respect to rollers and guides used in the post forming processes, a reduced quantity of lubricant or no lubricant at all is generally required for processing yams according to the invention. If employed, the quantity of finish is generally in an amount from 0.5 to 2.5 percent based on total fiber weight.



   One means of drawing the present filaments comprises: (i) feeding the quenched filament onto multiple sets of godets operating at gradually increasing speeds, to thereby subject the filament to the desired draw ratio. In a preferred embodiment, the first godet operates at 500 to 1000 m/min (meters per minute), preferably at 600 m/min and the final godet operates at 1200 to 6000 m/min, preferably at least 1800 m/min. One of skill in the art will recognize that these drawing conditions can be varied without affecting the operability of the invention.



   The fiber may be texturized or crimped by use of any suitable technique. One such process employs a texturing air jet utilizing hot air to crimp the fibers. Preferably, the texturing jet is of a split-type operating at an air pressure of from 3.0 to 10.0 bar (0.3 to 1.0 MPa) and a temperature of   120 C    to   280 C.    The crimped fiber is taken up on a sieve or perforated drum through which air is drawn to cool the fiber and set the crimp. Alternatively, or additionally, multiple filaments may be passed through an interlacing air jet, preferably employing an air pressure of from 1.0 to 8.0 bar (0.1 to 0.8 MPa) to entangle the filaments and add bulk to the resulting   yarn.    In a final operation, the fibers or combinations thereof are wound onto cylindrical packages, bobbins or spools.

   Suitably, the bulked fiber has a denier from 100 to 4000.



   In a further embodiment, two or more fibers wound on separate packages may be subjected to a twisting step to form a multi-ply   yarn.    Suitably the twisting step comprises threading at least two separate, preferably, crimped fibers onto a twister, such as those manufactured by Verdol, Inc. or Volkmann, Inc. Preferably, a multi-ply yarn of 600 to 8000 denier with 2 to 9 twists per inch, preferably a two-ply yarn of 800 to 1500 denier and 3 to 6 twists per inch is prepared. Suitably the twister operates at a spindle speed of from 5000 to 8000 revolutions per minute. It will be appreciated by the skilled artisan that the fibers of the present invention may also be combined with one or more different fibers with or without twisting to prepare yams having desirable properties.

   For example, a multi-ply yam comprised of at least two different fiber-types, at least one of which is prepared according to the present invention may be prepared. The remaining fiber or fibers may be a conventional natural or synthetic fiber or a different fiber according to the present invention.



   In some applications, especially for the manufacture of carpets, the yarn may be subjected to various heat treatments in order to impart a final level of crystallinity to the fibers. Heat setting confers dimensional stability and improved heat resistance (among other things) to the   yarn.    For twisted multi-ply yarns, heat setting relieves mechanical twisting stresses, improving the twist retention and appearance of carpet made from such twisted yarns. In general, the process involves heating the yarn to a suitable temperature, generally in the absence of tension, for a time and in a manner to achieve the desired yarn properties. Suitable heat setting processes include the Superba or the Suessen processes.



   Close control of time and temperature in the heat setting process are generally required to produce yams with consistent dyeability. Moreover, many yams shrink in as a result of the heat setting process, thereby increasing the variablity of the denier. Advantageously, yams according to the present invention are less susceptible to dye or optical streaking and accordingly more tolerant to variations in the heat setting process. Moreover, yams of the present invention and resulting goods prepared therefrom, are additionally subject to less shrinkage during heat setting, cleaning, dying, or other process steps, and in use, compared to conventional yarns. Preferred yarns, especially twisted, heat-set, multiply yarns, are yams that exhibit a denier reduction of less than 15 percent upon heat setting at   130 C    for one minute.



   Fibers according to the present invention desirably possess higher modulus compared to a fiber formed solely or essentially from Component (a). Carpets incorporating yams according to the present invention are characterized by improved stain and soil resistance and increased durability. This effect is especially pronounced where Component (a) comprises a lower modulus resin, such as polyester. The relatively rough surface of the present fibers contributes to its enhanced soil release properties, due to the fact that dirt particles cannot come in contact with as large a portion of the fiber's surface as would occur with a smooth surfaced fiber. In addition, the rough surface of the fiber supports the dirt particles higher in the yarn bundle or carpet pile where they can be more readily removed by washing or vacuuming.



   The yams of the invention may be employed for weaving or knitting cloth for apparel applications using standard knitting of weaving techniques known to those skilled in the art. Due to higher fiber to fiber frictional forces obtainable by use of the present invented fibers and yams, fabric prepared from these fibers give a more uniform fabric structure, fewer streaks or flashes, and less barre. The processability of the yams according to the invention is also benefited due at least in part to the surface properties thereof, resulting in reduced running tension, improved draftability, and reduced roll wrapping.



  Concerning the Manufacture of Carpet
The yams of the present invention are readily processed into carpets, mats, and for floor and wall covering applications. To produce carpets, yarns, especially, twisted yams are tufted, woven, or fusion bonded onto a pliable backing. The resulting carpet, referred to as a"greige good", may be dyed to the appropriate color. Next, the back side of the carpet is coated with a suitable adhesive or sealant, such as a latex, and dried to bind the tufted yarn to the primary backing. A secondary backing may then attached to the backside of the carpet, if desired. The tufted yarn may then optionally be subjected to known cutting operations to form loop pile, cut pile, or loop and cut pile types of carpeting.

   In addition, multiple ends of the twisted multiply yams may be incorporated into a fabric backing to produce a textured surface, as required to obtain the desired carpet design.



   Dying of the carpet may be by either a batch process or a continuous process, using those dyes previously discussed with respect to dying of fibers or yarns. Conventional deep dye and light dye technologies, space dyeing techniques, as well as knit-deknit dying techniques may all be employed.



   Preferably, the carpet is dyed by passing it through an aqueous dyeing unit, such as those commercially available from the Otting Company or Kuster Corporation. The carpet is passed through the unit by means of a conveyor. Generally, the carpet is first prewetted, for example, by passing through a trough of water to which has been added a wetting agent or surfactant. The carpet is then passed between a pair of nip rolls to remove excess water and then contacted with the medium containing the dye and dye auxiliaries, referred to as the"liquor". Typically, in an acid dye process, the pH of the liquor is maintained in the range from 4.5 to 8. The liquor is sprayed onto the carpet or applied by a doctor blade from a reservoir. Next, the carpet passes through a heating chamber, such as steam heated vessel to fix the dye onto the carpet.

   The carpet is then washed to remove residual liquor from the carpet, rinsed and dryed. A stain resistance additive or stain-blocker, for example a silane compound, may be included in the dye liquor or applied to the carpet simultaneously or subsequently to the dying process, if desired.



  Conventional stain resist and soil resist technologyies can be used with the fibers, carpets and fabrics of the present invention.



   A carpet or rug according to the present invention preferably exhibits at least one of the following attributes: decreased dye streaking, reduced staining, reduced soiling, improved color fastness to cleaning, improved color fastness to ultraviolet light, improved hand, improved recovery, or improved durability, in each case relative to a comparable carpet or rug comprising fibers prepared from a composition that lacks the thermoplastic polymer (b).



  RECAPITULATION
The following is a summation of the specific embodiments of the present invention as fully set forth and disclosed herein.



     1.    A thermoplastic polymeric composition that is useful for preparing extruded fibers and films, said composition comprising:  (a) from 86 to 92 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ;  (b) from 14 to 8 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and  (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least   5 C    less than Tc'.



   2. The composition of embodiment 1 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195    C.    



   3. The composition of embodiment 1 wherein the first thermoplastic polymer is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.



   4. The composition of embodiment 3 wherein the first thermoplastic polymer is nylon 6, nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C ;.) o    alkyl-, halo-, or polar group-substituted vinylaromatic monomers.



   5. The composition of embodiment 3 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.



   6. The composition of embodiment 5 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   Cl, 0 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers.



   7. The composition of embodiment 5 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   8. The composition of embodiment 1 having a yellowness index, YI of less than 10.0.



   9. The composition of embodiment 1 comprising from 0.1 to 10 percent based on total composition weight of a compatibilizer c).



   10. The composition of embodiment 9 wherein the compatibilizer is a polar group modified vinylidene aromatic homopolymer or copolymer.



   11. The composition of embodiment 10 wherein the compatibilizer is a polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring   Cl 0 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   12. The composition of embodiment 11 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more   Cl. lo    ring alkylsubstituted styrenes, said compatibilizer containing from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality. 



   13. The composition of embodiments 1-12 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of Component (a).



   14. The composition of embodiment 13 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   um.   



   15. The composition of embodiment 13 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   nm.   



   16. The composition of embodiment 14 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 pm.



   17. The composition of embodiments 1-12 wherein after forming of a fiber therefrom,
 Component (b) is in the form of occluded particles having a volume average minor axis size from
0.2 to 3.0 um in a matrix of Component (a), and said fiber has a laser light scatter ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   18. The composition of embodiment 15 wherein after forming of a fiber therefrom,
 Component (b) is in the form of occluded particles having a volume average minor axis size from
0.2 to 3.0   llm    and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   19. The composition of embodiments   1-12    wherein after forming of a fiber therefrom,
 Component (b) is in the form of occluded particles having a volume average minor axis size from
0.2 to 3.0   pm    in a matrix of Component (a), and said fiber has a soft hand.



   20. The composition of embodiment 15 wherein after forming of a fiber therefrom,
 Component (b) is in the form of occluded particles having a volume average minor axis size from
0.2 to 3.0   zm    and said fiber has a soft hand.



   21. The composition of embodiments   1-12    wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component  (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.



   22. The composition of embodiment 15 wherein after forming of a fiber therefrom,
 Component (b) is in the form of occluded particles having a volume average minor axis size from
0.2 to 3.0   pm    and said fiber has a soft hand and improved durability. 



   23. The composition of embodiment 19 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   gm    and said fiber has a soft hand and improved durability.



   24. The composition of embodiment 20 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 jAm and said fiber has a soft hand and improved durability.



   25. The composition of embodiments   1-12    additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.



   26. An extruded and drawn fiber comprising a thermoplastic polymeric composition comprising:  (a) from 76 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ;  (b) from 24 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and  (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least   5 C    less than Tc'.



   27. The fiber of embodiment 26 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than   195  C.   



   28. The fiber of embodiment 26 wherein the first thermoplastic polymer is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.



   29. The fiber of embodiment 28 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C, ¯, o    alkyl-, halo-, or polar group-substituted vinylaromatic monomers.



   30. The fiber of embodiment 27 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.



   31. The fiber of embodiment 30 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   CI-10 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C i-10    alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   32. The fiber of embodiment 30 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   33. The fiber of embodiment 26 having a yellowness index, YI of less than 10.0.



   34. The fiber of embodiment 26 comprising from 0.1 to 10 percent based on total composition weight of a compatibilizer c).



   35. The fiber of embodiment 34 wherein the compatibilizer is polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring   CI-10 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   36. The fiber of embodiment 35 wherein the compatibilizer is a polar group modified polystyrene or a polar group modified copolymer of styrene and one or more ring   C,, 0 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinyl aromatic monomer.



   37. The fiber of embodiment 36 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more   CI-10    ring alkyl-substituted styrenes, said compatibilizer containing from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality.



   38. The fiber of embodiments 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of
Component (a).



   39. The fiber of embodiment 38 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   pm.   



   40. The fiber of embodiment 38 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   um.   



   41. The fiber of embodiment 39 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   um.   



     42.    The fiber of embodiments 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   urn    in a matrix of
Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   43. The fiber of embodiment 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   44. The fiber of embodiments 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of
Component (a), and said fiber has a soft hand.



   45. The fiber of embodiment 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.



   46. The fiber of embodiments 26-37 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.



   47. The fiber of embodiment 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.



   48. The fiber of embodiments 26-37 wherein the composition comprises: from 80 to 95 percent by weight of Component (a); and from 20 to 5 percent by weight of Component (b), based on total weight of (a) and (b).



   49. The fiber of embodiments 26-37 wherein the composition comprises: from 86 to 92 percent by weight of Component (a); and from 14 to 8 percent by weight of Component (b), based on total weight of (a) and (b).



   50. The fiber of embodiments 26-37 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.



   51. A thermoplastic polymeric composition that is useful for preparing extruded fibers and films, said composition consisting essentially   of :     (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ; and  (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups, and optionally one or more non-polymeric additives.



   52. The composition of embodiment 51 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than   195  C.   



   53. The composition of embodiment 51 wherein Tc is at least   5 C    less than Tc'. 



   54. The composition of embodiment 51 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   CI-10 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   55. The composition of embodiment 52 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.



   56. The composition of embodiment 51 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.



   57. The composition of embodiment 51 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   58. The composition of embodiment 51 having a yellowness index, YI, of less than 10.0.



   59. The composition of embodiment 51 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).



   60. The composition of embodiment 59 consisting essentially of from 8 to 14 percent by weight of a Component (b).



   61. The composition of embodiment 56 wherein the second component is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.



   62. The composition of embodiment 61 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality.



   63. The composition of embodiments   51-62    wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2, um in a matrix of Component (a).



   64. The composition of embodiment 63 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   m.   



   65. The composition of embodiment 63 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   m.    



   66. The composition of embodiment 64 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   pm.   



   67. The composition of embodiments 51-62 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   68. The composition of embodiment 65 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   69. The composition of embodiments   51-62    wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    in a matrix of Component (a), and said fiber has a soft hand.



   70. The composition of embodiment 65 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand.



   71. The composition of embodiments 51-62 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of Component (b).



   72. The composition of embodiment 65 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   73. The composition of embodiment 69 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   74. The composition of embodiment 70 wherein after forming of a fiber therefrom,
Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   75. The composition of embodiments 51-62 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent. 



   76. An extruded and drawn fiber comprising a thermoplastic polymeric composition consisting essentially   of :     (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ; and  (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups; and optionally one or more non-polymeric additives.



   77. The fiber of embodiment 76 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than   195  C.   



   78. The fiber of embodiment 76 wherein Tc is at least   5 C    less than Tc'.



   79. The fiber of embodiment 76 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   Cl 5 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   80. The fiber of embodiment 77 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.



   81. The fiber of embodiment 76 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.



   82. The fiber of embodiment 76 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   83. The fiber of embodiment 76 having a yellowness index, YI, of less than 10.0.



   84. The fiber of embodiment 76 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).



   85. The fiber of embodiment 84 consisting essentially of from 8 to 14 percent by weight of a Component (b).



   86. The fiber of embodiment 81 wherein the second component is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.



   87. The fiber of embodiment 86 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality. 



   88. The fiber of embodiments 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2, um in a matrix of
Component (a).



   89. The fiber of embodiment 88 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   m.   



   90. The fiber of embodiment 88 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0, um.



   91. The fiber of embodiment 89 Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   11m.   



   92. The fiber of embodiments 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of
Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   93. The fiber of embodiment 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   94. The fiber of embodiments 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of
Component (a), and said fiber has a soft hand.



   95. The fiber of embodiment 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.



   96. The fiber of embodiments 76-87 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of
Component (b).



   97. The fiber of embodiment 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.



   98. The fiber of embodiment 94 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability. 



   99. The fiber of embodiment 95 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   100. The fiber of embodiments 76-87 additionally comprising from 0.1 to 5.0 percent based on total composition weight of a delustering agent.



   101. An extruded, drawn, and crimped fiber comprising a thermoplastic polymeric composition consisting essentially   of :     (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ; and  (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups; and optionally one or more non-polymeric additives.



   102. The fiber of embodiment 101 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than   195  C.   



   103. The fiber of embodiment 101 wherein Tc is at least   10 C    less than Tc'.



   104. The fiber of embodiment   101    wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C). ; o    alkylor halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   105. The fiber of embodiment 102 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.



   106. The fiber of embodiment   101    wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.



   107. The fiber of embodiment 101 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   108. The fiber of embodiment 101 having a yellowness index, YI, of less than 10.0.



   109. The fiber of embodiment   101    consisting essentially of from 5.0 to 20 percent by weight of a Component (b).



   110. The fiber of embodiment 109 consisting essentially of from 8 to 14 percent by weight of a Component (b). 



     111.    The fiber of embodiment   101    wherein Component (b) is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.



   112. The fiber of embodiment   111    wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.



   113. The fiber of embodiments 101-112 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of
Component (a).



   114. The fiber of embodiment 113 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   pm.   



   115. The fiber of embodiment 113 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   pm.   



   116. The fiber of embodiment 114 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   urn.   



   117. The fiber of embodiments 101-112 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    in a matrix of
Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   118. The fiber of embodiment 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   119. The fiber of embodiments 101-112 Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 Am in a matrix of Component (a), and said fiber has a soft hand.



   120. The fiber of embodiment 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   Jim    and said fiber has a soft hand.



   121. The fiber of embodiments 101-112 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of Component (b).



   122. The fiber of embodiment 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability. 



   123. The fiber of embodiment 119 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0. 2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   124. The fiber of embodiment 120 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.



   125. The fiber of embodiments 101-112 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.



   126. A multicomponent fiber comprising two or more longitudinal coextensive polymer domains, at least one such domain comprising a thermoplastic polymeric blend comprising:  (a) from 50 to 99 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ;  (b) from 50 to 1 percent by weight of a second thermoplastic polymer different from (a) having a crystallization temperature, Tc', and optionally,  (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least   5 C    less than Tc'.



   127. The fiber of embodiment 126 wherein the first thermoplastic polymer of the blend is a polyamide or copolyamide and Tc'is greater than   195  C.   



   128. The fiber of embodiment 126 wherein the first thermoplastic polymer of the blend is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.



   129. The fiber of embodiment 128 wherein the first thermoplastic polymer of the blend is nylon 6 or nylon 6,6, and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   CI-10 alkyl-,    halo-, or polar groupsubstituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers.



