EP0013186B1 - Process for melt-spinning a splittable conjugate filament; self-texturing splittable conjugate filament; and method of splitting such a filament - Google Patents

Process for melt-spinning a splittable conjugate filament; self-texturing splittable conjugate filament; and method of splitting such a filament Download PDF

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Publication number
EP0013186B1
EP0013186B1 EP79303081A EP79303081A EP0013186B1 EP 0013186 B1 EP0013186 B1 EP 0013186B1 EP 79303081 A EP79303081 A EP 79303081A EP 79303081 A EP79303081 A EP 79303081A EP 0013186 B1 EP0013186 B1 EP 0013186B1
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EP
European Patent Office
Prior art keywords
filament
filaments
sub
conjugate
hollow
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP79303081A
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German (de)
French (fr)
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EP0013186A1 (en
Inventor
Jing-Peir Yu
James Ernest Bromley
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monsanto Co
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Monsanto Co
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Filing date
Publication date
Application filed by Monsanto Co filed Critical Monsanto Co
Publication of EP0013186A1 publication Critical patent/EP0013186A1/en
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/24—Formation of filaments, threads, or the like with a hollow structure; Spinnerette packs therefor

Definitions

  • the invention relates to the art of conjugate filaments splittable into sub-filaments. More particularly, it relates to a process and product wherein the conjugate filament itself has no substantial texture while sub-filaments splittable therefrom have substantial latent torqueless helical crimp.
  • Conjugate filaments splittable into sub-filaments are known to the art, as typified by Hayashi U.S. Patent 4,051,287. As disclosed therein, alternating segments of polyamide and polyester are spun in a side-by-side adhering relationship to form a hollow filament splittable into sub-filaments. Such sub-filaments can be of smaller denier than can be conveniently spun as separate filaments, lending a soft hand to fabrics made therefrom.
  • the sub-filaments of Hayashi are not disclosed as possessing significant crimp, and, as illustrated in Figure 10 of the patent, are substantially flat (untextured) even though the conjugate filament had been textured by the false-twist heat-set method before being split into sub-filaments.
  • Tanner U.S. Patent 3,117,906 describes a process comprising generally preparing a grey fabric from yarn comprising composite filaments comprising at least two different synthetic polymeric components adhered together in side-by-side relation throughout substantially the entire length of the filament, said different components having different shrinkage characteristics when subjected to heat; subjecting the fabric to a treatment involving controlled conditions whereby the different components are separated to form separate filaments and heating the fabric to effect shrinkage of the filaments, the heating being of sufficient duration and intensity to cause the filaments from the different synthetic polymeric compositions to shrink to a substantially different degree.
  • the differential shrinkage causes the filaments that shrink less to be pulled into crimped and looped configurations and the fabric is thereby bulked, but the filaments do not themselves possess latent torqueless helical crimp.
  • the process of the present invention is one for melt-spinning a hollow conjugate filament, splittable into sub-filaments, from nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, the process comprising:-
