US20050147788A1 - Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void - Google Patents
Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void Download PDFInfo
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- US20050147788A1 US20050147788A1 US10/991,469 US99146904A US2005147788A1 US 20050147788 A1 US20050147788 A1 US 20050147788A1 US 99146904 A US99146904 A US 99146904A US 2005147788 A1 US2005147788 A1 US 2005147788A1
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- void
- filament
- extending
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- leg
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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
- D01D5/24—Formation of filaments, threads, or the like with a hollow structure; Spinnerette packs therefor
-
- 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
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
-
- 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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24008—Structurally defined web or sheet [e.g., overall dimension, etc.] including fastener for attaching to external surface
- Y10T428/24017—Hook or barb
Definitions
- the present invention relates to a spinneret plate for producing a bulked continuous filament having an exterior configuration of three smoothly contoured sides with an inwardly extending depressed region located adjacent each tip of each side and with a convex, generally delta-shaped, six-sided central void extending therethrough.
- “Glitter” is the property of the yarn relating to the yarn's ability to reflect incident light. The amount of glitter exhibited by a yarn is a measure of the relative fraction of light that is reflected by the yarn. “Bulk” is the property of the yarn, which most closely correlates to surface coverage ability of a given yarn.
- U.S. Pat. No. 3,329,553 discloses a trilobal filament having a void fraction in the range from ten to sixty-five percent (10-65%). This reference teaches that void ratio is correlated with bulk in that the higher the void ratio the greater the bulk.
- U.S. Pat. No. 6,048,615 (Lin, RD-7395), assigned to the assignee of the present invention, discloses a trilobal filament with concave-sided voids formed from a thermoplastic synthetic polymer. This yarn exhibits excellent durability and good soiling resistance, but has relatively high glitter.
- U.S. Pat. No. 5,380,592 (Tung), assigned to the assignee of the present invention, discloses a trilobal cross-section with three voids which improve bulk and soil hiding compared to the solid cross-section trilobal filament discussed immediately above.
- this yarn is still somewhat vulnerable to soiling owing to the channels or “cusps” in the sides. Filaments of this yarn are also more subject to discontinuity in the spinning process owing to the complexity of the spinneret used to form the yarn. Open voids may occur in individual filaments, resulting in severe dyeability differences from filament to filament.
- the present invention is directed to a spinneret plate for producing a thermoplastic synthetic polymer filament having a three-sided exterior configuration wherein each side exhibits a smoothly curved contour having an inwardly extending depressed region disposed adjacent to each tip of each side.
- the filament has a generally delta-shaped void with a geometric center and three major apices extending centrally and axially therethrough.
- Each side of the void is convex in shape and has a first and a second end.
- Each side of the void is formed from two facets that meet to define a minor apex intermediate the first and second end of each side.
- the spinneret plate has a cluster of three Y-shaped orifices centered about a central point.
- Each Y-shaped orifice has three linear legs meeting at a junction point corresponding to a major apex of the void.
- One leg of each orifice extends radially outwardly from the junction point, the axis of that one leg aligning with a radius extending outwardly from the central point.
- the axes of each of the other two legs of each orifice project toward an apex point disposed intermediate adjacent orifices, each intermediate point corresponding to a minor apex of the void.
- the radially outwardly extending leg of each Y-shaped orifice is wider than the other legs of the Y-shaped orifice.
- FIG. 1 is a cross sectional view of a bulked continuous filament in accordance with the present invention
- FIG. 2 is a view of the bottom surface of a spinneret plate having a cluster of orifices formed therein for producing the filament shown in FIG. 1 ;
- FIG. 3 is a view of the bottom surface of a spinneret plate used for spinning the filaments of Comparative Example 1;
- FIG. 4 is a view of the bottom surface of a spinneret plate used for spinning the filaments of Comparative Example 2.
- FIG. 1 is a cross section view of a bulked continuous filament generally indicated by reference character 10 in accordance with the present invention.
- a longitudinal axis 12 extending through the filament 10 serves its geometric center. The distance from the axis 12 to the point(s) on the exterior contour of the filament 10 closest to the axis defines the minor radius (R 1 ) of the filament.
- a major radius (R 2 ) is defines the distance from the axis 12 to the point(s) on the exterior contour of the filament that lie farthest therefrom.