   130. The fiber of embodiment 128 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.



   131. The fiber of embodiment 130 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-,    halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C,, 0    alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   132. The fiber of embodiment 130 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   133. The fiber of embodiment 126 which is a core/sheath fiber and the blend comprises the sheath.



   134. The fiber of embodiment 126 wherein the blend comprises from 0.1 to 10 percent based on total composition weight of a compatibilizer (c).



   135. The fiber of embodiment 134 wherein the compatibilizer is a polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring   C,, 0 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer..



   136. The fiber of embodiment 135 wherein the compatibilizer is a polar group modified polystyrene or a polar group modified copolymer of styrene and one or more ring   C, ¯, o    alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinyl aromatic monomer.



   137. The fiber of embodiment 136 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more   C, ¯, o    ring alkyl-substituted styrenes, said compatibilizer containing from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.



   138. The fiber of embodiments 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2, um in a matrix of
Component (a).



   139. The fiber of embodiment 138 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   m.   



   140. The fiber of embodiment 138 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   llm.   



   141. The fiber of embodiment 139 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   jAm.   



   142. The fiber of embodiments 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    in a matrix of
Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0. 



   143. The fiber of embodiment 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0    m    and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   144. The fiber of embodiments 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    in a matrix of
Component (a), and said fiber has a soft hand.



   145. The fiber of embodiment 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.



   146. The fiber of embodiments 126-137 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.



   147. The fiber of embodiment 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   llm    and said fiber has a soft hand and improved durability.



   148. The fiber of embodiments 126-137 wherein the blend composition comprises: from 80 to 95 percent by weight of Component (a); and from 20 to 5 percent by weight of Component (b), based on total weight of (a) and (b).



   149. The fiber of embodiment 133 wherein the core comprises nylon 6 or nylon 6,6.



   150. The fiber of embodiments 126-137 additionally comprising from 0. 1 to 10.0 percent based on total composition weight of a delustering agent.



   151. An extruded and drawn fiber or an extruded and stretched film comprising a thermoplastic polymeric composition comprising:  (a) from 76 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than   160  C    ; and  (b) from 24 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and optionally,  (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and said thermoplastic polymeric composition is prepared by melting and mixing a base resin comprising primarily Component (a) with a concentrate resin comprising primarily Component (b) and optionally Component (c) and further optionally, a minor amount of Component (a);

   and extruding and drawing the resulting molten thermoplastic polymeric composition in the form of a fiber or extruding and stretching the resulting thermoplastic polymeric composition in the form of a film.



   152. The fiber or film of embodiment 151 wherein the thermoplastic composition is prepared by a melt mixing process incorporating extensional flow mixing.



   153. The fiber or film of embodiment 151 wherein Tc is at least   10 C    less than Tc'.



   154. The fiber or film of embodiment 151 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring   C,, 0 alkyl-or    halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.



   155. The fiber or film of embodiment 154 wherein Component (a) comprises nylon 6 having a relative viscosity from 30 to 180.



   156. The fiber or film of embodiment 151 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.



   157. The fiber or film of embodiment 151 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.



   158. The fiber or film of embodiment 151 having a yellowness index, YI, of less than 10.0.



   159. The fiber or film of embodiment 151 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).



   160. The fiber or film of embodiment 159 comprising from 8 to 14 percent by weight of a Component (b).



   161. The fiber or film of embodiment 151 wherein Component (b) is a maleic anhydride modified or fumaric acid modified styrene homopolymer or a copolymer of styrene and p-methylstyrene.



   162. The fiber or film of embodiment 161 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.



   163. The fiber or film of embodiments 151-162 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2um in a matrix of
Component (a).



   164. The fiber or film of embodiment 163 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0   m.    



   165. The fiber or film of embodiment 163 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0   um.   



   166. The fiber or film of embodiment 164 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8   pm.   



   167. The fiber of embodiments 151-162 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of
Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   168. The fiber of embodiment 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   ! lm    and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.



   169. The fiber of embodiments 151-162 Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    in a matrix of Component (a), and said fiber has a soft hand.



   170. The fiber of embodiment 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand.



   171. The fiber of embodiments 151-162 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.



   172. The fiber of embodiment 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   pm    and said fiber has a soft hand and improved durability.



   173. The fiber of embodiment 169 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0   llm    and said fiber has a soft hand and improved durability.



   174. The fiber of embodiment 170 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.



   175. The fiber of embodiments 151-162 additionally comprising from 0.1 to   5.    0 percent based on total composition weight of a delustering agent. 



  EXAMPLES
The following Examples are provided for the purpose of illustration rather than limitation and do not preclude the presence of any additional additive or component. Unless stated to the contrary all parts and percentages stated throughout the specification are based on weight. In the examples the following equipment, processes and materials were employed, among others.



  Compounding Equipment
A Werner-Pfleiderer ZSK 40mm diameter, L/D ratio 34: 1, approximately 1.4 meters long vented twin-screw compounding extruder was used to prepare the compositions of the following examples. Standard compounding extruder settings are as follows:
Table A. compounding conditions for alloy manufacture
EMI60.1     


<tb>  <SEP> Feed <SEP> Rate <SEP> RPM <SEP> Torque <SEP> Zone <SEP> 2 <SEP> Zone <SEP> 3 <SEP> Zone <SEP> 4 <SEP> Zone <SEP> 5 <SEP> Zone <SEP> 6-8 <SEP> Die <SEP> Melt
<tb> Ibs/hr <SEP> (kg/hr) <SEP> percent <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C
<tb>  <SEP> 180 <SEP> (81.6) <SEP> 300 <SEP> 65-75 <SEP> 180-190 <SEP> 230-260 <SEP> 260-280 <SEP> 275-290 <SEP> 285-300 <SEP> 300 <SEP> 300
<tb> 
The molten polymer blend is extruded through a multiple hole die into cylindrical strands of 0.32 cm diameter,

   cooled in a water bath at ambient temperature, and passed between two air jets to remove the entrained water. The strands are then fed to a cutter which cuts the strands into cylindrical chips 2.8 mm in length and 2.1 mm in diameter. The blend chips are dried in a recirculating desiccant dryer at   90 C    for a minimum of 8-12 hours prior to use. Two compounding procedures are used. The masterbatch procedure consists of mixing the dispersed phase polymer and the compatiblizer in the first compounding pass. The resulting chips are dried before the second pass where the masterbatch is compounded with the continuous phase polymer to produce the final blend pellets.

   The single-pass procedure consists of mixing all three components; dispersed phase polymer, compatiblizer, and continuous phase polymer; in a single pass through the compounder to produce the final blend pellets.



   A Werner-Pfleiderer ZSK 30mm diameter, L/D ratio 30:   1,    approximately 0.9 meters long vented twin-screw compounding extruder was used to prepare the compositions of the following examples. Standard compounding extruder settings are as follows:
Table B. compounding conditions for alloy manufacture
EMI60.2     


<tb>  <SEP> Feed <SEP> Rate <SEP> RPM <SEP> Torque <SEP> Zone <SEP> 1 <SEP> Zone <SEP> 2 <SEP> Zone <SEP> 3 <SEP> Zone <SEP> 4 <SEP> Zone <SEP> 5 <SEP> Die <SEP> Melt
<tb> Ibs/hr <SEP> (kg/hr) <SEP> percent <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C <SEP>  C
<tb>  <SEP> 45 <SEP> (20.4) <SEP> 300 <SEP> 65-75 <SEP> 150-160 <SEP> 205-215 <SEP> 280-290 <SEP> 285-290 <SEP> 285-290 <SEP> 305 <SEP> 315
<tb> 
The molten polymer blend is extruded through a multiple hole die into cylindrical strands of 0.32 cm diameter,

   cooled in a water bath at ambient temperature, and passed between two air jets to remove the entrained water. The strands are then fed to a cutter which cuts the strands into cylindrical chips 2.8 mm in length and 2.1 mm in diameter.



  The blend chips are dried in a recirculating desiccant dryer at   90 C    for a minimum of 8-12 hours prior to use. Two compounding procedures are used. The masterbatch procedure consists of mixing the dispersed phase polymer and the compatiblizer in the first compounding pass. The resulting chips are dried before the second pass where the masterbatch is compounded with the continuous phase polymer to produce the final blend pellets. The single-pass procedure consists of mixing all three components; dispersed phase polymer, compatiblizer, and continuous phase polymer; in a single pass through the compounder to produce the final blend pellets.



  Fiber forming Equipment
Both laboratory scale and commercial scale multi-filament, fiber spinning equipment were employed to prepare fibers. Polymer compositions were dried prior to use and added to the extruders under a pad of dry nitrogen. Drawing and texturizing operations were performed as indicated.



  Laboratory Continuous Filament (CF) Line
The fiber forming extruder was a 25 mm diameter single screw extruder with length to diameter ratio (L/D) of 30: 1 fitted with 4 electrical zone heaters. It was followed by a metering pump and spin pack having a sintered metal filter. The spin pack is fitted with a fiber spinneret having 24 round holes. The filaments. fall through a cross-flow quench chamber and are then taken up onto two heated godets. The 24 filament yarn is wound onto cylindrical packages using a standard winder.



  Pilot Bulk Continuous Filament (BCF) Line
The extruder is a 30 mm diameter single screw extruder with a length to diameter ratio (L/D) of 30: 1 fitted with four electrical zone heaters. It is followed by a metering pump and spin pack fitted with a sintered metal filter. The spin pack is equipped with a fiber spinneret having 72 trilobal shaped dies which produce a fiber with modification ratio ranging from 1.8 to 2.3. The temperature of zones 1 through 4 of the extruder (feed throat to delivery end), spin pack, and product melt temperature are measured by means of thermocouples. Following extrusion the melted fibers drop through a cross-flow quench chamber to solidify into undrawn continuous filament   yarn.    Quenching is in   15 C    air unless otherwise specified.

   The undrawn quenched continuous filament yarn is drawn between a slow first godet roll and a fast second godet roll having respective temperatures and surface speeds as given in the examples. The drawn yarn is then introduced into a hot air texturizer tube where it is subjected to heated turbulent air to convert the continuous filament into a bulk continuous filament (BCF). The   bulked"plug"of BCF yarn    exits the texturizing tube onto a perforated cooling drum, which pulls ambient air through the hot textured plug via vacuum. The cooled BCF yarn bundle is delivered to an interlacing jet to produce an entangled   yarn.    The BCF yarn is then wound onto cylindrical packages using a standard winder operating at 1000 meter/minute unless otherwise specified.



  Pilot Continuous Filament (CF) Line
The extruder is a 30 mm diameter single screw extruder with a length to diameter ratio (L/D) of 30: 1 fitted with four electrical zone heaters. It is followed by a metering pump and spin pack fitted with a sintered metal filter. The spin pack is equipped with a fiber spinneret having 72 circular shaped dies of 0.25mm diameter. The temperature of zones 1 through 4 of the extruder (feed throat to delivery end), spin pack, and product melt temperature are measured by means of thermocouples. Following extrusion the melted fibers drop through a cross-flow quench chamber to solidify into undrawn continuous filament   yarn.    Quenching is in   15 C    air unless otherwise specified.

   The undrawn quenched continuous filament yarn is drawn between a slow first godet roll and a fast second godet roll having respective temperatures and surface speeds as given in the examples. The drawn yarn bundle is then wound onto cylindrical packages using a standard winder.



  Commercial Bulk Continuous Filament (BCF) Line
Fibers were spun on a commercial scale BCF spinning line common to the carpet industry. The spinning line uses three single screw extruders having a 75 mm diameter and a length to diameter ratio (L/D) of 30: 1 fitted with five electrical zone heaters. Each extruder is equipped with a metering pump and spin pack having a sintered metal filter. The spin pack is fitted with a fiber spinneret having 57 trilobal shaped dies. The temperature profile from zones 1 through 5 of each extruder (feed throat to delivery end), the spin head temperature and polymer melt temperature are given in the examples. Following extrusion the melted fibers dropped through a cross-flow quench chamber to solidify into undrawn continuous filaments, and quenched in   16 C    air unless otherwise specified.

   The undrawn, quenched, continuous filament bundles were drawn between a slow first godet roll and a fast second godet roll with respective speeds and temperatures given in the examples.



   The drawn yarn is then introduced into a hot air texturizer tube where it is subjected to turbulent heated air to convert the continuous filament into a bulk continuous filament. The bulked"plug"of BCF yarn exited the texturizing tube onto a perforated cooling drum which pulled ambient air through the hot textured plug under vacuum. The cooled BCF yarn plug is delivered to an interlacing jet to produce sufficient entanglement for subsequent processing into tufted carpet yarns. The yarn is then wound onto cylindrical packages using a standard winder. 



  Raw Materials
The raw materials utilized in the examples are identified as follows.



  Component (a)    N-6 RV 151    : Nylon-6 Homopolymer (CAS 25038-54-4), having a relative viscosity of   151,    a maximum of 0.08 weight percent moisture, a maximum of 1.5 weight percent water extractables, and a chip size of 2.5 x 2.5 mm) (Type 2700, available from DSM Company)
N-6 RV38: Nylon-6 Homopolymer (CAS 25038-54-4) having a relative viscosity of 38.



     (AkulonK222-D    from DSM Company).



     N-6. 6    RV50: Nylon 6,6 homopolymer (CAS 32131-17-2), Tm =   267 C,      (product &num;    181129, from   Sigma-Aldrich    Company).



     N-6,    6 RV250: Nylon 6,6 homopolymer (CAS 32131-17-2), high viscosity, extrusion grade, relative viscosity 230-280, (product &num;   429171,    from Sigma-Aldrich Company).



   N-6/6, 6 :   Nylon-6/Nylon    6,6 copolymer, (CAS 24993-04-2), Tm =   250 C      (Product &num;    42,924-4 from   Sigma-Aldrich    Company).



  Component   (b)   
SPS 1 : Syndiotactic polystyrene homopolymer having a target Mw of 250,000 (gel permeation chromatography) a melt flow rate (MFR) of 13 g/10 min. at   300 C    under a load of 1.2 kg (ASTM   D-1238),    and syndiotacticity greater than 96 percent   (QUESTRATM      QA101,    available from The Dow Chemical Company)
SPS2: Syndiotactic polystyrene homopolymer having a target Mw of 350,000 (gel permeation chromatography), a melt flow rate of 4 g/10 min. at   300 C    under a load of 1.2 kg (ASTM D-1238), and a syndiotacticity of greater than 96 percent   (QUESTRATM    QA102, The
Dow Chemical Company).



     SPMI    : Syndiotactic copolymer of styrene and 7 weight percent para-methylstyrene, having a target Mw of 325,000 (gel permeation chromatography)   (QUESTRATM    MA406, available from The Dow Chemical Company).



   SPM2: Syndiotactic copolymer of styrene and 4 weight percent para-methylstyrene,
Tc =   257 C   
SPM3: Syndiotactic copolymer of styrene and 0.7 weight percent para-methylstyrene
SPM4: Syndiotactic copolymer of styrene and 10 weight percent para-methylstyrene,
Tc =   246 C   
Component (b) and/or Component (c)
MGSPM 1 : Maleated syndiotactic copolymer of styrene and p-methylstyrene prepared in a ZSK40 twin screw extruder at   300  C    by melt mixing 95 weight percent of   SPM1,    3.0 weight percents fumaric acid, and 2.0 weight percent 2,3-dimethyl, 2,3-diphenyl butane, free radical initiator. The resulting anhydride group graft content is 0.5 weight percent by Fourier Transform
Infrared Analysis (FTIR).



   MGSPM2: Maleated syndiotactic copolymer of styrene and p-methylstyrene prepared in a
ZSK40 twin screw extruder at   300  C    by melt mixing 95 weight percent of SPM2,3.0 weight percents fumaric acid, and 2.0 weight percent 2,3-dimethyl, 2,3-diphenyl butane, free radical initiator. The resulting anhydride group graft content is 0.3 weight percent by Fourier Transform
Infrared Analysis (FTIR).



   MGSPM3: Maleated syndiotactic copolymer of styrene and p-methylstyrene prepared in a
ZSK40 twin screw extruder at   300  C    by melt mixing 95 weight percent of SPM3, 3.0 weight percents fumaric acid, and 2.0 weight percent 2,3-dimethyl, 2,3-diphenyl butane, free radical initiator. The resulting anhydride group graft content is 0.2 weight percent by Fourier Transform
Infrared Analysis (FTIR).



   MGSPS2 : Maleated syndiotactic homopolymer prepared in a ZSK40 twin screw extruder at   300  C    by melt mixing 95 weight percent of SPS2, 3.0 weight percents fumaric acid, and 2.0 weight percent 2,3-dimethyl, 2,3-diphenyl butane, free radical initiator. The resulting carbonyl group graft content is 0.34 weight percent by Fourier Transform Infrared Analysis (FTIR).



     FAPPOI    : Fumaric acid grafted poly (2,6-dimethyl-1,4-phenylene ether) (PPO) containing 0.8 weight percent grafted fumaric acid    FAPP02      : Fumaric    acid grafted poly (2,6-dimethyl-1,4-phenylene ether) (PPO) containing 1.6 weight percent grafted fumaric acid and 10 percent syndiotactic polystyrene (SPS1).



   SMA1 : Atactic styrene/maleic anhydride copolymer (SMA) (CAS 9011-13-6), having a melt index of 1.7 g/10 min   (230 C/2.    16 kg, ASTM D-1238) and containing 7 weight percent maleic anhydride
SMA2: atactic copolymer of styrene and maleic anhydride containing 0.2 weight percent maleic anhydride content by FTIR analysis.



   SMA3 : atactic copolymer of styrene and maleic anhydride containing 1.5 weight percent maleic anhydride content by FTIR analysis.