  • the invention also comprises a conjugate filament of nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, sub-filaments of said filament being releasably attached to one another in a side-by-side relationship, and said filament being substantially free of crimp, characterised in that unicomponent sub-filaments split from said conjugate filament possess substantial latent torqueless helical crimp.
  • the invention also includes a method comprising splitting a conjugate filament according to the invention into unicomponent sub-filaments.
  • the filament is hollow.
  • the preferred spinneret construction includes several generally arched or horseshoe-shaped slots 20 in spinneret blank 22 arranged symmetrically about a central point, the open ends of the horseshoe shape facing inwardly.
  • the several slots 20 constitute a combined orifice for spinning a single filament. Slots 20 extend entirely through blank 22 except for a recessed web region 24 at the apex of each slot 20.
  • the two dissimilar polymers are fed to the combined orifice as a sheath-core stream, with dotted circle 26 representing the interface between the two polymers.
  • the adjacent ends of adjacent slots 20 are sufficiently close that the streams issuing therefrom unite just below the spinneret.
  • the molten stream is thus a hollow structure composed of alternating axially extending segments of the two polymers. Surface tension and other effects tend to make the molten stream approach a hollow circular cross-section prior to solidification, substantially as shown in Hayashi Figure 1.
  • Each polymer segment accordingly has a portion of its periphery exposed to quenching on the exterior of the hollow stream, and an opposite portion shielded and not so exposed since it lies in the interior.
  • the molten steam is exposed while under the stress of spinning to quenching sufficiently rapid as to produce substantial latent torqueless helical crimp in the sub-filaments splittable from the conjugate filament.
  • Nylon 66 polymer and polyethylene terephthalate polymer are extruded at a temperature of 290°C through the combined orifice, the nylon polymer being the core of the sheath-core stream approaching the combined orifice.
  • Equal volumes of the two polymers are supplied, with the extrusion rate selected to produce a conjugate filament having a denier of 19.5 at a spinning speed of 1500 yards (about 1350 meters) per minute.
  • a quench zone just beneath the spinneret and 1 t meters in height is supplied with quenching air at 20°C, the air being directed horizontally onto the polymer stream and having a speed of 25 meters per minute. Below the quench zone, steam is applied to the filament, a conventional finish is applied, and the filament is wound.
  • the spun filament is then drawn at 65 meters per minute and at a draw ratio of 2.16 over a contact heater at 132°C, the heater being 0.4 meters long.
  • the resulting drawn yarn when mechanically worked to break the conjugate filament into 12 sub-filaments, develops no substantial torqueless helical crimp when subjected to boiling water.
  • Example I is repeated, except that the spinning speed is increased to 4500 meters per minute while the denier of the conjugate filament is reduced to 4.
  • the resulting sub-filaments after separation and immersion in boiling water, form a highly voluminous and lofty yarn.
  • Fabrics formed from the conjugate yarn acquire a very soft hand and increased bulk and covering power when the fabric is mechanically worked enough to separate the yarn into sub-filaments. Simple exposure of the fabric to boiling water is adequate in many instances, since the flexing of the yarn involved in certain fabric formations separates the sub-filaments.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Multicomponent Fibers (AREA)