- Each filament 10 has a generally three-sided exterior configuration formed from sides 14 A, 14 B and 14 C.
- the side 14 A is defined by a smoothly curved contour extending between a first rounded tip 16 A and a second rounded tip 16 B.
- the side 14 B is defined by a smoothly curved contour extending between the second rounded tip 16 B and a third rounded tip 16 C.
- the side 14 C is defined by a smoothly curved contour extending between the third rounded tip 16 B and the rounded first tip 16 A.
- the distance from a respective center of generation 18 A, 18 B, 18 C to each rounded tip 16 A, 16 B, 16 C is indicated by a tip radius R 3 (only one of which is illustrated in FIG. 1 for clarity of illustration).
- Each exterior side 14 A, 14 B, 14 C has a first inwardly extending depressed region 22 disposed near one tip and a second inwardly extending depressed region 24 disposed near the other tip.
- depressed region it is meant that the contour of the filament in that region extends inwardly toward the axis 12 of the filament.
- the intermediate region 26 of each side 14 A, 14 B, 14 C i.e., the region between the depressed regions 22 , 24 on that side) is bowed slightly outwardly from the axis 12 .
- Each exterior side 14 A, 14 B, 14 C of the filament 10 thus exhibits a generally “wavy” configuration having two concave regions (i.e., the depressed regions 22 , 24 ) and three convex regions (i.e., the bowed intermediate region 26 and the rounded regions 28 disposed near each rounded tip of each side).
- a filament 10 in accordance with the present invention has an exterior modification ratio (R 2 /R 1 ) in the range from about 1.4 to about 2.0, and more particularly in the range from about 1.6 to about 1.8.
- the ratio of the major radius (R 2 ) to the tip radius (R 3 ) defines a tip ratio (R 2 /R 3 ) in the range from about 2.0 to about 4.0, and more particularly in the range from about 2.0 to about 3.0.
- the filament 10 has a void 30 extending centrally and axially therethrough.
- the axis 12 defines the geometric center of the void.
- the central void 30 is a generally “delta-shaped” opening having three generally convex major sides 32 A, 32 B, 32 C. Adjacent pairs of major sides 32 A, 32 B, 32 C join at adjacent ends to define three major apices 34 A, 34 B, 34 C.
- each side 32 A, 32 B, 32 C is itself configured from a pair of discernable facets 38 A, 38 B.
- the facets 38 A, 38 B may be planar in contour or may be gently curving to approximate a planar contour.
- the facets 38 A, 38 B meet to define a minor apex 40 A, 40 B, 40 C located intermediate the ends of each respective major side 32 A, 32 B, 32 C.
- the major apices 34 A, 34 B, 34 C lie a distance R M from the geometric center 12 of the void 30 while the minor apices 40 A, 40 B, 40 C are spaced a distance R m from the same point.
- the ratio of the distance (R M ) to the distance (R m ) defines an apex ratio (R M /R m ) in the range from about 1.0 to about 1.55, and more particularly in the range 1.05 to 1.50.
- the void 30 may occupy from about four percent (4%) to about twenty-five percent (25%), and more particularly from about four percent (4%) to about fifteen percent (15%), of the cross sectional area of the filament 10 .
- the central void 30 is oriented within the filament 10 such that each major apex 34 A, 34 B, 34 C of the void 30 extends toward the approximate midpoint of the respective proximal side 14 A, 14 B, 14 C of the filament 10 , while each minor apex 40 A, 40 B, 40 C extends toward the respective proximal rounded tip 16 A, 16 B, 16 C.
- FIG. 1 These relationships are exemplified in FIG. 1 by the radial reference line 42 extending from the axis 12 of the filament 10 through the major apex 34 C and a point 44 disposed substantially midway along the intermediate region 26 of the side 14 C. Similar reference lines, omitted for clarity, may be drawn through the other major apices 34 A, 34 B and a substantial midpoint of the intermediate region on the respective proximal sides 14 A, 14 B of the exterior of the filament 10 .
- the alignment of the minor apices and the rounded tip of the filament is exemplified in FIG. 1 by a radial reference line 46 extending from the axis 12 of the filament 10 through the minor apex 40 C and the rounded tip 16 C of the filament. Similar reference lines, again omitted for clarity, may be drawn through the minor apices 40 A, 40 B and the respective rounded tips 16 A, 16 B of the filament.