   SMA4: atactic copolymer of styrene and maleic anhydride containing 0.5 weight percent maleic anhydride content by FTIR analysis.



   The above components may additionally contain nominal amounts of one or more additives, such as antioxidants, lubricants, anti-block agents, stabilizers, nucleators and pigments.



  Test Methods
Unless otherwise indicated, the following test methods are employed.



   Tenacity is measured in accordance with ASTM D3822-96. 



   Elongation is measured in accordance with ASTM D3822-96.



   Modulus (Young's Modulus) is measured in accordance with ASTM D3822-96.



   Shrinkage is calculated from the difference in linear density (denier) before and after heat setting according to the formula: shrinkage = 100 x   [ (Dahs-Dbhs)/Dbhs],    in which Dbhs is the denier of the sample before heat setting and Dahs is the denier of the sample after heatsetting.



   Relative viscosity is determined using a capillary viscometer (Cannon Ubbelohde,   11-type,    size 200A) while suspending the viscometer in a constant temperature bath set at   25  C.    Flow times of polymer solution and solvent are measured in the capillary viscometer. The relative viscosity is determined by the formula:   T) rel.    = T/To where   r) rel.    = relative viscosity
T = flow time of the solution in seconds
To = flow time of the solvent in seconds.



   Temperature of crystallization upon cooling (Tc) is measured by DSC. Approximately 10 mg of polymer pellet is weighed (to 0.001 mg) into an aluminum DSC pan, crimped with a lid, and placed into the sample cell of a TA Instruments Differential Scanning Calorimeter, Model   &num;910    equipped with a TA Instruments Model &num;920 Autosampler and TA Instruments Universal
V3.0E software. An identical blank aluminum pan with crimped lid was placed in the reference cell. The sample was heated at the rate of   20  C/minute    to   320  C,    held at   320  C    for 5 minutes, then cooled to   150  C    over 20 minutes. A plot of heat flow (Watts per gram) versus temperature is obtained.



   The following transitions may be observed:
Tg = glass transition, a second order transition
Tch = The temperature of peak heat flow of crystallization upon heating a solid polymer, a first order exothermic transition.



  Tm = The temperature of peak heat flow of melting during upon heating a solid polymer, a first order endothermic transition.



  Tc = The temperature of peak heat flow of crystallization upon cooling a molten polymer, a first order exothermic transition. 
The Tc for various materials tested in the foregoing manner are listed in Table   1.   



   Table 1
EMI66.1     


<tb>  <SEP> Material <SEP> Tc <SEP>  C
<tb> SPS1 <SEP> 238
<tb> SPS2 <SEP> 226
<tb> SPM <SEP> 1 <SEP> 195
<tb> SPM2 <SEP> 225
<tb> SPM4 <SEP> 199
<tb> N-6 <SEP> RV151 <SEP> 166
<tb> N-6RV38 <SEP> 172
<tb> N-6,6RV50 <SEP> 215
<tb> N-6,6RV250 <SEP> 210
<tb> N-6/6, <SEP> 6 <SEP> 207
<tb> 
Examples   1-3,    A, and B-Luster determination by laser light scattering
A five member luster panel was used to quantify the luster of dyed bulk continuous filament fiber samples. The BCF fibers were dyed a deep olive green color to make the assessment of luster easier compared to trying to rate bright white BCF fiber. Five standards were used along with a numerical rating scale. A rating of one (1) was used to indicate full dull similar to that typically found with wool fiber. A rating of five (5) was used to indicate a full bright nylon 6 sample.

   Standards having ratings of two (2), three (3), and four (4) were then chosen as midpoints. Individual samples of the fibers were also measured by the laser light scattering technique disclosed herein.



  * Compositions as disclosed in Table 2 were prepared and spun into fibers. The compositions of Examples 1 and 2 were prepared on the 40mm twin screw extruder using the masterbatch procedure. Example 3 and A were prepared on the 40mm twin screw extruder using the single pass procedure.



   Table 2
EMI66.2     


<tb> Ex. <SEP> Component <SEP> (a) <SEP> a <SEP> Component <SEP> (b) <SEP> Component <SEP> (c) <SEP> 
<tb>  <SEP> percent <SEP> percent <SEP> percent
<tb>  <SEP> 1 <SEP> 76. <SEP> 4 <SEP> 20 <SEP> 3. <SEP> 6
<tb>  <SEP> 2 <SEP> 87.3 <SEP> 10 <SEP> 2. <SEP> 7
<tb>  <SEP> 3 <SEP> 87.3 <SEP> 10 <SEP> 2. <SEP> 7
<tb> A* <SEP> 96. <SEP> #5 <SEP> 0 <SEP> 3. <SEP> 65
<tb> B* <SEP> 100 <SEP> 0 <SEP> 0
<tb>    a nylon N-6   
SPS2   c FAPPOI    * Comparative, not an example of the invention 
The above compositions were spun into yams containing 72 filaments and having an approximate denier of 1200 using the pilot BCF spinning line. The yams showed a range of luster from full bright to full dull.

   The yams were assigned a relative luster ranking   of :   
5 = nylon 6 = full bright Comparative B
4 = Comparative A
3 = Example 2
2 = Example   1       1    = full dull, Example 3
In addition, commercial BCF samples were analyzed by laser light scattering. These same
BCF fibers were also dyed the deep olive green and rated by a luster panel.

   The commercial fiber samples and corresponding luster panel ratings employed were:
Cl* DuPont 1710-94-0-896AS Semi Dull (luster panel rating of 2.9)
C2* DuPont 1105-136-0-615 (luster panel rating of 1.8)
C3* DuPont 1340-68-0-416A (luster panel rating of 2.2)
C4* DuPont 1430-68-0-P1369 Bright (luster panel rating of 4.1)
C5* DuPont 1425-124-0-P1365 Mid Dull (luster panel rating of 1.9)
The scattering ratio of the five luster panel standards and the above five commercial BCF samples is given in Table 3. A plot of luster panel ratings and laser light scattering ratio (along with a linear fit calculated thereto) is provided in Figure 12. The scattering ratio, Rs, as determined by laser light scattering is inversely related to luster as determined by the luster panel.



  Specifically, luster = (-10.906) Rs + 7.1675 gives a linear fit with   R2=    0.9065. Fibers according to the invention possess a luster panel rating less than 4, which corresponds to a scattering ratio of 0.29 or higher. Results are contained in Table 3.



   Table 3
EMI67.1     


<tb>  <SEP> Ex. <SEP> Luster <SEP> Panel <SEP> Rating <SEP> Scattering <SEP> Ratio <SEP> Comments
<tb>  <SEP> 3 <SEP> 1(assigned) <SEP> 0.552 <SEP> Full <SEP> Dull
<tb>  <SEP> 1 <SEP> 2 <SEP> (assigned) <SEP> 0.488
<tb>  <SEP> 2 <SEP> 3 <SEP> (assigned) <SEP> 0.414
<tb> A** <SEP> 4 <SEP> (assigned) <SEP> 0. <SEP> 333
<tb> B** <SEP> 5 <SEP> (assigned) <SEP> 0.232 <SEP> Full <SEP> Bright
<tb> C1** <SEP> 2. <SEP> 9 <SEP> 0. <SEP> 338 <SEP> Semi <SEP> Dull
<tb> C2** <SEP> 1. <SEP> 8 <SEP> 0. <SEP> 523
<tb> C3** <SEP> 2. <SEP> 2 <SEP> 0.

   <SEP> 442
<tb> C4** <SEP> 254Bright
<tb> C5** <SEP> 1.9 <SEP> 0.438 <SEP> Mid <SEP> Dull
<tb> 
Exemplifies analytic technique but not the composition of the invention
In order to further corroborate the laser light scattering technique for fiber analysis several blends of nylon 6 containing various levels of a known delustering agent,   Ti02,    were compounded on the 30mm twin screw extruder and formed into fibers on the laboratory continuous filament line using essentially the same conditions previously described and analyzed. Composition details and results are contained in Table 4, and also in Figure 13.



   Table 4
EMI68.1     


<tb>  <SEP> Ex. <SEP> Ti02 <SEP> level <SEP> Scattering <SEP> Ratio <SEP> Comments
<tb> D1** <SEP> 0 <SEP> 0.228 <SEP> Bright <SEP> nylon
<tb> D2** <SEP> 460 <SEP> m <SEP> 0. <SEP> 320
<tb> D3** <SEP> 720 <SEP> m <SEP> 0. <SEP> 367
<tb> D4** <SEP> 950 <SEP> m <SEP> 0. <SEP> 388
<tb> D5** <SEP> 1120 <SEP> m <SEP> 0. <SEP> 415
<tb> D6** <SEP> 1340 <SEP> nnm <SEP> 0.456
<tb> 
Exemplifies analytic technique but not the composition of the invention
The plot of scattering ratio, Rs, versus   Ti02    level shows excellent correlation.



  Specifically, a fit to the formula:   Rs    =   (164.    6) w + 0.2364, where w is the   TiO2    content in weight percent, gives a correlation factor squared, R2 = 0.9895. In the figure, it may also be seen that a scattering ratio of 0.29 corresponds to a   TiO2    level of 325 ppm.



  Examples 4-15 and   E-Effect    of level of dispersed phase on luster and tenacity
The effect of dispersed phase content on luster and tenacity were measured for various compositions. Compositions for examples 4 through 15 were prepared on the 30mm twin screw extruder using the masterbatch procedure for the compositions given in Table 5. The fiber for invention examples 4 through 15 and comparative example E were spun on the laboratory continuous filament line using the conditions given in Table 6.



   Table 5
EMI68.2     


<tb> Ex. <SEP> Component <SEP> (a) <SEP> a <SEP> Component <SEP> (b) <SEP> Component <SEP> (c)
<tb>  <SEP> (percent) <SEP> (percent) <SEP> (percent)
<tb> E* <SEP> 100
<tb>  <SEP> 4 <SEP> 92. <SEP> 5 <SEP> 5 <SEP> 2.5c
<tb>  <SEP> 5 <SEP> 86. <SEP> 8 <SEP> 10 <SEP> 3.2c
<tb>  <SEP> 6 <SEP> 81. <SEP> 3 <SEP> 15 <SEP> 3.7c
<tb>  <SEP> 7 <SEP> 75.8 <SEP> 20 <SEP> 4. <SEP> 2c
<tb>  <SEP> 8 <SEP> 70. <SEP> 4 <SEP> 25 <SEP> 4. <SEP> 6 <SEP> c
<tb>  <SEP> 9 <SEP> 65 <SEP> 30 <SEP> 5. <SEP> 0 <SEP> c
<tb>  <SEP> 10 <SEP> 90.7 <SEP> 7 <SEP> 2. <SEP> 3
<tb>  <SEP> 11 <SEP> 87.4 <SEP> 10 <SEP> 2. <SEP> 6
<tb>  <SEP> 12 <SEP> 81.9 <SEP> 15 <SEP> 3. <SEP> 1
<tb>  <SEP> 13 <SEP> 76.4 <SEP> 20 <SEP> 3. <SEP> 6
<tb>  <SEP> 14 <SEP> 71 <SEP> 25 <SEP> 4.0
<tb>  <SEP> 15 <SEP> 65.5 <SEP> 30 <SEP> 4.

   <SEP> 5 <SEP> d
<tb>  comparative, not an example of the invention   a Nylon,    N-6 bSPS2
 MGSPM1 dFAPPO1 
Table 6
EMI69.1     


<tb>  <SEP> Spin <SEP> Melt <SEP> Pack <SEP> Slow <SEP> Fast
<tb> Godet <SEP> Godet
<tb> Draw <SEP> Yarn
<tb>  <SEP> Pack <SEP> Temp <SEP> Pressure
<tb>  <SEP> Extruder <SEP> zone <SEP> Profile <SEP> ( C)
<tb> Ex.

   <SEP> Speed <SEP> Speed
<tb> Ratio <SEP> (denier)
<tb> ( C) <SEP> ( C) <SEP> (MPa)
<tb>  <SEP> (m/min) <SEP> m/min)
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb>  <SEP> E* <SEP> 275 <SEP> 280 <SEP> 265 <SEP> 265 <SEP> 265 <SEP> 269 <SEP> 5.3 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 294/24
<tb>  <SEP> 4 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 304 <SEP> 2.1 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 263/24
<tb>  <SEP> 5 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 2.3 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24
<tb>  <SEP> 6 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 2.4 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 285/24
<tb>  <SEP> 7 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 2.4 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 291/24
<tb>  <SEP> 8 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 2.5 <SEP> 250 <SEP> 750 

  <SEP> 3.0 <SEP> 285/24
<tb>  <SEP> 9 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 2.7 <SEP> 250 <SEP> 500 <SEP> 2.0 <SEP> 414/24
<tb>  <SEP> 10 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 304 <SEP> 2.6 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 288/24
<tb> 11 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 304 <SEP> 2.4 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 283/24
<tb>  <SEP> 12 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 3.2 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 285/24
<tb>  <SEP> 13 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 3.2 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 281/24
<tb>  <SEP> 14 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 3.7 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 279/24
<tb>  <SEP> 15 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 305 <SEP> 3.

   <SEP> 8 <SEP> 250 <SEP> 500 <SEP> 2.0 <SEP> 375/24
<tb>  comparative, not an example of the invention
Quench air is   24  C   
Slow godet roll temperature is   40  C    for comparative E and   60  C    for invention 4-15
Fast godet roll temperature is   110  C    for comparative E and   150  C    for invention 4-15.



   The tenacity, modulus, and scattering ratio for the fibers are given in Table 7. Based on the scattering ratio lower limit of 0.29 this technology shows delustering at 2 percent SPS2 level when compatibilized with FAPPO1 and 3 percent total sPS level (SPS2 + MGSPM1) when using the MGSPM1 compatibilizer. The upper composition claim for this technology, based on tenacity and the ability to spin fiber, is 35 percent SPS2 or   SPS2+MGSPM1.    More preferred is 30 percent or less SPS2 or   SPS2+MGSPM1    and most preferred is 20 percent or less of SPS2 or   SPS2+MGSPM1   
The modulus of the fiber increases with increasing SPS2 content demonstrating the reinforcing nature of the dispersed phase which can lead to improved durability, better dimensional stability, improved wrinkle recovery, or improved stiffness. 



  Table 7
EMI70.1     


<tb> Ex. <SEP> Tenacity, <SEP> Young's <SEP> Modulus, <SEP> Scattering <SEP> Ratio
<tb>  <SEP> gram/denier <SEP> gram/denier
<tb> E* <SEP> 2.5 <SEP> 17 <SEP> 0.208
<tb>  <SEP> 4 <SEP> 3. <SEP> 1 <SEP> 17 <SEP> 0. <SEP> 406
<tb>  <SEP> 5 <SEP> 2. <SEP> 5 <SEP> 19 <SEP> 0. <SEP> 466
<tb>  <SEP> 6 <SEP> 2. <SEP> 6 <SEP> 25 <SEP> 0. <SEP> 495
<tb>  <SEP> 7 <SEP> 2. <SEP> 2 <SEP> 29 <SEP> 0. <SEP> 498
<tb>  <SEP> 8 <SEP> 2. <SEP> 1 <SEP> 43 <SEP> 0. <SEP> 494
<tb>  <SEP> 9 <SEP> 1. <SEP> 1 <SEP> 31 <SEP> 0. <SEP> 481
<tb>  <SEP> 10 <SEP> 2. <SEP> 8 <SEP> 16 <SEP> 0. <SEP> 488
<tb>  <SEP> 11 <SEP> 2. <SEP> 6 <SEP> 19 <SEP> 0. <SEP> 527
<tb>  <SEP> 12 <SEP> 2. <SEP> 7 <SEP> 24 <SEP> 0. <SEP> 557
<tb>  <SEP> 13 <SEP> 2. <SEP> 5 <SEP> 30 <SEP> 0. <SEP> 552
<tb>  <SEP> 14 <SEP> 2. <SEP> 6 <SEP> 41 <SEP> 0. <SEP> 559
<tb>  <SEP> 15 <SEP> 1. <SEP> 7 <SEP> 32 <SEP> 0.

   <SEP> 531
<tb>  comparative, not an example of the invention
A skein of the foregoing fibers of known length was immersed in boiling water for 15 minutes. The fiber was removed and allowed to air dry for 72 hours. The length of the skeins was re-measured and the percent linear skein shrinkage calculated. The fibers were then tested for physical properties. Results are provided in Table 8.



   Linear skein shrinkage is measured as follows. A fiber sample of approximately 200 meters in length is wound to a 1 meter circumference. The sample is suspended on a hook and a weight of 275 grams is hung on the skein. The length before exposure to boiling water is measured and recorded as Lb. The length after immersion in boiling water and drying is measured and recorded as La. Linear skein shrinkage is then calculated according to the following equation.



   Percent Linear Skein Shrinkage   (LSS) = ( (Lb-La)/Lb)    x 100
The linear skein shrinkage due to boiling water exposure decreases with increasing SPS2 content demonstrating the improved dimensional stability of the invention which has many advantages in textile applications including reduced optical streaking in carpets, improved dimensional stability during fabric manufacturing, dyeing, and finishing, improved dimensional stability during home laundering and professional cleaning, improved yields during fabric manufacturing, ability to reduce heat setting requirements, and ability of a garment to maintain its shape.

   Comparing the modulus in Table 7 and Table 8, the modulus of the fiber is better maintained after exposure to boiling water which can have advantages in textile applications where maintaining the fit and form are important with exposure to hot water. 