Description

  • The invention relates to the art of conjugate filaments splittable into sub-filaments. More particularly, it relates to a process and product wherein the conjugate filament itself has no substantial texture while sub-filaments splittable therefrom have substantial latent torqueless helical crimp.
  • Conjugate filaments splittable into sub-filaments are known to the art, as typified by Hayashi U.S. Patent 4,051,287. As disclosed therein, alternating segments of polyamide and polyester are spun in a side-by-side adhering relationship to form a hollow filament splittable into sub-filaments. Such sub-filaments can be of smaller denier than can be conveniently spun as separate filaments, lending a soft hand to fabrics made therefrom. The sub-filaments of Hayashi are not disclosed as possessing significant crimp, and, as illustrated in Figure 10 of the patent, are substantially flat (untextured) even though the conjugate filament had been textured by the false-twist heat-set method before being split into sub-filaments.
  • Tanner U.S. Patent 3,117,906 describes a process comprising generally preparing a grey fabric from yarn comprising composite filaments comprising at least two different synthetic polymeric components adhered together in side-by-side relation throughout substantially the entire length of the filament, said different components having different shrinkage characteristics when subjected to heat; subjecting the fabric to a treatment involving controlled conditions whereby the different components are separated to form separate filaments and heating the fabric to effect shrinkage of the filaments, the heating being of sufficient duration and intensity to cause the filaments from the different synthetic polymeric compositions to shrink to a substantially different degree. The differential shrinkage causes the filaments that shrink less to be pulled into crimped and looped configurations and the fabric is thereby bulked, but the filaments do not themselves possess latent torqueless helical crimp.
  • The process of the present invention is one for melt-spinning a hollow conjugate filament, splittable into sub-filaments, from nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, the process comprising:-
    • a. Extruding a hollow molten stream formed from axially extending segments of said polymers arranged alternately in side-by-side adhering relationship to form said hollow molten stream;
    • b. quenching said stream to form a filament; and
    • c. withdrawing said filaments from said molten stream at a given spinning speed, characterised in that said given spinning speed is sufficiently high and said quenching is sufficiently rapid that unicomponent sub-filaments split from said filament possess substantial latent torqueless helical crimp.
  • The invention also comprises a conjugate filament of nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, sub-filaments of said filament being releasably attached to one another in a side-by-side relationship, and said filament being substantially free of crimp, characterised in that unicomponent sub-filaments split from said conjugate filament possess substantial latent torqueless helical crimp.
  • The invention also includes a method comprising splitting a conjugate filament according to the invention into unicomponent sub-filaments.
  • According to a preferred aspect of the filament of the invention, the filament is hollow.
  • Other aspects of the invention will in part appear hereinafter and will in part be obvious from the following detailed description taken together with the accompanying drawing, in which:
    • The Figure is a bottom plan view (looking up) of the preferred spinneret orifice used in practising the invention.
  • As shown in the Figure, the preferred spinneret construction includes several generally arched or horseshoe-shaped slots 20 in spinneret blank 22 arranged symmetrically about a central point, the open ends of the horseshoe shape facing inwardly. The several slots 20 constitute a combined orifice for spinning a single filament. Slots 20 extend entirely through blank 22 except for a recessed web region 24 at the apex of each slot 20. The two dissimilar polymers are fed to the combined orifice as a sheath-core stream, with dotted circle 26 representing the interface between the two polymers. The adjacent ends of adjacent slots 20 are sufficiently close that the streams issuing therefrom unite just below the spinneret. The molten stream is thus a hollow structure composed of alternating axially extending segments of the two polymers. Surface tension and other effects tend to make the molten stream approach a hollow circular cross-section prior to solidification, substantially as shown in Hayashi Figure 1.
  • Each polymer segment accordingly has a portion of its periphery exposed to quenching on the exterior of the hollow stream, and an opposite portion shielded and not so exposed since it lies in the interior. According to the invention, the molten steam is exposed while under the stress of spinning to quenching sufficiently rapid as to produce substantial latent torqueless helical crimp in the sub-filaments splittable from the conjugate filament.
    • Example I (Comparative)
  • Nylon 66 polymer and polyethylene terephthalate polymer, each of normal molecular weight for apparel end uses, are extruded at a temperature of 290°C through the combined orifice, the nylon polymer being the core of the sheath-core stream approaching the combined orifice. Equal volumes of the two polymers are supplied, with the extrusion rate selected to produce a conjugate filament having a denier of 19.5 at a spinning speed of 1500 yards (about 1350 meters) per minute. A quench zone just beneath the spinneret and 1 t meters in height is supplied with quenching air at 20°C, the air being directed horizontally onto the polymer stream and having a speed of 25 meters per minute. Below the quench zone, steam is applied to the filament, a conventional finish is applied, and the filament is wound.
  • The spun filament is then drawn at 65 meters per minute and at a draw ratio of 2.16 over a contact heater at 132°C, the heater being 0.4 meters long. The resulting drawn yarn, when mechanically worked to break the conjugate filament into 12 sub-filaments, develops no substantial torqueless helical crimp when subjected to boiling water.
    • Example II
  • Example I is repeated, except that the spinning speed is increased to 4500 meters per minute while the denier of the conjugate filament is reduced to 4. The resulting sub-filaments, after separation and immersion in boiling water, form a highly voluminous and lofty yarn. Fabrics formed from the conjugate yarn acquire a very soft hand and increased bulk and covering power when the fabric is mechanically worked enough to separate the yarn into sub-filaments. Simple exposure of the fabric to boiling water is adequate in many instances, since the flexing of the yarn involved in certain fabric formations separates the sub-filaments.