- a filament in accordance with the present invention is a bulked continuous filament prepared using a synthetic, thermoplastic melt-spinnable polymer.
- Suitable polymers include polyamides, polyesters, and polyolefins.
- the polymer is first melted and then is extruded (“spun”) through a spinneret plate 50 having appropriately sized orifices therein (to be described hereinafter) under conditions which vary depending upon the individual polymer thereby to produce a filament 10 having the desired denier, exterior modification ratio, tip ratio, apex ratio and void percentage.
- the filaments are subsequently quenched by air flowing across them at a flow rate of between 1.2-1.8 ft/sec (0.36 to 0.55 m/sec). Void percentage can be increased by more rapid quenching and increasing the melt viscosity of thermoplastic melt polymers, which can slow the flow allowing sturdy pronounced molding to occur.
- a plurality of filaments 10 are gathered together to form a yarn. Drawing and bulking of the combined filaments is performed by any method known in the art, with the preferred operating condition described below in the examples provided.
- a yarn formed therefrom is believed to be particularly advantageous for tufting [with other types of yarn(s), if desired] into carpet having especially desirable properties.
- the yarn could include other forms of filament(s).
- FIG. 2 illustrates a spinneret plate 50 useful for producing a filament 10 in accordance with the invention.
- the spinneret plate 50 is a relatively massive member having an upper surface (not shown) and a bottom surface 52 . As is well appreciated by those skilled in the art a portion of the upper surface of the spinneret plate is provided with a bore recess (not shown) whereby the plate 50 is connected to a source of polymer. Depending upon the rheology of the polymer being extruded the lower margins of the bore recess may be inclined to facilitate flow of polymer from the supply to the spinneret plate.
- a plurality of capillary openings each generally indicated by the reference character 54 extends through the plate 50 from the recessed upper surface to the bottom surface 52 .
- Each capillary opening 54 serves to form one filament. Only one such capillary opening 54 is illustrated in FIG. 2 .
- the number of capillary openings provided in a given plate thus corresponds to the number of filaments being gathered to form a predetermined number of yarn(s).
- additional filaments may be incorporated into the yarn in any convenient manner.
- each capillary opening 54 is itself defined by a cluster of three orifices 56 - 1 , 56 - 2 and 56 - 3 centered symmetrically about a central point 58 .
- Each orifice 56 - 1 , 56 - 2 and 56 - 3 is a generally “Y”-shaped opening comprising three linear legs 62 A, 62 B and 62 C.
- Each leg 62 A, 62 B and 62 C has a respective longitudinal axis 64 A, 64 B, 64 C extending therethrough.
- the axes 64 A, 64 B, 64 C are angularly spaced from each other by one hundred twenty degrees (120°).
- the axes 64 A, 64 B, 64 C of the legs 62 A, 62 B and 62 C of each orifice intersect at a junction point 68 .
- the junction points 68 are spaced a distance 70 from the center point 58 of the cluster.
- the orifices 56 - 1 , 56 - 2 and 56 - 3 are arranged with respect to each other such that one leg of each orifice 56 - 1 , 56 - 2 and 56 - 3 , e.g., the leg 62 A, extends from the junction point 68 in a radially outward direction relative to the central point 58 .
- the radially outwardly extending leg 62 A of each orifice 56 - 1 , 56 - 2 and 56 - 3 is oriented such that its axis 64 A aligns with a radius 70 extending outwardly from the central point 58 .
- Each junction point 68 of the orifices 56 - 1 , 56 - 2 , 56 - 3 respectively corresponds to a major apex 34 A, 34 B, 34 C of the void 30 of the filament being spun.
- each orifice 56 - 1 , 56 - 2 and 56 - 3 are arranged such that the axes 64 B, 64 C thereof project toward an apex point 72 disposed intermediate adjacent orifices. Extensions of each of the axes 64 B, 64 C of these legs 62 B, 62 C intersect at an apex point 72 .
- Each apex point 72 corresponds to a respective minor apex 40 A, 40 B, 40 C of the void 30 of the filament being spun.
- the ends of the confronting legs 62 B, 62 C are spaced from each other by a gap 74 A, 74 B, 74 C.
- the dimension of the gaps 74 A, 74 B, 74 C is indicated by the reference character C.
