CA2244055A1 - Fibers of arbitrary cross section and process of producing same - Google Patents

Fibers of arbitrary cross section and process of producing same Download PDF

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Publication number
CA2244055A1
CA2244055A1 CA002244055A CA2244055A CA2244055A1 CA 2244055 A1 CA2244055 A1 CA 2244055A1 CA 002244055 A CA002244055 A CA 002244055A CA 2244055 A CA2244055 A CA 2244055A CA 2244055 A1 CA2244055 A1 CA 2244055A1
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CA
Canada
Prior art keywords
polymer
process according
solvent
fiber
polymer solution
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.)
Abandoned
Application number
CA002244055A
Other languages
French (fr)
Inventor
Dominick A. Burlone
Olli-Pekka Tuominen
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.)
BASF Corp
Original Assignee
BASF Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BASF Corp filed Critical BASF Corp
Publication of CA2244055A1 publication Critical patent/CA2244055A1/en
Abandoned legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/253Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor

Abstract

The present invention relates, in general, to fiber spinning and, in particular,to a process of spinning fibers of more than one cross-sectional component and to fibers produced thereby.

Description

CA 022440~ 1998-09-03 FIBERS O~ ARBlTRARY CROSS SECTION AND
PROCESS OP PRODUCING SAME

TECHNICAL FIELD
The present invelllion relates, in general, to fiber spinning and, in particular, to a process of spinning fibers of more than one cross-sectional component and to l0 fibers produced thereby.

BACKGROUND
Various types of fibers having two or more cross-sectional components (ie multi-component fibers) are well known in the art, as are processes for their 15 production. E~camples of such fibers and production processes are set forth in U.S.
Patents 4,233,355 and 4,460,649.
Multicomponent fibers have been used to generate micro- or ultrafine filaments (see, for example, U.S. Patent Nos. 4,233,355, 4,966,808, 5,124,194 and 5,366,804). The fibers can be split into their components using mech~nic~l or 20 chemical (eg solvent) means. In USP 4,233,355, for example, microfibers are generated from multicomponent (composite) fibers by selective dissolution of one of CA 022440~ 1998-09-03 the components of the composite fiber using a solvent in which the microfibrous component is relatively insoluble.
The art does not include a description of a method of producing a fiber of virtually any cross sectional shape from a composite fiber having a preselected 5 relative arrangement of components of diLreling solubility in a given solvent. The present invention provides such a process.

OBJECTS AND SUMMARY OF THE INVENTION
It is a general object of the invention to provide a process of producing a fiber o of virtually any cross sectional shape.
It is a specific object of the invention to provide a process of producing a fiber of predetermined cross sectional shape from a composite fiber that includes at least two components that have dirrere.lt solubility characteristics and that are in a sPlecte-l relative arrangement.
It is a further object of the invention to provide a composite fiber comprising at least two components having differing solubility characteristics (eg water solubility characteristics).
The foregoing objects are met by a composite fiber having two or more cross sectional components comprising different materials (eg polymers), one of those 20 materials being more soluble in a particular solvent (eg water) than other. The CA 022440~ l998-09-03 components are present in a predetermined relative arrangement so that, upon dissolution of the more soluble component in the solvent, the relatively insoluble component rPm~in~ as a fiber having a predetermined cross sectional shape.
Further objects and advantages of the invention will be clear from the 5 description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS
Figures lA-E show cross sectional views of composite fibers comprising components having different solubility characteristics.
Figures 2A-E show cross sectional views of fibers resulting from dissolution of the soluble component of the composite fibers shown in Figure 1.