Claims (4)

1. A process for melt-spinning a hollow conjugate filament, splittable into sub-filaments, from nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, the process comprising:-
a. extruding a hollow molten stream formed from axially extending segments of said polymers arranged alternately in side-by-side adhering relationship to form said hollow molten stream;
b. quenching said stream to form a filament; and
c. withdrawing said filament from said molten stream, at a given spinning speed, characterised in that said given spinning speed is sufficiently high and said quenching is sufficiently rapid that unicomponent sub-filaments split from said filament possess substantial latent torqueless helical crimp.
2. A conjugate filament of nylon 66 and polyethylene terephthalate polymers axially arranged in an adhering relationship, sub-filaments of said filament being releasably attached to one another in a side-by-side relationship, and said filament being substantially free of crimp, characterised in that unicomponent sub-filaments split from said conjugate filament possess substantial latent torqueless helical crimp.
3. A filament defined in Claim 2, wherein said filament is hollow.
4. A method comprising splitting a conjugate filament defined in either of Claims 2 and 3 into unicomponent sub-filaments.
EP79303081A 1979-01-02 1979-12-31 Process for melt-spinning a splittable conjugate filament; self-texturing splittable conjugate filament; and method of splitting such a filament Expired EP0013186B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US84879A 1979-01-02 1979-01-02
US848 1979-01-02

Related Child Applications (2)

Application Number Title Priority Date Filing Date
EP82105614A Division EP0065788A3 (en) 1979-01-02 1979-12-31 Conjugate filament spinning process
EP82105614A Division-Into EP0065788A3 (en) 1979-01-02 1979-12-31 Conjugate filament spinning process

Publications (2)

Publication Number Publication Date
EP0013186A1 EP0013186A1 (en) 1980-07-09
EP0013186B1 true EP0013186B1 (en) 1983-12-07

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EP79303081A Expired EP0013186B1 (en) 1979-01-02 1979-12-31 Process for melt-spinning a splittable conjugate filament; self-texturing splittable conjugate filament; and method of splitting such a filament
EP82105614A Ceased EP0065788A3 (en) 1979-01-02 1979-12-31 Conjugate filament spinning process

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EP82105614A Ceased EP0065788A3 (en) 1979-01-02 1979-12-31 Conjugate filament spinning process

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EP (2) EP0013186B1 (en)
JP (1) JPS55128016A (en)
KR (1) KR840001633B1 (en)
CA (1) CA1145907A (en)
DE (1) DE2966478D1 (en)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4246219A (en) * 1979-03-27 1981-01-20 Monsanto Company Multisegmented filament spinning process
EP0074445A1 (en) * 1981-09-15 1983-03-23 Monsanto Company Spinning process and multifilament yarn
EP0074446B1 (en) * 1981-09-15 1985-05-22 Monsanto Company Multifilament yarn and spinning process therefor
US5093061A (en) * 1982-03-08 1992-03-03 Monsanto Deep dyeing conjugate yarn processes
JPS6075665A (en) * 1983-10-01 1985-04-30 東レ株式会社 Fibrile interlacing method of multicomponent fiber
EP0376625B1 (en) * 1988-12-28 1996-09-18 Asahi Kasei Kogyo Kabushiki Kaisha Acrylic synthetic fiber and process for preparation thereof
CN109957856B (en) * 2017-12-25 2022-07-19 上海凯赛生物技术股份有限公司 Parallel composite fiber and preparation method thereof

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3117906A (en) * 1961-06-20 1964-01-14 Du Pont Composite filament
JPS5228918B2 (en) * 1972-05-23 1977-07-29
JPS581221B2 (en) * 1974-12-12 1983-01-10 帝人株式会社 Shikagawa henshiyokubutsuno
US4246219A (en) * 1979-03-27 1981-01-20 Monsanto Company Multisegmented filament spinning process

Also Published As

Publication number Publication date
DE2966478D1 (en) 1984-01-12
KR840001633B1 (en) 1984-10-12
KR830001428A (en) 1983-04-30
EP0065788A2 (en) 1982-12-01
EP0065788A3 (en) 1984-11-28
EP0013186A1 (en) 1980-07-09
CA1145907A (en) 1983-05-10
JPS55128016A (en) 1980-10-03

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