CA2476236A1 - Soft hand, low luster, high body carpet filaments - Google Patents

Soft hand, low luster, high body carpet filaments Download PDF

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Publication number
CA2476236A1
CA2476236A1 CA002476236A CA2476236A CA2476236A1 CA 2476236 A1 CA2476236 A1 CA 2476236A1 CA 002476236 A CA002476236 A CA 002476236A CA 2476236 A CA2476236 A CA 2476236A CA 2476236 A1 CA2476236 A1 CA 2476236A1
Authority
CA
Canada
Prior art keywords
nipple section
filament
lobe
yarn
lateral walls
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.)
Granted
Application number
CA002476236A
Other languages
French (fr)
Other versions
CA2476236C (en
Inventor
John B. Boyle
Bruce W. Portus
Carole G. Shealy
James A. Matrunich
Alexander Lobovsky
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.)
Honeywell International Inc
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of CA2476236A1 publication Critical patent/CA2476236A1/en
Application granted granted Critical
Publication of CA2476236C publication Critical patent/CA2476236C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • 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
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament
    • Y10T428/2967—Synthetic resin or polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2973—Particular cross section
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2973—Particular cross section
    • Y10T428/2978—Surface characteristic

Abstract

Novel filaments and yarns for carpets, upholstery and other applications, the spinneret and method for their production and carpets manufactured therefrom.
The filaments of the invention are solid multi-lobal filaments of complex convex-concave surface contour possessing low luster, low moment of inertia, high color intensity upon dyeing and high covering power. Carpets manufactured therefrom possess low luster, soft hand, high covering power and high body suitable for premium residential application. The filaments of the invention are produced at high throughput and productivity by the method of the invention.

Claims (28)

1. A filament comprising a solid cross-section having a perimeter comprised of a plurality of lobes that are joined to one another by concave line segments, said cross-section having a modification ratio of about 2.4 to about 5; wherein upon traversing in one direction completely around the perimeter, the position of a center of curvature for the perimeter changes from one side of said perimeter to the other side at least eighteen times.
2. The filament of Claim 1, wherein each lobe of the filament is comprised of a convex region; a concave transition region; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic or straight.
3. The filament of Claim 1, wherein each lobe of the filament is comprised of a first convex region; a first concave transition region; a second convex region; a second concave transition region; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic or straight.
4. The filament of Claim 1, wherein each lobe of said filament has a composite curve profile having a first arm angle a of about 5° to about 30°; and a second arm angle .beta. of about 60° to about 85°; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic and straight.
5. The filament of Claim 1, wherein each lobe of said filament has a composite curve profile having a first arm angle .alpha., of about 5°
to about 30°; a second arm angle .beta. of about 60° to about 85°;
and a third arm angle .gamma. of about 60° to about 85°; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic and straight.
6. The filament of Claim 1, wherein the number of lobes is at least three.
7. The filament of Claim 6, wherein the lobes are substantially equispaced.
8. The filament of Claim 1, wherein the number of lobes is three, four or five.
9. The filament of either Claim 2, 3, 4 or 5, wherein said lateral walls of said nipple section are essentially straight and parallel.
10. The filament of either Claim 2, 3, 4 or 5, wherein said lateral walls of said nipple section are essentially straight and converging.
11. The filament of either Claim 2, 3, 4 or 5, wherein said nipple section has a perimeter selected from the group consisting of parabolic or elliptical.
12. A yarn comprised of a plurality of the filaments of claim 1.
13. The yarn of claim 12, further comprising about 0.05 to about 3 wt.% of heat activated binder fibers.
14. The yarn of claim 12, wherein said multi-lobal filaments are selected from the group consisting of trilobal filaments, tetralobal filaments, pentalobal filaments, and mixtures thereof.
15. The yarn of claim 12 wherein said multi-lobal filaments are trilobal filaments.
16. The yarn of claim 12 wherein each lobe comprises a convex region; a concave transition region; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic or straight.
17. The yarn of claim 12 wherein each lobe comprises a first convex region; a first concave transition region; a second convex region; a second concave transition region; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic or straight.
18. The yarn of claim 12 wherein each lobe has a composite curve profile comprising a convex region defining an arm angle .beta. ranging from 60° to 85°, a concave transition region, and a nipple section extending to the outermost point of the lobe; said nipple section having lateral walls selected from the group consisting of elliptical, parabolic or straight.
19. The yarn of claim 12 wherein each lobe has a composite curve profile comprising a first arm angle a of about 5° to about 30°; a second arm angle .beta. of about 60.beta. to about 85.beta.; a third arm angle .gamma. of about 60° to about 85°; and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic and straight.
20. The yarn of any one of claims 16, 17, 18 and 19 wherein said lateral walls of said nipple section are essentially straight and parallel.
21. The yarn of any one of claims 16, 17, 18 and 19 wherein said lateral walls of said nipple section are essentially straight and converging.
22. The yarn of any one of claims 16, 17, 18 and 19 wherein said nipple section has a perimeter selected from the group consisting of parabolic or elliptical.
23. A carpet comprised of multi-filament yarns of claim 12.
24. The carpet of claim 23 wherein each lobe has a first an arm angle .alpha., ranging from about 5° to about 30°, a second arm angle .beta.
ranging from about 60° to about 85°, and a nipple section extending to the outermost point of the lobe, said nipple section having lateral walls selected from the group consisting of elliptical, parabolic and straight.
25. The carpet of claim 23 wherein said lateral walls of said nipple section are straight and converging.
26. A capillary spinneret orifice comprising: at least three essentially identical legs originating at a central point in a multi-lobal central region; one or more contiguous bulge regions extending along each such leg from said multi-lobal central region, and a nipple section extending from the outermost said bulge region to the outermost point of each said leg.
27. The capillary spinneret orifice of claim 27 wherein the orifice area is about 4 x 10-4 in2 (0.26 mm2) to about 11 x 10-4 in2 (0.71 mm2) and the width of the nipple section is about 0.0030 inches (0.0762 mm) to about 0.004 inches (0.106) mm).
28. A method of yarn production comprising the steps of:
(a) forming a melt of a filament-forming synthetic polymer;