  Table 8
EMI71.1     


<tb> Ex. <SEP> % <SEP> Skein <SEP> Tenacity, <SEP> Elongation, <SEP> Young's <SEP> Modulus,
<tb>  <SEP> Shrinkage <SEP> gram/denier <SEP> % <SEP> gram/denier
<tb> E* <SEP> 14.0 <SEP> 2. <SEP> 7 <SEP> 68 <SEP> 12
<tb>  <SEP> 4 <SEP> 11.9 <SEP> 3. <SEP> 2 <SEP> 100 <SEP> 14
<tb>  <SEP> 5 <SEP> 10.6 <SEP> 2. <SEP> 2 <SEP> 64 <SEP> 16
<tb>  <SEP> 6 <SEP> 10.3 <SEP> 2. <SEP> 4 <SEP> 63 <SEP> 18
<tb>  <SEP> 7 <SEP> 8. <SEP> 8 <SEP> 2. <SEP> 2 <SEP> 48 <SEP> 24
<tb>  <SEP> 8 <SEP> 6.1 <SEP> 2. <SEP> 5 <SEP> 30 <SEP> 42
<tb>  <SEP> 2. <SEP> 9 <SEP> 1. <SEP> 0 <SEP> 24 <SEP> 31
<tb>  <SEP> 10 <SEP> 10.5 <SEP> 2. <SEP> 6 <SEP> 78 <SEP> 11
<tb>  <SEP> 11 <SEP> 10.0 <SEP> 2. <SEP> 7 <SEP> 74 <SEP> 14
<tb>  <SEP> 12 <SEP> 10.3 <SEP> 2. <SEP> 9 <SEP> 62 <SEP> 18
<tb>  <SEP> 13 <SEP> 9.7 <SEP> 2. <SEP> 7 <SEP> 55 <SEP> 23
<tb>  <SEP> 14 <SEP> 10.0 <SEP> 2.

   <SEP> 4 <SEP> 32 <SEP> 30
<tb>  <SEP> 15 <SEP> 6.7 <SEP> 1. <SEP> 9 <SEP> 36 <SEP> 29
<tb> 
Example 16-27 Correlation of Luster and Scattering Ratio with Size Of Occluded Particle
Fibers according to the present invention were formed by spinning, drawing and finishing various blends on the pilot BCF spinning line using representative spinning conditions. Samples were placed in formic acid at room temperature to dissolve the nylon matrix, leaving a dispersion of fine particles of the occluded phase which was unaffected by the formic acid. The particles are filtered and recovered. Figure 17, is a scanning electron micrograph (SEM) of a representative sample of such particles in a fiber prepared according to Example 25. Representative samples of such fibers were prepared, imaged and analyzed using standard particle size analysis software according to the following procedure.



   Samples of fibers (0.012 g) were placed in individual fresh 10 ml glass sample vials with screw tops. 2 ml of concentrated (95-97 percent) formic acid was added to each sample vial. The vials were gently shaken for 20 seconds to facilitate the dissolution of the nylon and retained in stationary position at   25  C    for 4 hours. The solutions were again shaken to evenly distribute the sPS particles in the formic acid solution. An aliquot (0.1 ml) of each dispersion was removed with a fresh 1 ml capacity plastic syringe and placed in a fresh 10 ml glass sample vial with a screw top. 4.9 ml of formic acid was then added to each of the vials to make 5 ml of total dispersion in each vial. Some solutions were further diluted as necessary to obtain separation of the sPS particles in the photographs.

   The diluted dispersions were gently shaken for 2-3 seconds and approximately 2 ml of solution was then removed with a syringe and filtered through either a 0.1 or 0.02 micron pore size inorganic membrane filter. The filter residue was washed three times with formic acid to remove any residual nylon.



   The filters on which the dispersed sPS particles were collected were briefly air dried and attached to aluminum scanning electron microscopy stubs. The specimens were sputtered with chromium in a high-resolution chromium coater. The prepared specimens were imaged by scanning electron microscope (Hitachi   S-4100 FEG    scanning electron microscope, available from
Hitachi, Ltd.). Images of   4096x4096    pixels were collected electronically with a 4PI digital imaging system, available from 4PI Analysis, Inc.



   Computer image analysis software was used to analyze the shape and size of the sPS particles (Scion Image particle size analysis application software for personal computers with the
Windows operating system, available from Scion Corp.). Particles were outlined manually on the images. Image was then used to measure the projected area and perimeter of the particles along with a fit of an ellipse (major and minor axis) to the projected shape of each particle. While most of the particles appeared ellipsoid or oblate spheroid in shape, resulting in a good fit to the model, some particles were found to be more rectangular in projected shape, (which indicated a more cylindrical shape in three dimensions), and were refitted manually to a rectangular model of length and width. 400-4000 particles, depending on the sample, were analyzed from each example.

   The terms minor axis and projected minor axis are used interchangeably herein with the terms diameter and particle diameter. Likewise, major axis and projected major axis are used interchangeable with the terms length and particle length.



   Average quantities of the sPS particles'projected major axes and projected minor axes (diameter) were calculated based on weightings of the number, projected area, estimated particle volume, and projected minor axis of the particles. The general equation for determination of a weighted average was used:
EMI72.1     
 where xw, is the average quantity (for example diameter) calculated based on the weighting factor of w (for example, particle volume),   w ;    is the individual weighting factor for particle i (for example the estimated volume of particle i), and   x ;    is the particle dimension to be averaged (for example, the diameter of particle i).

   From the volume weighted average, the cumulative probability of particle diameter was calculated:
EMI72.2     
 where   F (j)    is the cumulative probability for particle j, and   Vi    is the estimated volume of particle i, and the particles are ordered from smallest diameter to largest, so that particle 1 has the smallest diameter and particle N has the largest diameter. Based on this distribution, it is possible to calculate the particle which has a diameter at the 99th percentile of this volume based distribution. This particle diameter is called the (D99). The physical meaning   of D99    is that it is the particle diameter in the 99th volume based percentile, that is, 99 percent of the estimated total particle volume is occupied by particles which are smaller in diameter than the D99.

   As a result, the D99 is an approximation of the maximum diameter. The true maximum diameter would require an infinite set of measurements, and as a result, would not be a practical quantity for measurement and analysis. Both D99 and the volume average particle diameter are displayed in
Table 9.



   Table 9
EMI73.1     


<tb> Ex. <SEP> Luster <SEP> Panel <SEP> Scattering <SEP> Tenacity <SEP> of <SEP> BCF <SEP> Volume <SEP> Average <SEP> D99 <SEP> minor <SEP> axis
<tb>  <SEP> Rating <SEP> Ratio <SEP> fiber <SEP> (g/d) <SEP> minor <SEP> axis <SEP> (pm) <SEP> ( m)
<tb> 16 <SEP> 1. <SEP> 7 <SEP> 0.49 <SEP> 2.5 <SEP> 1.08 <SEP> 1. <SEP> 78
<tb> 171 <SEP> 3.3 <SEP> 0.39 <SEP> 2.8 <SEP> 0.83 <SEP> 1. <SEP> 50
<tb>  <SEP> 2 <SEP> 3. <SEP> 2 <SEP> 0.41 <SEP> 2.5 <SEP> 0.51 <SEP> 0. <SEP> 75
<tb>  <SEP> 19 <SEP> 2.3 <SEP> 0.46 <SEP> 2. <SEP> 2 <SEP> 0.59 <SEP> 1.27
<tb> 20 <SEP> a <SEP> 3. <SEP> 9 <SEP> 0.41 <SEP> 2.6 <SEP> 0.32 <SEP> 0. <SEP> 63
<tb> 214b <SEP> 4. <SEP> 6 <SEP> 0. <SEP> 33 <SEP> 2.6 <SEP> 0.24 <SEP> 0.38
<tb> 22"4. <SEP> 6 <SEP> 0.36 <SEP> 2.7 <SEP> 0.26 <SEP> 0.60
<tb> 23'2. <SEP> 5 <SEP> 0.49 <SEP> 2.6 <SEP> 0.75 <SEP> 1.35
<tb> 14-'3.

   <SEP> 0 <SEP> 0.41 <SEP> 2.7 <SEP> 0.33 <SEP> 0.61
<tb> 255 <SEP> 1. <SEP> 0 <SEP> 0.55 <SEP> 1. <SEP> 1 <SEP> 1. <SEP> 00 <SEP> 2.71
<tb> 26 <SEP> 1. <SEP> 4 <SEP> 0.49 <SEP> 2.2 <SEP> 1.24 <SEP> 1.94
<tb> 27 <SEP> 4. <SEP> 6 <SEP> 0.38 <SEP> 2.9 <SEP> 0.21 <SEP> 0.39
<tb>    87    percent Nylon N-6/10 percent SPS2/3 percent MGSPM1
2 87.8 percent Nylon N-6/10 percent SPS2/2.2 percent SMA4 3. 87. 3 percent Nylon N-6/10 percent SPS2/2.7 percent FAPPO 1 4a. 88. 65 percent Nylon N-6/10 percent SPS2/1.35 percent   FAPP02      4b-88.    65 percent Nylon N-6/10 percent SPM2/1.35 percent   FAPP02      4c. 88.    65 percent Nylon N-6/10 percent SPM1/1. 35 percent   FAPP02   
5   87.

   3    percent Nylon N-6/10 percent SPS2/2.7 percent FAPPO1, prepared by single-pass compounding (no precompounding of SPS2 and FAPPO1)
   6 87    percent Nylon 6 (RV = 38)/10 percent SPS2/3 percent MGSPM1
   7 87.    3 percent Nylon N-6,6 (RV = 240)/10 percent SPS2/2.7 percent FAPPO1
The thermoplastic alloys used in forming the fibers were compounded on 30 mm or 40 mm twin-screw extruders using the masterbatch procedure. The exception is Example 25, which was compounded on a 40 mm twin-screw extruder using the single pass procedure. All of the materials were formed into fibers on a pilot-scale BCF spinning line.

   All of the materials contained approximately 10 percent crystalline syndiotactic polymer phase (including samples containing   MGSPM1).    A plot of the volume average projected particle minor axis size and the luster of the BCF yarn as determined by an expert panel, along with a linear calculated fit is shown in Figure 14. 



   A linear correlation (y=-0.25x + 1.4) was found between the volume average projected particle minor axis size (y) and the fiber luster (x) as measured by a panel, having a square of the correlation coefficient, R2 of 0.79. More particularly, a volume average minor axis size of occluded particles greater than 0.20 um, preferably greater than 0.25 um at levels of Component (b) of approximately 8-14 weight percent is highly desired in order to produce fibers having reduced luster. The same information is also plotted using luster of the BCF yarn as measured by scattering ratio (x-axis) in Figure 15, giving a linear correlation (y=4.5x-1.3) between the volume average projected particle minor axis size (y) and the scattering ratio of the fibers (x) having a square of the correlation coefficient,   R2 of    0.65.

   Fibers having a scattering ratio determined by the foregoing method that is greater than 0.33, more preferably greater than 0.35, are highly desired according to the invention.



   Tenacity was also found to be correlated with the 99th percentile (on a volume percentile basis) of projected minor axis particle diameter, which is an approximation of the maximum particle diameter. When plotted as a function of tenacity a correlation is observed. Specifically, a linear fit to the equation: D99 particle diameter = (-1.3) x + 4.2, where x is tenacity in g/den, has a square of the correlation coefficient of R2 = 0.64. Results are shown in Figure 16.



   Good fiber spinning properties are believed to result at least in part from fibers having acceptable fracture dynamics. One factor affecting this property is believed to be minor axis size of the largest occluded particle. As such, the illustrated correlation between tenacity and D99 minor axis particle diameter is indicative of good fiber spinning properties. Specifically, D99 of less than 3.0   llm    is highly desired.



  Examples   28-38-Use    of various Compatiblizers and Two Component,   Self Compatiblized    Blend
The compositions of Table 10 were compounded on the 30mm or 40mm twin screw extruder using the masterbatch procedure for examples 28-36 and the single pass procedure for examples 37-38. The resultant blends were spun into fibers on the laboratory continuous filament line for examples 28-29 and the pilot BCF spinning line for examples 30-38. The BCF samples were rated for luster by the luster panel. Examples 28-36 contained 10 percent SPS2. Examples 37 and 38 contain only two components: nylon 6 and a maleated syndiotactic copolymer of styrene and p-methylstyrene. 



  Table 10
EMI75.1     


<tb>  <SEP> Component <SEP> Mol <SEP> Percent
<tb>  <SEP> (a) <SEP> N-6 <SEP> Component <SEP> (b) <SEP> Component <SEP> (c) <SEP> MA <SEP> in <SEP> (b)
<tb> Ex. <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> and <SEP> (c) <SEP> Luster <SEP> Tenacity
<tb> 28 <SEP> 89.00 <SEP> SPS2 <SEP> (10) <SEP> SMA2 <SEP> (1. <SEP> 00) <SEP> 0.018-3.80
<tb> 29 <SEP> 89.75"SMA3 <SEP> (0.25) <SEP> 0.039-3.60
<tb> 30 <SEP> 87.80"SMA4 <SEP> (2. <SEP> 20) <SEP> 0.096 <SEP> 3.20 <SEP> 2.50
<tb> 31 <SEP> 87.30"FAPP01 <SEP> (2. <SEP> 70) <SEP> 0.181 <SEP> 3.00 <SEP> 2.70
<tb> 32 <SEP> 87.30"FAPPO1(2. <SEP> 70) <SEP> 0.181 <SEP> 2.25 <SEP> 2.20
<tb> 33 <SEP> 87.00"MGSPM1 <SEP> 3. <SEP> 00 <SEP> 0.123 <SEP> 1.65 <SEP> 2.50
<tb> 34 <SEP> 87.00"MGSPM1 <SEP> (3.00) <SEP> 0.123 <SEP> 3.33 <SEP> 2.80
<tb> 35 <SEP> 87.00 <SEP> MGSPMI <SEP> (3.

   <SEP> 00) <SEP> 0.123 <SEP> 2.50 <SEP> 2.55
<tb> 36 <SEP> 87.00 <SEP> MGSPS2 <SEP> (3. <SEP> 00) <SEP> 0.083 <SEP> 2.90 <SEP> 2.50
<tb> 37 <SEP> 90.00 <SEP> MGSPM3 <SEP> (10) <SEP> 0. <SEP> 212 <SEP> 2.50 <SEP> 2.20
<tb> 38 <SEP> 90.00"-0.319 <SEP> 4.40 <SEP> 2.50
<tb> 
Excepting for Examples 37 and   38, all    blends contain 10 percent SPS2.



   Examples 37 and 38 contain only nylon and 10 percent MGSPM3 or MGSPM2.



   Luster panel rating of olive green dyed fibers on a scale from 1.0 (lowest luster) to 5.0 (highest luster)    C.    grams per denier.



  Examples   39-46,    F Yellowness Index. YI testing
Dry tumbled blends of SPS2, nylon N-6, and various compatibilizers (Component (c) including maleic anhydride grafted syndiotactic styrene/p-methylstyrene copolymers   (MGSPM1),    maleic anhydride grafted syndiotactic polystyrene (MGSPS2), atactic styrene/maleic anhydride copolymer   (SMA4),    or fumaric acid grafted polyphenylene oxide (FAPPO1 or   FAPP02)    in various weight ratios were compounded on a 30mm or 40mm twin screw extruder using the masterbatch procedure. In addition, a dry tumbled blend of nylon N-6 Component (a) with maleic anhydride grafted-styrene/p-methylstyrene copolymer (MGSPM4) was compounded on a twin screw extruder using the single-pass procedure.



   The resulting thermoplastic alloys were spun into BCF using the pilot BCF spinning line and representative fiber spinning conditions. The resulting bulk continuous fibers were then wound onto white cards three layers thick according to recommendation under AATCC method
Test Method 16-1998. The yellowness index of the fibers were then measured via ASTM E-31300. The alloy samples using grafted polyphenylene oxide polymers as the compatibilizer, even at low levels, have an unacceptable level of yellowness while the samples using the other compatiblization technologies have yellowness index similar to the comparative nylon sample.



  Compositions and results are provided in Table 11. 



  Table 11
EMI76.1     


<tb> Ex. <SEP> Component <SEP> Component <SEP> (b) <SEP> Component <SEP> (c) <SEP> Yellowness
<tb>  <SEP> (a) <SEP> percent <SEP> percent <SEP> (percent) <SEP> Index
<tb> F* <SEP> 100 <SEP> 2. <SEP> 3
<tb> 39 <SEP> 88.65 <SEP> SPS2 <SEP> (10) <SEP> FAPPO2a <SEP> (1.35 <SEP> 10.5
<tb> 40 <SEP> 93.1 <SEP> SPS2 <SEP> (5) <SEP> FAPPO1 <SEP> (1. <SEP> 9) <SEP> 18.8
<tb> 41 <SEP> 87.3 <SEP> SPS2 <SEP> (10) <SEP> FAPPO1 <SEP> (2. <SEP> 7) <SEP> 17. <SEP> 2
<tb> 42 <SEP> 81.9 <SEP> SPS2 <SEP> (15) <SEP> FAPPO1 <SEP>   <SEP> 3. <SEP> 1 <SEP> 24.4
<tb> 43 <SEP> 87 <SEP> SPS2 <SEP> (10) <SEP> MGSPS2' <SEP> (3.0) <SEP> 4.3
<tb> 44 <SEP> 87 <SEP> SPS2 <SEP> 10) <SEP> MGSPM1d(3.0 <SEP> 5.0
<tb> 45 <SEP> 87.8 <SEP> SPS2 <SEP> (10) <SEP> SMA4' <SEP> (2. <SEP> 2) <SEP> 3.0
<tb> 46 <SEP> 90 <SEP> MGSPM2 <SEP> (10) <SEP> 4.