DETAILED DESCRIPTION OF THE INVEN IION
The present invention relates, in one embo~iiment, to a process of preparing 15 fibers of various cross sections, including cross sections not easily achievable using conventional melt spinning techniques. The process comprises preparing a composite fiber comprising at least two components having dirrerent solubility characteristics in a given solvent. The components are positioned in the composite fiber relative to each other such that, upon dissolution of one of the components in CA 022440~ 1998-09-03 the solvent, the component more insoluble in that solvent rem~in.~ as a fiber having the desired cross sectional shape.
Depending on the ori~nt~tion of component m~t~ri~l~, a variety of composite fiber cross sections and component fiber shapes can be achieved (see, for example, 5 Figures 1 and 2). By removal of the more soluble or dispersible component, component fiber shapes can be achieved that are diffficult to obtain through direct extrusion because of surface tension effects that otherv-~ise tend to 'round out' cross sectional features after extrusion.
While advantage can be taken of dirre~ g solubility characteristics with o respect to a variety of solvents (including polar solvents such as water, acetone, alcohols, dimethylform~mifle (DMF), methyl ethyl ketone (MEK) and cellosolves), the present invention will be described in detail with respect to di~li~g water solubility characteristics (the terms "water soluble" and "water insoluble" being used below merely for purposes of clarity). Further, it will be appreciated from a reading 15 of the following that the multicomponent fiber can include a plurality of components of differing solubility characteristics. The description that follows, however, will focus on a bicomponent, composite fiber.
Production of the composite fiber of the invenLion can be achieved using conventional spinning techniques (eg melt spinning techniques). The water 20 insoluble component can be supplied to the fiber spinning apparatus simultaneously CA 022440~ 1998-09-03 with the supplying to that apparatus of the water soluble component. In the spinning apparatus, the water soluble and water insoluble components are arranged in a predetermined relative arrangement to achieve a selected cross sectional shape of the water insoluble component. The water soluble and water insoluble s components are extruded from the spinning apparatus in the predetermined arrangement. The water soluble component is removed by dissolution in an aqueous solution so that the water insoluble component rem~in~ in the selected cross sectional shape adopted as a result of the presence of the water soluble component in the spinneret.
o The components of the composite fiber (eg component polyrners) can be supplied to the spinning apparatus, for example, via a transfer line, using conventional methods, including pumping under positive pressure. Thermoplastic polymer components are melted at appro~liate tempelaL~ res (eg about 10/C to about 75/C higher than the polymer melt point) prior to pumping. Independent 15 supply me~ h~ni~m~ can be used for each component. Various methodologies can be used to selectively arrange the components of the composite fiber in the spinning apparatus in a predeterrnined relative arrangement. Particularly advantageous isthe method disclosed in USP 5,162,074 which utilizes distributor plates in whichdistributor flow paths are etched on one or both sides to distribute polymer 20 components to approyliate spinneret hole locations. The etching process permits ,. .

CA 022440~ 1998-09-03 the distribution path to be sufficiently small to facilitate issuing multiple discrete polymer component streams axially into each spinneret orifice inlet hole.
Polymer components can be extruded through the spinneret orifices, which can be a variety of shapes. In the case of melt spun polymers, extrusion can be into 5 a quench rhimney to form filaments cooled by a flow of gaseous medium, such as air, which hardens the filaments. When dry spinning is used, the quench conditions are selected so as to effect removal of the solvent. The use of hot air or hot, dry air is typical. As above, the conditioned air flows over the filament as the filament passes through the quench chimney. (Composite fibers of the invention can also o comprise a melt spun core insoluble component (eg a polypropylene melt) and a polymer solution soluble sheath component (eg a solution of polyv.llylpyl.olidine (PVP) in ethanol). Such composite fibers need not undergo a solvent removal step - prior to dissolution of the soluble component (eg PVP).) After extrusion, the water soluble component is removed. Removal can be 15 effected, for example, by passing the fiber (eg after quenching (or solvent removal)) through a bath that contains a solvent in which the water soluble component is soluble (eg water) under conditions such that solubilization/dissolution occurs.
Alternatively, the fiber can be further processed, for example, to staple fiber, and then treated as stock as, for example, in a stock dyeing operation. The fiber and 20 yarn can also be processed into final goods and the finished goods can then be , . .