(b) placing said melt in communication with a capillary spinneret, said spinneret defining a plurality of orifices, wherein each said orifice is comprised of multiple legs originating at a central point in a multi-lobal central region, one or more contiguous bulge regions extending along each such leg from said multi-lobal central region, and a nipple section extending from the outermost said bulge region to the outermost point of the leg;
(c) extruding said melt through said orifices of said spinneret to form a melt stream;
(d) drawing the melt stream;
(e) cooling to solidify said melt stream to form a multi-filament yarn;
(f) and drawing said yarn to a total draw ratio of about 1.5:1 to about 3.6:1.
CA2476236A 2002-02-11 2003-02-10 Soft hand, low luster, high body carpet filaments Expired - Lifetime CA2476236C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/073,739 US6673450B2 (en) 2002-02-11 2002-02-11 Soft hand, low luster, high body carpet filaments
US10/073,739 2002-02-11
PCT/US2003/003926 WO2003069031A1 (en) 2002-02-11 2003-02-10 Soft hand, low luster, high body carpet filaments

Publications (2)

Publication Number Publication Date
CA2476236A1 true CA2476236A1 (en) 2003-08-21
CA2476236C CA2476236C (en) 2012-05-15

Family

ID=27732345

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2476236A Expired - Lifetime CA2476236C (en) 2002-02-11 2003-02-10 Soft hand, low luster, high body carpet filaments

Country Status (5)

Country Link
US (2) US6673450B2 (en)
EP (1) EP1474549A1 (en)
CN (1) CN100352976C (en)
CA (1) CA2476236C (en)
WO (1) WO2003069031A1 (en)

Families Citing this family (20)

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US6841247B2 (en) * 2002-08-16 2005-01-11 Honeywell International Inc. Fibers having improved dullness and products containing the same
CA2552861A1 (en) * 2004-01-08 2005-04-08 Teijin Fibers Limited Polyester differential shrinkage blended woven yarn and process for producing the same
US7560159B2 (en) * 2004-02-23 2009-07-14 Teijin Fibers Limited Synthetic staple fibers for an air-laid nonwoven fabric
NL1028224C2 (en) * 2005-02-08 2006-08-09 Ten Cate Thiolon Bv Plastic fiber of the monofilament type for use in an artificial grass sports field as well as an artificial grass mat suitable for sports fields provided with such plastic fibers.
AU2006322087A1 (en) * 2005-12-06 2007-06-14 Invista Technologies S.Ar.L. Hexalobal cross-section filaments with three major lobes and three minor lobes, carpet tufted from yarn with such filaments, and capillary spinneret orifice for producing such filaments
KR101427739B1 (en) * 2006-09-21 2014-08-07 가부시키가이샤 가네카 Fiber for artificial hair improved in settability and hair accessories made by using the fiber
MX2009009403A (en) * 2007-03-06 2010-04-09 Futuris Automotive Interiors U Tufted pet fiber for automotive carpet applications.
US20080292831A1 (en) * 2007-03-06 2008-11-27 Futuris Automotive Interiors (Us), Inc. Tufted pet fiber for automotive carpet applications
EP2132031A1 (en) * 2007-03-14 2009-12-16 Futuris Automotive Interiors (US), Inc. Low mass acoustically enhanced floor carpet system
US20110287210A1 (en) * 2008-08-22 2011-11-24 Invista North America S.Ar.L Bulked continuous filaments with trilobal cross-section and round central void and spinneret plates for producing filament
US20110177283A1 (en) * 2010-01-18 2011-07-21 Futuris Automotive Interiors (Us), Inc. PET Carpet With Additive
AT510458B1 (en) * 2010-09-17 2013-08-15 Intier Automotive Eybl Ges M B H Ebergassing & Co Ohg COATING COMPOSITION FOR THE SOUND REDUCING CLADDING OF A MOTOR VEHICLE AREA AND METHOD FOR THE PRODUCTION THEREOF
US20130344331A1 (en) * 2012-06-20 2013-12-26 Shaw Industries Group, Inc. Yarn filament and method for making same
CN105683427A (en) * 2013-09-13 2016-06-15 费德罗-莫格尔动力系统有限公司 High surface area fiber and method of construction thereof
WO2015038860A2 (en) * 2013-09-13 2015-03-19 Federal-Mogul Powertrain, Inc. High surface area fiber and method of construction thereof
US11692284B2 (en) 2016-08-18 2023-07-04 Aladdin Manufacturing Corporation Trilobal filaments and spinnerets for producing the same
USD841838S1 (en) 2016-11-04 2019-02-26 Mohawk Industries, Inc. Filament
JP7072567B2 (en) * 2017-05-30 2022-05-20 デンカ株式会社 Fiber for artificial hair
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Also Published As

Publication number Publication date
AU2003212986A1 (en) 2003-09-04
WO2003069031A1 (en) 2003-08-21
EP1474549A1 (en) 2004-11-10
US20040071963A1 (en) 2004-04-15
US20030157319A1 (en) 2003-08-21
CA2476236C (en) 2012-05-15
CN1646737A (en) 2005-07-27
CN100352976C (en) 2007-12-05
US6673450B2 (en) 2004-01-06

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Effective date: 20230210