   <SEP> 6
<tb> 
Comparative, not an example of the invention a maleic anhydride grafted polyphenylene oxide containing 1.6 weight percent grafted maleic anhydride content. b maleic anhydride grafted polyphenylene oxide containing 0.8 weight percent grafted maleic anhydride content. c maleic anhydride grafted syndiotactic polystyrene, 0.34 percent grafted maleic anhydride, tacticity greater than 96 percent. d maleated syndiotactic copolymer of 93 percent styrene and 7 percent p-methylstyrene, containing 0.55 percent grafted maleic anhydride and tacticity greater than 96 percent.    eatactic    styrene/maleic anhydride copolymer, 0.5 percent maleic anhydride. f Example 46 consists essentially of Component (a) and Component (b), a two component blend.



  Examples   Fa,      39a.    41a, 43a, 44a - Light Stability Of Undyed Fiber Samples
Samples of the above mentioned BCF of different composition were tested for color stability to UV light according to the American Association of Textile Chemists and Colorants (AATCC) Test Method 16-1998, option E. The BCF yams were wound on white cards three layers thick for testing. All tests were performed by Professional Testing Laboratory of Dalton
GA. Samples were exposed for 80 and 160 hours to high pressure mercury discharge lights, and then compared to control samples that had no exposure. Results in the form of D65, 10 degree color change, hE are contained in Table 18.

   In the table, change in color of reflected light,   AE,    is calculated through the formula:    AE    =   ((L-L2) 2 + (a,-a2) 2 + (b,-b2) 2)'n    where 1 is the initial state and 2 is the final state, and L, a and b are measures of the reflected light with respect to lightness or intensity, red/green and yellow/blue, respectively.



   The color change demonstrates that the samples using grafted polyphenylene oxide polymers as the compatiblizer have unacceptable color fastness compared to the nylon comparative and the examples using the MGSPS2 and MGSPM1 compatiblizers. 



  Table 12
EMI77.1     


<tb> Exposure
<tb> Time <SEP> (hr) <SEP> Fa* <SEP> Ex. <SEP> 39a <SEP> Ex. <SEP> 41a <SEP> Ex. <SEP> 43a <SEP> Ex. <SEP> 44a
<tb>  <SEP> 0 <SEP> 0. <SEP> 00 <SEP> 0. <SEP> 00 <SEP> 0. <SEP> 00 <SEP> 0. <SEP> 00 <SEP> 0. <SEP> 00
<tb>  <SEP> 80 <SEP> 1.53 <SEP> 3.88 <SEP> 7.97 <SEP> 1.06 <SEP> 1.46
<tb>  <SEP> 160 <SEP> 1.79 <SEP> 4.88 <SEP> 9.85 <SEP> 1.36 <SEP> 1.49
<tb> 
Example 47  &  G-Demonstration of fine denier spinning, apparel fiber and fabric samples
A blend of SPS2, MGSPMI, and nylon N-6 in the weight ratio of 10: 3: 87 was compounded on a 40mm twin screw extruder using the masterbatch procedure.

   The resultant blend was spun on the pilot continuous filament line using the following conditions:
Metering pump delivery: 14.7 grams/minute
Extruder barrel temperature profile:   290 C/325 C/325 C/310 C   
Spin head temperature:   310 C   
Melt temperature:   302 C   
Pack pressure: 363 psig (2.6 MPa)
Quenching is in   14 C    air
Slow Godet:   75 C    and 434 m/min.



   Fast Godet:   175 C    and 1300 m/min.



   Draw Ratio: 3: 1
Yarn Denier: 100/72,1.4 dpf
The tenacity of the resulting 100/72 yarn is 2.4 gram/denier with 65 percent elongation.



   A comparative fiber G was formed under comparable conditions using pure nylon N-6.



  The extruder is a 38 mm diameter single screw extruder with a length to diameter ratio (L/D) of 24 fitted with three electrical zone heaters. It is followed by a metering pump and spin pack fitted with a sintered metal filter. The spin pack is, equipped with a fiber spinneret having 64 circular shaped dies of 0.3 mm diameter. Fiber forming conditions were as follows:
Metering pump delivery: 8.3 grams/minute
Extruder barrel temperature profile:   260 C/275 C/260 C   
Spin head temperature:   260 C   
Melt temperature:   258 C   
Pack pressure: 380 psig (2.6 MPa)
Quenching is in   13 C    air
Slow Godet:   40 C    and 233 m/min.



   Fast Godet:   90 C    and 750 m/min.



   Draw Ratio: 3.2: 1
Yarn Denier: 100/64,1.56 dpf
The tenacity of the resulting 100/64 yarn is 4.0 gram/denier with 75 percent elongation.



   The two fibers were twisted at 2 twist per inch and then woven into fabric with a four harness crowfoot satin weave construction. The greige fabrics were immersed in boiling water for 15 minutes and then allowed to air dry. The dimension in the warp and fill direction before and after boiling water exposure were measured. Shrinkage was then calculated in both the warp and fill directions. Results are provided in Table 13.



   Table 13
Warp Shrinkage Fill Shrinkage
Ex. Warp Ends Fill Ends Weight percent percent
47 93/inch 80/inch 2.54 oz/yd2 7 5 6.6
G* 90/inch 87/inch 2.46 oz/yd2 7.5 7.6  * comparative, not an example of the invention
Examination of the resulting fabric samples after treatment in the foregoing manner indicated that the fabric prepared according to the invention (Example 47) had a more pleasing hand (softer feel) and better coverage (more opaque) than the comparative fabric.



  Example 48 Preparation of fibers using master batch blending and extensional flow mixing
A dry tumbled blend of SPS2 and FAPPO 1 (fumaric acid modified polyphenyleneoxide containing 0.8 percent grafted fumaric acid) in the weight ratio of 78.74: 21.26 was compounded in one pass at   290 C,    extruded into cylindrical strands and cooled to room temperature in a water bath. The strands are blown free of water and cut into chips 2.8 mm in length and 2.1 mm in diameter. The chips (referred to as masterbatch chips) are dried in a recirculating desiccant dryer at   90 C    for 8 hours to a moisture level of less than 0.08 percent.



   A dry tumbled blend of nylon N-6 and the foregoing masterbatch chips in a weight ratio of 87.3: 12.7 was fed to a 63.5 mm diameter single screw extruder, oriented for preparation of polymer particles, as indicated in Figure 6. The extruder, 60, comprises a single screw, 69, inside a cylindrical mixer body, 65, having three temperature control zones, 61,62, and 63. The set points for the zones from the inlet to outlet were 260,315, and   315 C    respectively. The transfer lines, 64, mixer body, 65, and cylindrical die, 66, were controlled at 290 C. The rpm for the extruder was set at 50 rpm which supplied a net 13.61 kg/hr flow rate through the system.

   In order to improve the mixing of the nylon 6 and masterbatch chips, the molten polymer leaving the extruder was fed through an in-line extensional flow mixing device, 67, (model EFM-250 static mixer, available from Extensional Flow Mixer, Inc. Mississaauga, Ontario). The variable gap in the mixer device was set to 3 mm. The material exiting the mixing device was extruded into cylindrical strands and cooled to room temperature in a water bath, 68. The strands were cut into chips approximately 4 mm in length and 3 mm in diameter. The resulting pellets were dried in a recirculating desiccant dryer to a moisture content of 0.08 percent or less and spun on the pilot
BCF spinning line. 



   Fiber forming conditions were as follows:
Metering pump delivery: 135 grams/minute
Extruder barrel temperature profile:   300 C/325 C/325 C/295 C   
Spin head temperature:   295 C   
Melt temperature:   290 C   
Pack pressure: 795 psig (5.6 MPa)
Quenching is in   15 C    air
Slow Godet:   75 C    and 334 m/min.



   Fast Godet:   160 C    and 1000 m/min.



   Draw Ratio: 3: 1
Texturizer Temperature  &  Pressure:   190 C    and 80 psig (0.63 MPa)
Interlacing Pressure: 45 psi (0.40 MPa)
Yam Denier : 100/64,1.56 dpf
The resulting BCF yarn had 1197 total denier for the 72 filament yarn bundle after drawing, texturizing, air interlacing and winding. The tenacity of the resulting 1197/72 yarn is 2.5 gram/denier. The luster panel rating was 3.6.



   It is understood that the fiber spinning equipment could also incorporate an extensional mixer, substantially as described in the preceding paragraph, or a static mixer at a position between the extruder and spin pack. With such a modified fiber spinning apparatus, it is possible to achieve sufficient dispersion of preblended pellets of Component (b) and (c) in Component (a) by combining the various components during the melt extrusion of fibers, such that initial compounding of a blend or alloy of all components is unnecessary.



  Example 49, bicomponent fiber spinning
A dry tumbled blend of nylon N-6, SPS2 and FAPPO1 (fumaric acid modified polyphenyleneoxide, containing 0.8 percent grafted fumairc acid) in the weight ratio 87.3: 10: 2.7, was compounded in a twin screw extruder using the single-pass procedure and dried.



   Bicomponent (core/sheath) fibers were formed under the following spinning conditions.



  Two single screw, 30 mm diameter extruders (one for the blend, used in the sheath and one for neat nylon 6, used as the core) with a length to diameter ratio (L/D) of 30: 1 fitted with four electrical zone heaters were used. Each extruder was fitted with a metering pump and spin pack fitted with a sintered metal filter. The spin pack is equipped with a fiber spinneret having 72 trilobal shaped dies, each capable of making a sheath-core, bi-component, coextruded fiber with a trilobal-shaped core. The temperature of zones 1 through 4 of the extruders (feed throat to delivery end) and spin are measured by means of thermocouples. Each metering pump delivered 68 grams/minute.

   The blend extruder barrel temperature profile was   290 C/320 C/310 C/300 C,    the nylon extruder barrel temperature profile was   260 C/280 C/275 C/275 C,    the spin head temperature was   300 C.    Pack pressure was 795 psig (5.6   MPa).    The sheath (formed from the thermoplastic blend of the invention) comprised 50 percent by volume of the total fiber crosssection, with the balance being neat nylon 6, comprising the fiber core. 



   Following extrusion the molten fibers drop through a cross-flow quench chamber to solidify into partially drawn continuous filament   yarn.    Quenching was in   15 C    air. The partially drawn quenched continuous filament yarn was drawn between a slow first godet roll and a fast second godet roll having respective temperatures   of 75 C    and   160 C    and respective surface speeds of 339 and 950 meter/minute, thus drawing at a ratio of 2.8.



   The cooled yarn bundle is then wound onto cylindrical packages using a standard winder operating at 950 meter/minute. The resulting flat yarn had 1250 total denier for the 72 trilobal filament yarn bundle after drawing and winding. The tenacity of the resulting 1250/72 yarn is 1.9 gram/denier.



  Example 50-Demonstration of commercial BCF spinning
A blend   of SPS2, FAPPO1,    and nylon N-6 in the weight ratio of 10: 2.7: 87.3 was compounded on the 40mm twin screw extruder using the masterbatch procedure. The resultant blend pellets were spun on the commercial BCF spinning line using the conditions below and in
Table 14:
Extruder barrel temperature profile:   275 C,      288 C,      285 C,      285 C,      285 C   
Spin head temperature:   285 C   
Melt temperature:   285 C   
Pack pressure: 110 psig (0.86 MPa)
Quenching is in   16 C    air
Slow Godet:   75 C   
Fast Godet :   180 C   
Texturizer Temperature  &  Pressure:

     210 C    and 6.0 bar (0.6 MPa)
Interlacing Pressure: 3.0 bar (0.30 MPa)
Comparative H
100 percent Component (a) (Nylon-6)
The equipment of Example 50 was used to prepare yams of Nylon N-6 polymer chips using the conditions below and in Table 14:
Extruder barrel temperature profile:   247 C,      257 C,      256 C,      254 C,      254 C   
Spin head temperature:   260 C   
Melt temperature:   260 C   
Pack pressure: 1550 psig (10.8 MPa)
Quenching is in   16 C    air
Slow Godet:   75 C   
Fast Godet :   180 C   
Texturizer Temperature  &  Pressure:   210 C    and 6.0 bar (0.6 MPa)
Interlacing Pressure:

   3.0 bar (0.30 MPa)   Comparative I    :
A blend of Styron 685D (atactic polystyrene), SMA1, and nylon N-6 in the weight ratio of 10: 1 : 89 was compounded on the 40mm twin screw extruder using the single pass procedure. The resultant blend pellets were spun on the commercial BCF spinning line using the conditions below and in Table 14:
Extruder barrel temperature profile:   260 C/280 C/270 C/270 C/270 C   
Spin head temperature:   270 C   
Melt temperature:   270 C   
Pack pressure: 1500 psig (10.4 MPa)
Quenching is in   16 C    air
Slow Godet:   75 C   
Fast Godet :   180 C   
Texturizer Temperature  &  Pressure:   210 C    and 6.0 bar (0.6 MPa)
Interlacing Pressure:

   3.0 bar (0. 30 MPa)
A comparison of the yams and spinning conditions reported in Table 14, demonstrates the improvement in spinnability achievable by use of compositions according to the invention, compared to fibers and yams according to Comparative H and   I.    The fiber of Example 50 was easier to form and spin on commercial scale fiber forming equipment at enhanced line speeds compared to fibers of Comparative H or   I,    at the same denier per filament. No fiber breakage or fiber stability problems were encountered using the composition of Example 50 while comparative example I was difficult to spin and produced numerous fiber breaks.



   Table 14
EMI81.1     


<tb>  <SEP> Slow <SEP> Fast
<tb>  <SEP> Line <SEP> Godet <SEP> Godet <SEP> Take <SEP> Up <SEP> Yarn
<tb>  <SEP> Speed <SEP> polymer <SEP> Filament <SEP> Yarn <SEP> Speed <SEP> Speed <SEP> Draw <SEP> Speed <SEP> Tenacity
<tb>  <SEP> Yarn <SEP> (m/min) <SEP> (g/min) <SEP> (denier) <SEP> (denier) <SEP> (m/min) <SEP> (m/min) <SEP> Ratio <SEP> (m/min) <SEP> (g/denier)
<tb> Ex. <SEP> 50a <SEP> 1600 <SEP> 160 <SEP> 14.8 <SEP> 847 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 1.9
<tb> Ex. <SEP> 50b <SEP> 1600 <SEP> 240 <SEP> 24.2 <SEP> 1378 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 1.9
<tb> Ex. <SEP> 50c <SEP> 1600 <SEP> 302 <SEP> 29.5 <SEP> 1679 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 1.7
<tb> Ex. <SEP> 50d <SEP> 1800 <SEP> 260 <SEP> 23.6 <SEP> 1346 <SEP> 640 <SEP> 1800 <SEP> 2.8 <SEP> 1650 <SEP> 2.0
<tb> Ex.

   <SEP> 50e <SEP> 2000 <SEP> 300 <SEP> 23.1 <SEP> 1317 <SEP> 706 <SEP> 2000 <SEP> 2.8 <SEP> 1770 <SEP> 2.0
<tb>  <SEP> Ha* <SEP> 1600 <SEP> 160 <SEP> 15.8 <SEP> 898 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 2.9
<tb>  <SEP> Hb* <SEP> 1600 <SEP> 240 <SEP> 23.4 <SEP> 1333 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 2.6
<tb>  <SEP> Hc* <SEP> 1600 <SEP> 302 <SEP> 29.5 <SEP> 1686 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 2.7
<tb>  <SEP> Hd* <SEP> 1800 <SEP> 260 <SEP> 23.0 <SEP> 1310 <SEP> 640 <SEP> 1800 <SEP> 2.8 <SEP> 1650 <SEP> 2.5
<tb>  <SEP> He* <SEP> 2000 <SEP> 300 <SEP> 23.3 <SEP> 1330 <SEP> 706 <SEP> 2000 <SEP> 2.8 <SEP> 1770 <SEP> 2.7
<tb>  <SEP> Ia* <SEP> 1600 <SEP> 280 <SEP> 27.5 <SEP> 1567 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 2.2
<tb>  <SEP> Ib* <SEP> 1600 <SEP> 300 <SEP> 29.7 <SEP> 1692 <SEP> 565 <SEP> 1600 <SEP> 2.8 <SEP> 1400 <SEP> 2.0
<tb>   * 

  Comparative, not an example of the invention
Example   51-53,      J,      K,     &  L-Reduced heat set shrinkage
The compositions of examples 51-53 were compounded on the 40mm twin screw extruder using the masterbatch procedure. The composition of example M was compounded on the 40mm twin screw extruder using the single-pass method. The resultant blends (shown in Table 15) were spun into fibers on the pilot BCF spinning line using the conditions given in Table 16. Scanning electron micrographs of the fibers are depicted in Figures la (Example 51), 1b (Example 52), lc (Example 53), 2a (K), 2b (L), and 2c (M).



   Table 15
EMI82.1     


<tb> Ex. <SEP> Component <SEP> (a) <SEP> a <SEP> Component <SEP> (b) <SEP> Component <SEP> (c) <SEP> Component <SEP> (d)
<tb>  <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> (percent)
<tb> 51 <SEP> 93. <SEP> 1 <SEP> 5 <SEP> 1. <SEP> 9
<tb> 52 <SEP> 873 <SEP> 3 <SEP> 2. <SEP> 7 <SEP> c
<tb> 53 <SEP> 81.9 <SEP> 15 <SEP> 3. <SEP> 1
<tb> J* <SEP> 100
<tb> K* <SEP> 99.8 <SEP> 0.2
<tb> L* <SEP> 99. <SEP> 6 <SEP> 0.