CA 022440~ 1998-09-03 treated with solvent (eg water) to remove the soluble component. This last approach can result in a woven or knit fabric or floor cov~ling having a fiber structure, after dissolution of the water soluble component, that may not be possible to produce without dissolution.
s Fibers produced in accordance with the present invention can be processed, for example, using conventional terhniques of drawing, te~ g, finiching etc, andcan be colored using pigments or dyes. The insoluble component, for example, caninclude heat or light stabilizers.
End use applications of the fibers of the invention include typical textile o applications in apparel, home furnishings or industAal products in which the resulting fiber cross section enh~ncPs function, performance, properties, or aesthetics. Fiber cross sections achievable by the invention can Pnh~nce tactile and comfort properties, alter luster and light reflecting properties, Pnh~nce covering power, Pnh~nce absorl,Livi~y and wicking power and alter bend modulus and crimp 15 ability.
Suitable insoluble component materials include melt-spun polymers, for example, nylon 6 and 66, polyester, polyethylene and poly~rol,ylene. Suitable soluble or dispersible components include copolymers of the same as well as soluble homopolymers such as polycaprolactone and polyethylene oxides. The insoluble or 20 undispersible components can be solubilized with comonomers that contain CA 0224405~ 1998-09-03 solubilizing or dispersing functional groups, such as vinyl, sulfonate, phosphonate or ethoxylate groups.
In a specific embodiment of the invention, nylon or polyester is used as the water insoluble component and a melt spinnable polymer such as described in USP
5 3,846,507 (eg water soluble polyamide as described therein) can be used as the water soluble component. In accordance with this embodiment, nylon-6 with a water- or solvent-soluble sulfonated polyamide so that the insoluble nylon-6, for example, is coextruded as the core component and the soluble sulfonated polyamide is the sheath component. These components can be oriented such that a composite o fiber is produced having, for example, a half barbell-shaped core imbedded in a fiber with an overall round cross section. Because the overall cross section is round, it will tend to retain its shape and will not distort after extrusion. After removal of the soluble component from the composite fiber using, for example, water or steam, a half barbell-shaped inner core rem~in~ as the final fiber. Any of a variety of 15 alternative inner core structures can be achieved in accordance with the invention (see, for example Figures 2A-2E).
The following further non-limiting Example describes certain aspects of the invention in g.eater detail.

CA 022440~ 1998-09-03 EXAMPLE
Nylon-6 chips and sulfonated nylon are melted in separate single-screw extruders and pumped via separate gear pumps to a bicomponent spin pack. The spin pack consists of filters and distribution plates that separately route the 5 polymers to the backhole of a capillary in a spinnerette. The spinnerette contains a number of holes depending on the desired number of fibers in the yarn, desired throughout, etc. After extrusion, the fibers pass through a quench zone in which cool air solidifies the molten polymers. The threadline is then passed over a series of guides immersed in a hot water bath. After the bath, the threadline is air- or 10 steam-textured and wound or cut into staple fiber.
One skilled in the art will appreciate from a reading of this disclosure that various changes in form and detail can be made without departing from the true scope of the invention.

Claims (22)