   <SEP> 4
<tb> M* <SEP> 89 <SEP> 10 <SEP> e <SEP> 1
<tb>  * Comparative, not an example of the invention   a Nylon,    N-6   'SPS2 'FAPP01    dTiO2 eStyron 685D fSMA1
Table 16
EMI82.2     


<tb>  <SEP> Spin <SEP> Melt <SEP> Pack <SEP> Slow <SEP> Fast
<tb> Godet <SEP> Godet
<tb>  <SEP> Yarn <SEP> Tenacity
<tb>  <SEP> Pack <SEP> Temp <SEP> Pressure
<tb>  <SEP> Extruder <SEP> Zone <SEP> Profile <SEP> ( C) <SEP> Speed <SEP> Speed
<tb> Ex <SEP> denier <SEP> (g/den)
<tb>  <SEP> (denier) <SEP> (g/den)
<tb> ( C) <SEP> ( C) <SEP> (MPa)
<tb>  <SEP> (m/min) <SEP> (m/min)

  
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb>  <SEP> 51a <SEP> 270 <SEP> 288 <SEP> 285 <SEP> 285 <SEP> 285 <SEP> 285 <SEP> 9.1 <SEP> 321 <SEP> 1000 <SEP> 1525 <SEP> 2.9
<tb>  <SEP> 52a <SEP> 270 <SEP> 288 <SEP> 286 <SEP> 285 <SEP> 285 <SEP> 285 <SEP> 8.0 <SEP> 321 <SEP> 1000 <SEP> 1513 <SEP> 2.7
<tb>  <SEP> 53a <SEP> 270 <SEP> 288 <SEP> 286 <SEP> 286 <SEP> 286 <SEP> 286 <SEP> 8.7 <SEP> 321 <SEP> 1000 <SEP> 1517 <SEP> 2.2
<tb>  <SEP> Ja* <SEP> 260 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 260 <SEP> 260 <SEP> 9.7 <SEP> 308 <SEP> 1000 <SEP> 1450 <SEP> 3.1
<tb>  <SEP> Ka* <SEP> 260 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 260 <SEP> 262 <SEP> 9.7 <SEP> 321 <SEP> 1000 <SEP> 1483 <SEP> 3.3
<tb>  <SEP> La* <SEP> 260 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 260 <SEP> 262 <SEP> 9.7 <SEP> 321 <SEP> 1000 <SEP> 1514 <SEP> 3.1
<tb>  <SEP> Ma* <SEP> 260 <SEP> 270 <SEP> 265 <SEP> 265 <SEP> 265 <SEP> 266 <SEP> 7.7 

  <SEP> 321 <SEP> 1000 <SEP> 1558 <SEP> 2.8
<tb>   * Comparative, not an example of the invention
Quench air is 15  C
Slow godet roll temperature is   80  C   
Fast godet roll temperature is   180  C    for example 51-53,120  C for comparatives J, K, L, M
Texturizer temperature  &  pressure is   190  C    and 100 psig (0.8 MPa)
Interlacing pressure is 50 psi (0.45 MPa)
Heat Shrinkage of Twisted Heat Set Yams
The yams produced in Comparative K, L, and M and in Examples 51-53 were twisted on a Verdol Model 400, cable-twisting apparatus to form twisted yams having 4.5 turns per inch (1.77 turns per cm) in the"S"direction using a spindle speed of 5200 rpm and a winder speed of 27.8 m/min. The twisted yam was then reeled into 89 inch (2.3 m) circumference reels for tumbling and heat set using a batch autoclave.

   The heat setting was done at   132 C    for 54 minutes. 



  The denier of the twisted yam before heat setting and after heat setting is given in Table 17 along with the shrinkage on heat setting and the tenacity of the twisted and heat set   yarn.   



   Table 17
EMI83.1     


<tb>  <SEP> Comp. <SEP> (a) <SEP> Denier <SEP> Denier <SEP> Heat <SEP> Set
<tb>  <SEP> Nylon-6 <SEP> Comp. <SEP> (b) <SEP> Comp. <SEP> (c) <SEP> Comp. <SEP> (d) <SEP> Before <SEP> After <SEP> Shrinkage <SEP> Tenacity
<tb>  <SEP> Yarn <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> Heat <SEP> Set <SEP> Heat <SEP> Set <SEP> (percent) <SEP> (g/denier)
<tb>  <SEP> Lb* <SEP> 99.6--0. <SEP> 4c <SEP> 3056 <SEP> 3564 <SEP> 16.6 <SEP> 3.1
<tb>  <SEP> Kb* <SEP> 99.8 <SEP> 0. <SEP> 2 <SEP> C <SEP> 3012 <SEP> 3566 <SEP> 18.4 <SEP> 3.3
<tb> Ex. <SEP> 51b <SEP> 93.1 <SEP> 5 <SEP> SPS2 <SEP> 1. <SEP> 9a-3040 <SEP> 3444 <SEP> 13. <SEP> 3 <SEP> 2.9
<tb> Ex. <SEP> 52b <SEP> 87. <SEP> 3 <SEP> 10 <SEP> (SPS2) <SEP> 2.7 <SEP> a-3036 <SEP> 3408 <SEP> 12. <SEP> 3 <SEP> 2.7
<tb> Ex.

   <SEP> 53b <SEP> 81.9 <SEP> 15 <SEP> (SPS2) <SEP> 3.1 <SEP> a-3042 <SEP> 3310 <SEP> 8.8 <SEP> 2.2
<tb>  <SEP> Mb* <SEP> 89 <SEP> 10 <SEP> (AtPS) <SEP> d <SEP> I. <SEP> Ob-3116 <SEP> 3576 <SEP> 14. <SEP> 8 <SEP> 2.8
<tb>  comparative, not an example of the invention   'FAPP01    b SMA I   tri02    d'tactic polystyrene does not possess a crystalline melting point or otherwise meet the requirements of
Component (b) of the invention.



   As illustrated in Table 17, the cable-twisted heat set yams prepared with the fibers of
Examples 5 la to 53a exhibit reduced shrinkage compared to the yams prepared with the fibers of
Comparative La, Ka and Ma. In particular, each of the Examples of twisted yams prepared with at least 5 weight percent syndiotactic polystyrene exhibited shrinkage of less than 15 percent, the yams prepared with at least 10 weight percent syndiotactic polystyrene exhibited shrinkage of less than 13 percent, and the yam prepared with 15 weight percent syndiotactic polystyrene exhibited less than 10 percent shrinkage.



  Color Fastness
The twisted and heat set BCF fiber samples of example 51b, 52b, 53b, and Jb (prepared by twisting fiber Ja in the same manner as twisted fibers   51b-53    b were prepared) were skein dyed a deep olive green according to the dye recipe and procedure given below. The resulting color for both the invention examples and the comparative example were a deep olive green. The fiber samples were placed in lingerie bags and washed according to the procedure given below. 



  Dye Recipes:
Level Acid Dye Recipe-Olive Green
Dyeacid Yellow 3R 200 percent: 0.00338 gram/gram fiber
Dyeacid Red 2B 200 percent: 0.0002 gram/gram fiber
Dyeacid TMBlue 4R 200 percent: 0.00256 gram/gram fiber    Dyelev    TMAC : 0.02 gram/gram fiber ammonium sulfate: 0.02 gram/gram fiber ammonia: 0.01 gram/gram fiber sodium thioSulfate : 0.0025 gram/gram fiber    Dyelev'rm    AC, a 48 percent aqueous solution   of Dowfax w2A1,    The Dow Chemical Company
DyeacidTM Yellow 3R 200 percent available from Dye Systems Inc. of Dalton Georgia
DyeacidTM Red 2B 200 percent available from Dye Systems Inc. of Dalton Georgia    Dyeacid Blue    4R 200 percent available from Dye Systems Inc. of Dalton Georgia
Dye Procedure    1.    Add water to dye to give a liquor ratio of 30: 1 to 40: 1.



   2. Add skeins to water and circulate bath.



   3. Weigh out and add   Dyelev    AC, ammonium sulfate, ammonia, and sodium thiosulfate to   110    liters of water according to weight of fiber to be dyed. Add to dye bath and circulate for 15 min. Target initial pH of 8 and target final pH of 6.5 to 7.



   4. Add dye solution according to weight of fiber to be dyed.



   5. Heat mixture to   93  C    over approximately 45 minutes while agitating
6. Hold at   93  C    for 15 minutes while agitating
7. Begin bath cool down  &  rinse by adding cold rinse water and overflow, then drain.



   8. Rinse with cold water, remove skeins, and dry at   120  C.   



  Wash Procedure
The yams were. placed in lingerie bags. Two sets of each yarn, 15 grams each, were placed in a standard residential wash machine for the first three wash cycles. After 3 wash cycles, one yarn for each material was removed and saved while the other yarn continued for another three cycles (total of six cycles). The yams were dried in a conventional residential dryer after each wash cycle.



   Approximately 85 grams of commercial laundry detergent (Tide Deep Clean Formula,
Mountain Spring liquid laundry detergent) was used per load for each wash cycle. The medium load setting used approximately 16 gallons of warm water in the wash cycle and 17 gallons of cold water in the rinse cycle. Total wash cycle time was 30 minutes.



   The 3 wash cycle, 6 wash cycle, and control yams were wound onto cards three layers thick according to recommendation under AATCC method Test Method 16-1998. The color of the yarn was measured and the colorfastness quantified by change in color of reflected light,   AE,    calculated through the formula: hE =   ( (L.-L2)' + (a,-a2)'+ (b)')'",    where 1 is the initial state and 2 is the final state, and L, a and b are measures of the reflected light with respect to lightness or intensity, red/green and yellow/blue, respectively.



   The change in color (AE) with wash cycles is tabulated in Table 18. The data show that the color fastness of the yarn comprising examples   5 lb-53b    is better to that of the comparative nylon 6 control (Jb*) after 6 washes. Similar results are expected using other acid dye technologies such as milling acid dyes and pre-metalized dyes. Conventional fixing agent technologies can also be used with the invention to further improve the wash fastness.



   Table 18
EMI85.1     


<tb> Example <SEP> 0 <SEP> washes <SEP> hE <SEP> 3 <SEP> washes <SEP> AE <SEP> 6 <SEP> washes <SEP> hE
<tb>  <SEP> Jb* <SEP> 0 <SEP> 6. <SEP> 0 <SEP> 10. <SEP> 4
<tb>  <SEP> 51b <SEP> 0 <SEP> 4. <SEP> 4 <SEP> 6. <SEP> 7
<tb>  <SEP> 52b <SEP> 0 <SEP> 4. <SEP> 5 <SEP> 6. <SEP> 7
<tb>  <SEP> 53b <SEP> 0 <SEP> 3. <SEP> 7 <SEP> 6. <SEP> 4
<tb>  * comparative, not an example of the invention
Production of Cut Pile Carpet
The yams produced in Examples   51a    to   53a    and in Comparative Example La and Ka were cable-twisted on a Verdol Model 400 cable twisting apparatus to produce yams containing 4.5 turns per inch (1.6 turns per cm) in the"S"direction, using a spindle speed of 5200 rpm and a winder speed of 31.6 m/min.

   The twisted yarns were reeled onto 89 inch (2.3   m)    circumference reels for tumbling and heat setting using a batch autoclave. The heat setting was done at   132 C    for 54 minutes.



   The twisted and heat set yarns were tufted on a 5/32 gauge cut pile tufting machine into a primary carpet backing. Pile height was 20/32 inches (1.6 cm) and 40 oz (1134 g) of yarn were used per square yard (1356 gram/square meter) of carpet. The tufted carpets were then dyed according to the recipe provided in Table 19 and in accordance with the following procedure:    1.    An appropriate amount of water is added to the dye bath to ensure adequate covering of the carpet to be dyed.



   2. The Sequestrant EDTA,   DyelevTMAC,    ammonium sulfate, and sodium thiosulfate are added to the dye bath and the pH adjusted to approximately 6.5.



   3. The greige good carpet is added to the dye bath to wet the fibers.



   4. The dye is then added to the dye bath.



   5. The dye bath is then heated to approximately   90 C    over 30 to 45 minutes time while gently agitating.



   6. The dye bath is held at   90 C    for 30 minutes while agitating.



   7. The dyed carpet is then removed and rinsed in cold water and allowed to dry. 



  Table 19: Dye Recipe
EMI86.1     


<tb>  <SEP> Ingredient <SEP> Source <SEP> Amount <SEP> (g/g <SEP> fiber)
<tb> Sequestrant <SEP> EDTA <SEP> Dye <SEP> Systems, <SEP> Inc. <SEP> (Dalton, <SEP> GA) <SEP> 0.005
<tb> DyelevTMAC <SEP> Dye <SEP> Systems, <SEP> Inc. <SEP> (Dalton, <SEP> GA) <SEP> 0.01
<tb> Ammonium <SEP> Sulfate <SEP> Aldrich <SEP> Chemical <SEP> 0. <SEP> 01
<tb> Sodium <SEP> Thiosulfate <SEP> Aldrich <SEP> Chemical <SEP> 0. <SEP> 005
<tb> Dyeacid <SEP> Yellow <SEP> 3R, <SEP> 200 <SEP> percent <SEP> Dye <SEP> Systems, <SEP> Inc. <SEP> (Dalton, <SEP> GA) <SEP> 0.0008
<tb> Dyeacid <SEP> Red <SEP> 2B, <SEP> 200 <SEP> percent <SEP> Dye <SEP> Systems, <SEP> Inc. <SEP> (Dalton, <SEP> GA) <SEP> 0.00024
<tb> Dyeacid <SEP> Blue <SEP> 4R, <SEP> 200 <SEP> percent <SEP> Dye <SEP> Systems, <SEP> Inc.

   <SEP> (Dalton, <SEP> GA) <SEP> 0.00016
<tb> 
After drying, the carpets were coated with styrene/butadiene latex, dried, sheared, and then cut into samples for contract walker evaluation. The purpose of the contract walker evaluation is to assess the appearance retention of a pile floor covering as a result of pedestrian traffic in a controlled environment. The test is well know and commonly employed in the carpet industry. The contract walker testing was preformed by Professional Testing Laboratory of
Dalton, GA, USA, according to the following procedure:    1.    Specimens 230 mm. x 560 mm are cut from both the length and width direction and fastened by suitable means to the floor with the long dimension perpendicular to the traffic flow.



   2. Pedestrians walk in fifty minute intervals. All specimens are thoroughly vacuumed every hour before traffic is resumed. Multiple electronic counters are used to determine when the predetermined amount of traffic has been applied.



   3. After the predetermined amount of traffic was applied all specimens are again vacuumed with the last pass of the vacuum being in the direction of the original pile.



   All specimens are allowed to recover at room temperature a minimum of 16 hours before grading by a panel of technicians.



   4. Specimens are individually rated in accordance with Carpet and Rug Institute (CRI)    TM101    using the CRI Reference Scales. Ratings are averaged and reported to the nearest 0.1. The higher the rating the better the expected performance. The rating is 5  = No noticeable wear, 4 = Slight wear, 3 = Moderate wear, 2 = Significant wear, and
1 = Severe wear.



   5. Each specimen was rated every 5000 cycles and replaced on the floor for more traffic until 20,000 cycles was obtained.



   The results of the appearance testing are set forth in the following Table 20 and in
Figure 4. 



  Table 20 Appearance Retention Ratings
EMI87.1     


<tb>  <SEP> Appearance <SEP> Retention <SEP> Ratings
<tb>  <SEP> 0 <SEP> 5000 <SEP> 10, <SEP> 000 <SEP> 15,000 <SEP> 20,000
<tb> Example <SEP> Yarn <SEP> Cycles <SEP> Cycles <SEP> Cycles <SEP> Cycles <SEP> Cycles
<tb>  <SEP> Kc* <SEP> K <SEP> 5.0 <SEP> 3.8 <SEP> 3.6 <SEP> 3.5 <SEP> 3.2
<tb>  <SEP> 51c <SEP> Ex. <SEP> 51 <SEP> 5.0 <SEP> 4.0 <SEP> 3.8 <SEP> 3.6 <SEP> 3.5
<tb>  <SEP> 52c <SEP> Ex. <SEP> 52 <SEP> 5.0 <SEP> 4.3 <SEP> 4.0 <SEP> 3.8 <SEP> 3.6
<tb>  <SEP> 53c <SEP> Ex. <SEP> 53 <SEP> 5. <SEP> 0 <SEP> 4. <SEP> 5 <SEP> 4.3 <SEP> 4. <SEP> 0 <SEP> 3. <SEP> 6
<tb>  <SEP> Lc* <SEP> L <SEP> 5. <SEP> 0 <SEP> 3. <SEP> 8 <SEP> 3.6 <SEP> 3.

   <SEP> 5 <SEP> 3.4
<tb>   * Comparative, not an example of the invention
The durability of the carpets of the invention are improved over the comparative controls while having a more pleasing hand.



  Examples 54-55, Mc
The fiber forming conditions of Example 51 and 52 were substantially repeated to prepare 72 filament yams of 1390 total denier from compositions according to the invention comprising
Nylon 6, syndiotactic polystyrene and a compatibilizer that were compounded on a 40mm twin screw extruder using the masterbatch procedure. A substantially pure Nylon 6 was included as a comparative sample. The fiber forming conditions are given in Table   21.   



   Table 21
EMI87.2     


<tb>  <SEP> Comp. <SEP> Comp. <SEP> Comp.
<tb>



   <SEP> (a) <SEP> (b) <SEP> (c) <SEP> Spin <SEP> Melt <SEP> Pack
<tb> Ex. <SEP> Nylon <SEP> 6a <SEP> SPS2b <SEP> FAPPO1 <SEP> Extruder <SEP> Zone <SEP> Profile <SEP> ( C) <SEP> Pack <SEP> Temp <SEP> Pressure <SEP> Tenacity
<tb>  <SEP> ( C) <SEP> ( C) <SEP> (MPa) <SEP> (szene
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb>  <SEP> 54 <SEP> 94.5 <SEP> 5 <SEP> 0.5 <SEP> 260 <SEP> 275 <SEP> 265 <SEP> 265 <SEP> 268 <SEP> 267 <SEP> 8.93 <SEP> 2. <SEP> 4
<tb>  <SEP> 55 <SEP> 89 <SEP> 10 <SEP> 1 <SEP> 260 <SEP> 275 <SEP> 268'270 <SEP> 268 <SEP> 273 <SEP> 91.4 <SEP> 2. <SEP> 0
<tb> Mc* <SEP> 100 <SEP> 0 <SEP> 0 <SEP> 255 <SEP> 270 <SEP> 265 <SEP> 265 <SEP> 265 <SEP> 267 <SEP> 8.86 <SEP> 3.

   <SEP> 2
<tb>   * Comparative, not an example of the invention    a Type 2700    available from DSM Company    b Questra TM QA102,    available from The Dow Chemical Company
The spinnerettes were fed at a metering pump feed rate of 150 g/min. The first and second godet rolls were operated at   80 C/308    m/sec. and   150 C/1000    m/sec., respectively, to give a draw ratio of 3.25. Texturizing was conducted using hot air at   170 C    and 35 psig (241 kPa) pressure. Entanglement was obtained by an interlacing jet at an air pressure 44 psig (300 kPa).



   The yams produced in Examples 54 and 55 and in Comparative M were twisted at 4.0 turns per inch, heat set, and tufted into carpet backing to produce a 40ounce/square yard   (1.      4kg/m2),    5/32 gauge cut pile carpet with 5/8 inch   (16mm)    pile height. The carpets were split into two groups. The first group was not dyed but was backed with a latex binder, sheared, and left as greige goods for residential stain testing to demonstrate the improved stain resistance of the invention. A small area of the greige carpet was spotted with a standard quantity of ten representative stains and allowed to remain on the sample for 24 hours. The carpet was then cleaned with a mild detergent and allowed to dry.

   The American Association of Textile Chemists and Colorists (AATCC) Gray Scale for Evaluating Staining was used to rate the resulting stains.



  The ratings are: 5 = No stain, 4 = Slight stain, 3 = Noticeable stain, 2 = Considerable stain,   1 =   
Severe stain. The stain ratings are given in Figure 5. The carpets made from the yams of
Examples 54 and 55 show less staining to cola, coffee, tomato juice, orange juice, and red wine that the carpet made from the yarn of Comparative M. In addition, the degree of spreading of the stain on the carpets made from the yams of Examples 54 and 55 was much less than that of the carpet made from the yarn of Comparative M demonstrating the reduced wicking of the invention.



   The second group of unbacked greige carpets was dyed yellow using the procedure of previous Examples 51c-53c and the dye formula of Table 22, before coating and shearing.



   Table 22
EMI88.1     


<tb>  <SEP> Amount
<tb>  <SEP> Ingredient <SEP> Source/fiber)
<tb> Dyeacid <SEP> Yellow <SEP> 3R, <SEP> 200 <SEP> percent <SEP> Dye <SEP> Systems, <SEP> Inc. <SEP> (Dalton, <SEP> GA, <SEP> USA) <SEP> 0.00046
<tb>  <SEP> Dyeacid <SEP> Red <SEP> 2B, <SEP> 200 <SEP> percent <SEP> ; <SEP> ; <SEP> 0. <SEP> 00003
<tb>  <SEP> Sequestrant <SEP> EDTA"0. <SEP> 005
<tb>  <SEP> D <SEP> AC <SEP> ; <SEP>   <SEP> 0. <SEP> 02
<tb>  <SEP> ammonium <SEP> sulfate <SEP> Aldrich <SEP> Chemical <SEP> 0. <SEP> 02
<tb>  <SEP> sodium <SEP> thiosulfate <SEP> Aldrich <SEP> Chemical <SEP> 0. <SEP> 005
<tb> 
The carpet   (Mc)    made of the twisted and heat set yarn of Comparative Mb showed color streaking. The dyed carpet made of the twisted and heat set yam of Example 54 showed dramatically reduced color streaking and had a pleasing soft hand and reduced luster.

   The dyed carpet made of the twisted and heat-set yam of Example 55 showed no color streaking and had a more pleasing soft hand and reduced luster compared to the dyed carpet of Example 54 and
Comparative Mc.



  Examples 56-65, N
The compositions given in Table 23 were prepared on a 30mm twin screw extruder using the single-pass procedure. The resultant blends were spun into fiber on the laboratory continuous filament line with the exception that the fibers were not drawn but left as partially oriented yams (POY). The fiber forming conditions are given in Table 23. The melt temperature was   300 C.   



  Pack pressure is 430 psig (2.96 MPa). Metering pump delivery is 5.9 grams/minute which produced a continuous filament yam of approximately 1450 total denier for the 24 filament yams.



  Following extrusion the melted fibers are dropped through ambient air to solidify into undrawn continuous filament yam. The undrawn quenched continuous filament yam is pulled over an idler and then drawn and wound onto cylindrical packages using a Leesona winder at 100 meter/minute giving a draw ratio of approximately 3 to 1. Results are contained in Table 23.



   Enhanced fiber tenacity and residual elongation are observed for compositions of the invention containing a compatibilizer. Improved modulus is seen for such fiber formulations containing more than 10 weight percent Component (b).



   Table 23
EMI89.1     


<tb>  <SEP> ¯ <SEP> Comp. <SEP> (a) <SEP> a <SEP> Comp. <SEP> (b) <SEP> b <SEP> Comp. <SEP> (c) <SEP> c <SEP> Tenacityd <SEP> Elongation <SEP> Modulus
<tb> Ex. <SEP> percent <SEP> percent <SEP> percent <SEP> (g/denier) <SEP> (percent) <SEP> (g/denier)
<tb> N* <SEP> 100 <SEP> 0 <SEP> 0 <SEP> 0.

   <SEP> 68 <SEP> 630 <SEP> 3.5
<tb> 56 <SEP> 90 <SEP> 10 <SEP> 0 <SEP> 0.40 <SEP> 370 <SEP> 3.7
<tb> 57 <SEP> 89 <SEP> 10 <SEP> 1 <SEP> 0.62 <SEP> 610 <SEP> 4.4
<tb> 58 <SEP> 88 <SEP> 10 <SEP> 2 <SEP> 0.60 <SEP> 600 <SEP> 4.8
<tb> 59 <SEP> 78 <SEP> 20 <SEP> 2 <SEP> 0.65 <SEP> 525 <SEP> 11.0
<tb> 60 <SEP> 78 <SEP> 20 <SEP> 2 <SEP> 0.54 <SEP> 530 <SEP> 8.0
<tb> 61 <SEP> 78 <SEP> 20 <SEP> 2 <SEP> 0.59 <SEP> 350 <SEP> 15.0
<tb> 62 <SEP> 70 <SEP> 30 <SEP> 0 <SEP> 0.20 <SEP> 40 <SEP> 5.8
<tb> 63 <SEP> 69 <SEP> 30 <SEP> 1 <SEP> 0.58 <SEP> 430 <SEP> 11.0
<tb> 64 <SEP> 68 <SEP> 30 <SEP> 2 <SEP> 0.62 <SEP> 420 <SEP> 12.0
<tb> 65 <SEP> 58 <SEP> 40 <SEP> 2 <SEP> 0.70 <SEP> 400 <SEP> 12.0
<tb>   * Comparative, not an example of the invention    "Nylon N-6       b SPS2,    with the exception of Example 60 (SPS 1) and Example 61   (SPM1)

  .       c FAPPO 1    d tenacity of POY
Example   66.    O-Use of low molecular weight nylon 6
A blend of SPS2, MGSPM1, N-6 RV38 in the ratio of 10: 3: 87 was compounded on a 30mm twin screw extruder using the masterbatch procedure. This blend uses a lower molecular weight nylon versus invention example 35 which used a high molecular weight nylon and had a tenacity of 2.55 g/den and a luster panel rating of 2.5. The blend was spun on the pilot BCF spinning line along with comparative example O, the N-6 RV38 control. Quench air is   15  C.   



  Slow godet roll speed is 334 m/min. Fast godet speed is 1000 m/min. Texturizer temperature  &  pressure is   190  C    and 80 psi (0.55 MPa). Interlacing pressure is 40 psi (0.28 MPa) Additional spinning conditions and resultant tenacity are given in Table 24. Both samples spun well. The luster panel rating of invention example 66 was 1.4 showing the decrease in luster due to the decrease in nylon molecular weight. The luster panel rating of comparative example O was 5.0. 



  Table 24
EMI90.1     


<tb>  <SEP> Slow <SEP> Fast
<tb>  <SEP> Spin <SEP> Melt <SEP> Pack
<tb> Extruder <SEP> Zone <SEP> Profile <SEP> ( C) <SEP> 
<tb> Godet <SEP> Godet <SEP> 
<tb> Pack <SEP> Temp <SEP> Pressure <SEP> Tenacity
<tb> ( C)( C)(Mpa)(g/den) <SEP> 
<tb> Ex. <SEP> Temp. <SEP> Temp.
<tb>



  ( C)( C)
<tb>  <SEP> Extruder <SEP> Zone <SEP> Profile <SEP> ( C)
<tb> Ex. <SEP> Temp. <SEP> Temp.
<tb>



   <SEP> ( C) <SEP> ( C) <SEP> (MPa) <SEP> (g/den)
<tb>  <SEP> ( C) <SEP> ( C)
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb>  <SEP> 66 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 300 <SEP> 293 <SEP> 4.0 <SEP> 75 <SEP> 160 <SEP> 2. <SEP> 2
<tb>  <SEP> 0* <SEP> 260 <SEP> 270 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 255 <SEP> 6. <SEP> 0 <SEP> 1 <SEP> 75 <SEP> 160 <SEP> 2. <SEP> 8
<tb>   * Comparative, not an example of the invention
Invention Examples 67-72
A blend of nylon N-6 (component (a)), SPS2 (component (b)), SMA1 (component (c)), and octadecanamide (component (d)), in the ratios given in Table 25 were compounded on a 30mm twin screw extruder using the masterbatch method. In these examples the SPS2,   SMA1,    and octadecanamide were mixed in the masterbatch.

   The purpose of the octadecanamide is to reduce the amount of maleic anhydride groups on the SMA1 by pre-reacting some of the groups before mixing the SMA1 into the nylon N-6. This allows the user to use commonly available compatiblizers and adjust the amount of nylon amine end groups that will be reacted with the compatiblizer to allow good dyeability as well as compatibility of components (a) and (b).



   Table 25
EMI90.2     


<tb> Ex. <SEP> Component <SEP> (a) <SEP> a <SEP> Component <SEP> (b) <SEP> b <SEP> Component <SEP> (c) <SEP> c <SEP> Component <SEP> (d) <SEP> d
<tb>  <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> (percent)
<tb> 67 <SEP> 89.0 <SEP> 10.0 <SEP> 1.0 <SEP> 0
<tb> 68 <SEP> 88.96 <SEP> 10. <SEP> 0 <SEP> 1.0 <SEP> 0.041
<tb> 69 <SEP> 88.93 <SEP> 10. <SEP> 0 <SEP> 1.0 <SEP> 0.071
<tb> 70 <SEP> 88.90 <SEP> 10. <SEP> 0 <SEP> 1. <SEP> 0 <SEP> 0. <SEP> 101
<tb> 71 <SEP> 88.87 <SEP> 10. <SEP> 0 <SEP> 1.0 <SEP> 0.131
<tb> 72 <SEP> 88. <SEP> 84 <SEP> 10. <SEP> 0 <SEP> 1.0 <SEP> 0.162
<tb>  a Nylon N-6    bSPS2 c SMA1    d octadecanamide
The resultant blend was spun into fiber using the laboratory continuous filament spinning line and the fiber spinning conditions given in Table 26.

   The quench air was set at   23  C.    Fiber properties are provided in Table 26. 



  Table 26
EMI91.1     


<tb>  <SEP> Spin <SEP> Melt <SEP> Pack
<tb>  <SEP> Extruder <SEP> Zone <SEP> Profile
<tb> Godet <SEP> Godet <SEP> 
<tb> Draw <SEP> Yarn <SEP> Tenacity <SEP> 
<tb> Ex. <SEP> Speed <SEP> Speed
<tb> Ratio <SEP> (denier) <SEP> (g/den) <SEP> 
<tb> ( C) <SEP> (n/min) <SEP> (n/min) <SEP> 
<tb>  <SEP> ( C) <SEP> ( C) <SEP> (MPa)

  
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb> 67 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3.5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 3.1
<tb> 68 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3.5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 3.0
<tb> 69 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3.5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 3.0
<tb> 70 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3.5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 2.9
<tb> 71 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3. <SEP> 5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 2. <SEP> 8
<tb> 72 <SEP> 290 <SEP> 325 <SEP> 315 <SEP> 310 <SEP> 310 <SEP> 308 <SEP> 3. <SEP> 5 <SEP> 250 <SEP> 750 <SEP> 3.0 <SEP> 280/24 <SEP> 2.

   <SEP> 8
<tb> 
Example 73
A blend of SPS2, MGSPMI, and nylon N6; 6,6 in the weight ratios 10: 3: 87 were compounded on a 30mm twin screw extruder using the masterbatch method. The resultant blend was spun into fiber using the pilot BCF spinning line. The fiber spinning conditions are as follows:
Extruder barrel temperature profile:   285 C/310 C/305 C/305 C   
Spin head temperature:   305 C   
Melt temperature:   300 C   
Pack pressure: 1200 psig (8.4 MPa)
Quenching is in   14 C    air
Slow Godet:   75 C    and 334 m/min.



   Fast Godet:   160 C    and 1000 m/min.



   Texturizer Temperature  &  Pressure:   190 C    and 80 psig (0.66 MPa)
Interlacing Pressure: 50 psi (0.44 MPa)
The resulting BCF yarn had 1202 total denier for the 72 filament yarn bundle after drawing, texturizing, air interlacing and winding. The tenacity of the resulting 1202/72 yarn is 2.4 gram/denier. The luster panel rating was 3.0.



  Invention Example 74-77, P Use   of sPS-PMS copolymers    as dispersed phase
A blend of SPS2, SPM1, SPM2, SPM4, MGSPM1, and nylon N-6 were compounded on a 30mm twin screw extruder using the masterbatch procedure and the weight ratios given in Table 27. The resultant blends were spun into fiber on the pilot BCF spinning line using the spinning conditions given in Table 28. These examples demonstrate the ability to use lower melting point copolymers as the dispersed phase to improve the modification ratio without the use of specially designed dies. 



  Table 27
EMI92.1     


<tb> Ex. <SEP> Component <SEP> (a) <SEP> a <SEP> Component <SEP> (b) <SEP> Component <SEP> (c)'
<tb>  <SEP> (percent) <SEP> (percent) <SEP> (percent)
<tb> 74 <SEP> 87 <SEP> 10 <SEP> 3
<tb> 75 <SEP> 87 <SEP> 10c <SEP> 3
<tb> 76 <SEP> 87 <SEP> 10 <SEP> 3
<tb> 77 <SEP> 87 <SEP> 10e <SEP> 3
<tb> P* <SEP> 100 <SEP> 0 <SEP> O
<tb> 
Comparative, not an example of the invention   a Nylon N-6 'SPS2 c SPM2 d SPM 1    e SPM4      
Table 28
EMI92.2     


<tb>  <SEP> Slow <SEP> Fast <SEP> Fiber <SEP> Luster
<tb>  <SEP> Spin <SEP> Melt <SEP> Pack
<tb>  <SEP> Godet <SEP> Godet <SEP> Mod.

   <SEP> Panel
<tb> Pack <SEP> Temp <SEP> Pressur <SEP> Tenacity <SEP> 
<tb>  <SEP> Extruder <SEP> Zone <SEP> Profile
<tb> Ex <SEP> Speed <SEP> Speed <SEP> Ratio <SEP> Rating <SEP> 
<tb> ( C) <SEP> ( C) <SEP> (MPa)(g/den)
<tb>  <SEP> ( C) <SEP> (m/min) <SEP> (m/min)
<tb>  <SEP> 1 <SEP> 2 <SEP> 3 <SEP> 4
<tb> 74 <SEP> 290 <SEP> 320 <SEP> 320 <SEP> 305 <SEP> 305 <SEP> 299 <SEP> 8.5 <SEP> 334 <SEP> 1000 <SEP> 2.1 <SEP> 2.4 <SEP> 2.2
<tb> 75 <SEP> 275 <SEP> 290 <SEP> 290 <SEP> 275 <SEP> 275 <SEP> 271 <SEP> 8.8 <SEP> 334 <SEP> 1000 <SEP> 2.4 <SEP> 3.9 <SEP> 2.4
<tb> 76 <SEP> 275 <SEP> 290 <SEP> 290 <SEP> 275 <SEP> 275 <SEP> 272 <SEP> 8.9 <SEP> 334 <SEP> 1000 <SEP> 2.6 <SEP> 3.5 <SEP> 2.3
<tb> 77 <SEP> 260 <SEP> 270 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 257 <SEP> 10.4 <SEP> 334 <SEP> 1000 <SEP> 2.8 <SEP> 3.4 <SEP> 2.4
<tb> P* <SEP> 260 <SEP> 270 <SEP> 270 <SEP> 260 <SEP> 260 <SEP> 256 <SEP> 

  9.2 <SEP> 334 <SEP> 1000 <SEP> 2. <SEP> 6 <SEP> 5.0 <SEP> 2. <SEP> 8
<tb>   * Comparative, not an example of the invention
Note: Quench air is   23 C,    slow godet roll at   75 C,    fast godet roll at   160 C,    texturizer temperature at    190 C,    texturizer pressure at 0.55 MPa,   interlacer    pressure at 0.28 MPa.