1. A process for preparing a fiber comprising:
a) supplying a first spinnable polymer or polymer solution to a fiber spinning apparatus;
b) simultaneously supplying to said apparatus a second spinnable polymer or polymer solution, co-spinnable with said first polymer or first polymer solution, wherein said first polymer or first polymer solution is more soluble or dispersible in a solvent than said second polymer or second polymer solution;
c) in the fiber spinning apparatus, arranging said first polymer or first polymer solution and said second polymer or second polymer solution in a predetermined relative arrangement to achieve a selected cross sectional shape of said first polymer or first polymer solution;
d) extruding from the spinning apparatus a filament of said first polymer or first polymer solution and said second polymer or second polymer solution in the predetermined relative arrangement; and e) contacting said filament resulting from step (d) with said solvent under conditions such that substantially all of said second polymer or second polymer solution dissolves or disperses in said solvent and said first polymer or first polymer solution remains in said selected cross sectional shape.
2. The process of claim 1 wherein said solvent is a polar solvent.
3. The process of claim 2 wherein said solvent is water, a ketone, an alcohol, an ether, an ester or an amide.
4. The process according to claim 3 wherein said ketone is acetone or a methyl or ethyl ketone.
5. The process according to claim 3 wherein said amide is dimethylformamide.
6. The process of claim 1 wherein said first polymer is supplied to said fiber spinning apparatus in step (a).
7. The process of claim 6 wherein said first polymer is a melt spinnable polymer.
8. The process of claim 7 wherein said first polymer is nylon, polyester, polyethylene, or polypropylene.
9. The process of claim 1 wherein said second polymer is supplied to said spinning apparatus in step (b).
10. The process of claim 9 wherein said second polymer is a melt spinnable polymer.
11. The process according to claim 10 wherein said second polymer is a nylon, polyester, polyethylene or polypropylene copolymer.
12. The process according to claim 10 wherein said second polymer comprises comonomers containing solubilizing or dispersing functional groups.
13 The process according to claim 12 wherein said functional groups are vinyl, sulfonate, phosphonate or ethoxylate groups.
14. The process according to claim 10 wherein said second polymer is a soluble homopolymer.
15. The process according to claim 14 wherein said homopolymer is a polycaprolactone or a polyethylene oxide.
16. The process of claim 6 wherein said second polymer is supplied to said spinning apparatus in step (b).
17. The process of claim 16 wherein said second polymer is a melt spinnable polymer.
18. The process according to claim 17 wherein said second polymer is a nylon, polyester, polyethylene or polypropylene copolymer.
19. The process according to claim 18 wherein said second polymer comprises comonomers containing solubilizing or dispersing functional groups.
20. The process according to claim 17 wherein said second polymer is a soluble homopolymer.
21. The process according to claim 20 wherein said homopolymer is a polycaprolactone or a polyethylene oxide.
22. The process according to claim 21 wherein said functional groups are vinyl, sulfonate, phosphonate or ethoxylate groups.
CA002244055A 1997-12-01 1998-09-03 Fibers of arbitrary cross section and process of producing same Abandoned CA2244055A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/982,024 1997-12-01
US08/982,024 US5876650A (en) 1997-12-01 1997-12-01 Process of making fibers of arbitrary cross section

Publications (1)

Publication Number Publication Date
CA2244055A1 true CA2244055A1 (en) 1999-06-01

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CA (1) CA2244055A1 (en)

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US20030077444A1 (en) * 2001-05-10 2003-04-24 The Procter & Gamble Company Multicomponent fibers comprising starch and polymers
US20020168912A1 (en) * 2001-05-10 2002-11-14 Bond Eric Bryan Multicomponent fibers comprising starch and biodegradable polymers
US6797212B2 (en) * 2002-04-18 2004-09-28 Medarray, Inc. Method for forming hollow fibers
US20060278086A1 (en) * 2003-06-12 2006-12-14 Matsushita Electric Industrial Co., Ltd. Air cleaner, functional filter and method of manufacturing the filter, air cleaning filter, and air cleaner device
US20060083917A1 (en) * 2004-10-18 2006-04-20 Fiber Innovation Technology, Inc. Soluble microfilament-generating multicomponent fibers
US8557159B2 (en) * 2009-11-08 2013-10-15 Medarray, Inc. Method for forming hollow fiber bundles
US9925730B2 (en) 2009-11-08 2018-03-27 Medarray, Inc. Method for forming hollow fiber bundles
US8580184B2 (en) 2010-06-21 2013-11-12 Jean Patrick Montoya Hollow fiber mat with soluble warps and method of making hollow fiber bundles
US9863920B2 (en) 2014-06-27 2018-01-09 Eastman Chemical Company Fibers with chemical markers and physical features used for coding
US20150375149A1 (en) 2014-06-27 2015-12-31 Eastman Chemical Company Acetate tow and filters with shape and size used for coding
US9442074B2 (en) 2014-06-27 2016-09-13 Eastman Chemical Company Fibers with surface markings used for coding

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FZDE Discontinued