  Examples 78-79
A blend   of SPS2, MGSPS 1,    nylon N-6,6 RV50 and nylon N-6,6 RV250 in the ratios given in Table 29 were compounded on a 30mm twin screw extruder using the masterbatch method. The resultant blend was spun into fiber using the laboratory continuous filament spinning line using fiber spinning conditions substantially the same as those of Examples 74-77. Scattering
Ratio was determined by the technique of laser light back scatter, substantially as disclosed with respect to Examples 16-27 and elsewhere in the specification.



   Table 29
EMI92.3     


<tb> Ex. <SEP> Component <SEP> Component <SEP> (b) <SEP> c <SEP> Component <SEP> (c) <SEP> d <SEP> Tenacity <SEP> Scattering <SEP> Ratio
<tb>  <SEP> (a) <SEP> (percent) <SEP> (percent) <SEP> (percent) <SEP> (g/denier)
<tb> 78 <SEP> 87 <SEP> a <SEP> 10 <SEP> 3 <SEP> 2. <SEP> 8 <SEP> 0.41
<tb> 79 <SEP> 87 <SEP> 10 <SEP> 3 <SEP> 3.6 <SEP> 0. <SEP> 38
<tb>  a nylon N-6,6 RV50 b nylonN-6,6 RV250   c SPS2    dMGSPS1

Claims

CLAIMS: 1. A thermoplastic polymeric composition that is useful for preparing extruded fibers and films, said composition comprising: (a) from 86 to 92 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; (b) from 14 to 8 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least 5 C less than Tc'.

2. The composition of claim 1 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195 C.

3. The composition of claim 1 wherein the first thermoplastic polymer is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.

4. The composition of claim 3 wherein the first thermoplastic polymer is nylon 6, nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring Cl, o alkyl-, halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C,, 0 alkyl-, halo-, or polar group-substituted vinylaromatic monomers.

5. The composition of claim 3 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.

6. The composition of claim 5 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring Cl 1O alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C} 0 alkyl-, halo-, or polar group-substituted vinylaromatic monomers.

7. The composition of claim 5 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

8. The composition of claim 1 having a yellowness index, YI of less than 10.0.

9. The composition of claim 1 comprising from 0.1 to 10 percent based on total composition weight of a compatibilizer c).

10. The composition of claim 9 wherein the compatibilizer is a polar group modified vinylidene aromatic homopolymer or copolymer.

11. The composition of claim 10 wherein the compatibilizer is a polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring C,, 0 alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

12. The composition of claim 11 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more C).) o ring alkyl-substituted styrenes, said compatibilizer containing from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality.

13. The composition of claims 1-12 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of Component (a).

14. The composition of claim 13 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2. 0, um.

15. The composition of claim 13 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 pm.

16. The composition of claim 14 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 um.

17. The composition of claims 1-12 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of Component (a), and said fiber has a laser light scatter ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

18. The composition of claim 15 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

19. The composition of claims 1-12 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a soft hand.

20. The composition of claim 15 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 urn and said fiber has a soft hand.

21. The composition of claims 1-12 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.

22. The composition of claim 15 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 ! lm and said fiber has a soft hand and improved durability.

23. The composition of claim 19 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 urn and said fiber has a soft hand and improved durability.

24. The composition of claim 20 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.

25. The composition of claims 1-12 additionally comprising from 0. 1 to 10. 0 percent based on total composition weight of a delustering agent.

26. An extruded and drawn fiber comprising a thermoplastic polymeric composition comprising: (a) from 76 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; (b) from 24 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least 5 C less than Tc'.

27. The fiber of claim 26 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195 C.

28. The fiber of claim 26 wherein the first thermoplastic polymer is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.

29. The fiber of claim 28 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring C,, O alkyl-, halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C, ¯, o alkyl-, halo-, or polar group-substituted vinylaromatic monomers.

30. The fiber of claim 27 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.

31. The fiber of claim 30 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring CI-10 alkyl-, halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C,, O alkyl-or halosubstituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

32. The fiber of claim 30 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

33. The fiber of claim 26 having a yellowness index, YI of less than 10.0.

34. The fiber of claim 26 comprising from 0.1 to 10 percent based on total composition weight of a compatibilizer c).

35. The fiber of claim 34 wherein the compatibilizer is polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring C,, O alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

36. The fiber of claim 35 wherein the compatibilizer is a polar group modified polystyrene or a polar group modified copolymer of styrene and one or more ring C, lO alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinyl aromatic monomer.

37. The fiber of claim 36 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more Cl lO ring alkyl-substituted styrenes, said compatibilizer containing from 0.01 to 5. 0 mole percent copolymerized maleic anhydride or fumaric acid functionality.

38. The fiber of claims 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of Component (a).

39. The fiber of claim 38 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0 pm.

40. The fiber of claim 38 wherein Component (b) is in the. form of occluded particles having a D99 minor axis size less than 3.0 u. m.

41. The fiber of claim 39 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 um.

42. The fiber of claims 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

43. The fiber of claim 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0. 2 to 3.0 um and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

44. The fiber of claims 26-37 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of Component (a), and said fiber has a soft hand.

45. The fiber of claim 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand.

46. The fiber of claims 26-37 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.

47. The fiber of claim 40 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

48. The fiber of claims 26-37 wherein the composition comprises: from 80 to 95 percent by weight of Component (a); and from 20 to 5 percent by weight of Component (b), based on total weight of (a) and (b).

49. The fiber of claims 26-37 wherein the composition comprises: from 86 to 92 percent by weight of Component (a); and from 14 to 8 percent by weight of Component (b), based on total weight of (a) and (b).

50. The fiber of claims 26-37 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.

51. A thermoplastic polymeric composition that is useful for preparing extruded fibers and films, said composition consisting essentially of : (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; and (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups, and optionally one or more non-polymeric additives.

52. The composition of claim 51 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195 C.

53. The composition of claim 51 wherein Tc is at least 5 C less than Tc'.

54. The composition of claim 51 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6 and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring CI-10 alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

55. The composition of claim 52 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.

56. The composition of claim 51 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.

57. The composition of claim 51 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

58. The composition of claim 51 having a yellowness index, YI, of less than 10.0.

59. The composition of claim 51 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).

60. The composition of claim 59 consisting essentially of from 8 to 14 percent by weight of a Component (b).

61. The composition of claim 56 wherein the second component is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.

62. The composition of claim 61 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality.

63. The composition of claims 51-62 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of Component (a).

64. The composition of claim 63 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2. 0 m.

65. The composition of claim 63 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 um.

66. The composition of claim 64 wherein after forming of a fiber or film therefrom, Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 pm.

67. The composition of claims 51-62 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

68. The composition of claim 65 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

69. The composition of claims 51-62 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a soft hand.

70. The composition of claim 65 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.

71. The composition of claims 51-62 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of Component (b).

72. The composition of claim 65 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.

73. The composition of claim 69 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.

74. The composition of claim 70 wherein after forming of a fiber therefrom, Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.

75. The composition of claims 51-62 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.

76. An extruded and drawn fiber comprising a thermoplastic polymeric composition consisting essentially of : (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; and (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups; and optionally one or more non-polymeric additives.

77. The fiber of claim 76 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195 C.

78. The fiber of claim 76 wherein Tc is at least 5 C less than Tc'.

79. The fiber of claim 76 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring Cl 5 alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

80. The fiber of claim 77 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.

81. The fiber of claim 76 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and pmethylstyrene.

82. The fiber of claim 76 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

83. The fiber of claim 76 having a yellowness index, YI, of less than 10.0.

84. The fiber of claim 76 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).

85. The fiber of claim 84 consisting essentially of from 8 to 14 percent by weight of a Component (b).

86. The fiber of claim 81 wherein the second component is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.

87. The fiber of claim 86 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride or fumaric acid functionality.

88. The fiber of claims 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2lAm in a matrix of Component (a).

89. The fiber of claim 88 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0 pm.

90. The fiber of claim 88 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 um.

91. The fiber of claim 89 Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 um.

92. The fiber of claims 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

93. The fiber of claim 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

94. The fiber of claims 76-87 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um in a matrix of Component (a), and said fiber has a soft hand.

95. The fiber of claim 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand.

96. The fiber of claims 76-87 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of Component (b).

97. The fiber of claim 90 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

98. The fiber of claim 94 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 llm and said fiber has a soft hand and improved durability.

99. The fiber of claim 95 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 Hm and said fiber has a soft hand and improved durability.

100. The fiber of claims 76-87 additionally comprising from 0.1 to 5.0 percent based on total composition weight of a delustering agent.

101. An extruded, drawn, and crimped fiber comprising a thermoplastic polymeric composition consisting essentially of : (a) from 65 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; and (b) from 35 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and comprising polar functional groups; and optionally one or more non-polymeric additives.

102. The fiber of claim 101 wherein the first thermoplastic polymer is a polyamide or copolyamide and Tc'is greater than 195 C.

103. The fiber of claim 101 wherein Tc is at least 10 C less than Tc'.

104. The fiber of claim 101 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring CI-10 alkylor halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

105. The fiber of claim 102 wherein the polyamide is nylon 6 having a relative viscosity from 30 to 180.

106. The fiber of claim 101 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and pmethylstyrene.

107. The fiber of claim 101 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

108. The fiber of claim 101 having a yellowness index, YI, of less than 10.0.

109. The fiber of claim 101 consisting essentially of from 5.0 to 20 percent by weight of a Component (b).

110. The fiber of claim 109 consisting essentially of from 8 to 14 percent by weight of a Component (b).

111. The fiber of claim 101 wherein Component (b) is a maleic anhydride modified or fumaric acid modified syndiotactic polystyrene or a maleic anhydride modified or fumaric acid modified syndiotactic copolymer of styrene and p-methylstyrene.

112. The fiber of claim 111 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.

113. The fiber of claims 101-112 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2pm in a matrix of Component (a).

114. The fiber of claim 113 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0 pm.

115. The fiber of claim 113 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 pm.

116. The fiber of claim 114 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 pm.

117. The fiber of claims 101-112 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 llm in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

118. The fiber of claim 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

119. The fiber of claims 101-112 Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a soft hand.

120. The fiber of claim 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.

121. The fiber of claims 101-112 wherein the polar groups in Component (b) are reactive polar functional groups and are present in an amount from 0.001 to 0.25 mol percent of Component (b).

122. The fiber of claim 115 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

123. The fiber of claim 119 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand and improved durability.

124. The fiber of claim 120 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 jAm and said fiber has a soft hand and improved durability.

125. The fiber of claims 101-112 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.

126. A multicomponent fiber comprising two or more longitudinal coextensive polymer domains, at least one such domain comprising a thermoplastic polymeric blend comprising: (a) from 50 to 99 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; (b) from 50 to 1 percent by weight of a second thermoplastic polymer different from (a) having a crystallization temperature, Tc', and optionally, (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and wherein Tc is at least 5 C less than Tc'.

127. The fiber of claim 126 wherein the first thermoplastic polymer of the blend is a polyamide or copolyamide and Tc'is greater than 195 C.

128. The fiber of claim 126 wherein the first thermoplastic polymer of the blend is a polyamide or copolyamide and the second thermoplastic polymer is a polyvinylidene aromatic polymer having isotactic or syndiotactic stereostructure.

129. The fiber of claim 128 wherein the first thermoplastic polymer of the blend is nylon 6 or nylon 6,6, and the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring C,, O alkyl-, halo-, or polar groupsubstituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C,, O alkyl-, halo-, or polar group-substituted vinylaromatic monomers.

130. The fiber of claim 128 wherein the polyamide is nylon 6 having relative viscosity from 30 to 180.

131. The fiber of claim 130 wherein the second thermoplastic polymer is syndiotactic polystyrene, a syndiotactic copolymer of styrene and one or more ring CI-10 alkyl-, halo-, or polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring Cl, o alkyl-or halosubstituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

132. The fiber of claim 130 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

133. The fiber of claim 126 which is a core/sheath fiber and the blend comprises the sheath.

134. The fiber of claim 126 wherein the blend comprises from 0. 1 to 10 percent based on total composition weight of a compatibilizer (c).

135. The fiber of claim 134 wherein the compatibilizer is a polar group modified polystyrene, a copolymer of one or more vinylaromatic monomers and one or more polar comonomers, a polar group modified copolymer of styrene and one or more ring CI-10 alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer..

136. The fiber of claim 135 wherein the compatibilizer is a polar group modified polystyrene or a polar group modified copolymer of styrene and one or more ring CI-10 alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinyl aromatic monomer.

137. The fiber of claim 136 wherein the compatibilizer is a maleic anhydride modified or fumaric acid modified homopolymer of styrene or a maleic anhydride modified or fumaric acid modified copolymer of styrene and one or more Cl lu ring alkyl-substituted styrenes, said compatibilizer containing from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.

138. The fiber of claims 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2lAm in a matrix of Component (a).

139. The fiber of claim 138 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0 um.

140. The fiber of claim 138 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 pm.

141. The fiber of claim 139 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 jum.

142. The fiber of claims 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

143. The fiber of claim 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

144. The fiber of claims 126-137 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a soft hand.

145. The fiber of claim 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand.

146. The fiber of claims 126-137 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.

147. The fiber of claim 140 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

148. The fiber of claims 126-137 wherein the blend composition comprises: from 80 to 95 percent by weight of Component (a); and from 20 to 5 percent by weight of Component (b), based on total weight of (a) and (b).

149. The fiber of claim 133 wherein the core comprises nylon 6 or nylon 6,6.

150. The fiber of claims 126-137 additionally comprising from 0.1 to 10.0 percent based on total composition weight of a delustering agent.

151. An extruded and drawn fiber or an extruded and stretched film comprising a thermoplastic polymeric composition comprising: (a) from 76 to 97 percent by weight of a first thermoplastic polymer having a crystallization temperature, Tc, greater than 160 C ; and (b) from 24 to 3 percent by weight of a second thermoplastic polymer chemically different from (a) having a crystallization temperature, Tc', and optionally, (c) a compatibilizer for (a) and (b), wherein said percentages are based on the sum of (a) and (b), and said thermoplastic polymeric composition is prepared by melting and mixing a base resin comprising primarily Component (a) with a concentrate resin comprising primarily Component (b) and optionally Component (c) and further optionally, a minor amount of Component (a);

and extruding and drawing the resulting molten thermoplastic polymeric composition in the form of a fiber or extruding and stretching the resulting thermoplastic polymeric composition in the form of a film.

152. The fiber or film of claim 151 wherein the thermoplastic composition is prepared by a melt mixing process incorporating extensional flow mixing.

153. The fiber or film of claim 151 wherein Tc is at least 10 C less than Tc'.

154. The fiber or film of claim 151 wherein the first thermoplastic polymer is nylon 6 or nylon 6,6, or a copolymer of nylon 6 and nylon 6,6, and the second thermoplastic polymer is a syndiotactic copolymer of styrene and one or more polar group-substituted vinylaromatic monomers, or a polar group modified derivative of syndiotactic polystyrene or a syndiotactic copolymer of styrene and one or more ring C,, O alkyl-or halo-substituted vinylaromatic monomers or a polar group-substituted vinylaromatic monomer.

155. The fiber or film of claim 154 wherein Component (a) comprises nylon 6 having a relative viscosity from 30 to 180.

156. The fiber or film of claim 151 wherein the second thermoplastic polymer is a polar group modified derivative of a syndiotactic polystyrene or a syndiotactic copolymer of styrene and p-methylstyrene.

157. The fiber or film of claim 151 wherein the second thermoplastic polymer has a tacticity greater than 95 percent and Mw greater than 50,000.

158. The fiber or film of claim 151 having a yellowness index, YI, of less than 10.0.

159. The fiber or film of claim 151 consisting essentially of from 5. 0 to 20 percent by weight of a Component (b).

160. The fiber or film of claim 159 comprising from 8 to 14 percent by weight of a Component (b).

161. The fiber or film of claim 151 wherein Component (b) is a maleic anhydride modified or fumaric acid modified styrene homopolymer or a copolymer of styrene and pmethylstyrene.

162. The fiber or film of claim 161 wherein Component (b) contains from 0.01 to 5.0 mole percent copolymerized maleic anhydride of fumaric acid functionality.

163. The fiber or film of claims 151-162 wherein Component (b) is in the form of occluded particles having a volume average minor axis size greater than 0.2lAm in a matrix of Component (a).

164. The fiber or film of claim 163 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.3 to 2.0 pm.

165. The fiber or film of claim 163 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 3.0 urn.

166. The fiber or film of claim 164 wherein Component (b) is in the form of occluded particles having a D99 minor axis size less than 2.8 um.

167. The fiber of claims 151-162 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

168. The fiber of claim 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a laser light scattering ratio greater than or equal to 0.29 or luster panel rating determined from standardized fiber samples of less than or equal to 4.0.

169. The fiber of claims 151-162 Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm in a matrix of Component (a), and said fiber has a soft hand.

170. The fiber of claim 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 um and said fiber has a soft hand.

171. The fiber of claims 151-162 wherein the quantity of Component (c) ranges from 0 to less than 5 percent based on combined weight of Component (a) and Component (b) and that the total quantity of reactive, functional groups in Component (c) (if present) based on the sum of Component (b) + Component (c) be from 0.001 to 0.25 mol percent.

172. The fiber of claim 165 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

173. The fiber of claim 169 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0.2 to 3.0 pm and said fiber has a soft hand and improved durability.

174. The fiber of claim 170 wherein Component (b) is in the form of occluded particles having a volume average minor axis size from 0. 2 to 3.0 pm and said fiber has a soft hand and improved durability.

175. The fiber of claims 151-162 additionally comprising from 0.1 to 5.0 percent based on total composition weight of a delustering agent.