- the legs 62 A, 62 B, 62 C of each of Y-shaped orifice 56 - 1 , 56 - 2 and 56 - 3 when measured along their respective axes, are equal in length.
- the length dimensions of the legs 62 A, 62 B, 62 C are indicated by the respective reference character A 1 , A 2 , A 3 .
- the width dimensions of the legs 62 A, 62 B, 62 C are indicated by the respective reference character B 1 , B 2 , B 3 .
- the width dimension of the radially extending leg 62 A (indicated by the reference character B 1 ) is wider than the width dimensions (indicated by the reference characters B 2 , B 3 ) of the other legs 62 B, 62 C.
- the spinneret plate may be fabricated in any appropriate manner, as by using the laser technique disclosed in U.S. Pat. No. 5,168,143, (Kobsa et al., QP-4171-A), assigned to the assignee of the present invention.
- Trilobal cross sections with voids have been practiced in the past [e.g., U.S. Pat. 6,048,615 (Lin)].
- hollow filament yarns are difficult to make because of cross section shape control. Void percent and exterior modification ratio are both sensitive to polymer viscosity and quench air flow. As is well understood by one skilled in the art, without tight control of these parameters, lack of cross section shape uniformity can result in streaks when the yarns are finally tufted into a carpet.
- the stable polymer flow provided by the use of the spinneret in accordance also results in surprising robustness of cross section formation in the spinning process.
- the fiber cross section shape is measurably less sensitive to quench airflow, and thus provides a distinct advantage versus the prior art as a result of the greater consistency of shape provided along the length of the formed filaments and yarns made therefrom.
- the disclosed spinneret plate is especially useful in the manner of producing the disclosed filament cross-section because it is simpler and less expensive to produce than previous hollow filament spinnerets.
- Nylon 6,6 filaments having various cross-sections were produced for Comparative Examples A and B and for Invention Examples 1 and 2 from appropriately configured spinnerets, each with one hundred thirty-six (136) capillaries.
- the nylon 6,6 polymer used for all of the examples was a bright polymer.
- the polymer spin dope did not contain any delusterant and had a relative viscosity (RV) of sixty-eight plus/minus approximately three units (68, +/ ⁇ ⁇ 3 units).
- RV relative viscosity
- the polymer temperature before the spinning pack was controlled at about two hundred ninety plus/minus one degree Centigrade (290, +/ ⁇ 1° C.).
- the spinning throughput was seventy pounds (70 lbs; 31.8 kg) per hour.
- the relative viscosity (RV) was measured by dissolving 5.5 grams of nylon 6,6 polymer in fifty cubic centimeters (50 cc) of formic acid.
- the RV is the ratio of the absolute viscosity of the nylon 66/formic acid solution to the absolute viscosity of the formic acid. Both absolute viscosities were measured at twenty-five degrees Centigrade (25° C.).
- the polymer was extruded through the different spinnerets and divided into two (2) sixty-eight filament (68) segments.
- the capillary dimensions for the spinnerets are described below.
- the molten fibers were then rapidly quenched in a chimney, where cooling air at about nine degrees Centigrade ( ⁇ 9° C.) was blown past the filaments at three hundred cubic feet per minute [300 cfm (732 m/min)] through the quench zone.
- the filaments were then coated with a lubricant for drawing and crimping.
- the coated yarns were drawn at 2197 yards per minute (2.75 x draw ratio) using a pair of heated draw rolls.
- the draw roll temperature was one hundred ninety degrees Centigrade (190° C.).
- the filaments were then forwarded into a dual-impingement hot air bulking jet similar to that described in Coon, U.S. Pat. No. 3,525,134 (Coon, assigned to the assignee of the present invention) to form two (2) twelve hundred five denier (1205 denier, 1340 decitex), 17.7 denier per filament (dpf) yarns (19 decitex per filament).
- the temperature of the air in the bulking jet was two hundred twenty degrees Centigrade (220° C.).
- BCF bulked continuous filament
- the yarns were then tufted into twenty-eight ounce per square yard (28 oz/sq. yd; 949 g/sq. meter) having 0.21875 inch [ ⁇ fraction (7/32) ⁇ ′′, 0.56 cm] pile height loop pile carpets on a ⁇ fraction (1/10) ⁇ inch gauge (0.254 cm) loop pile tufting machine.
- the tufted carpets were dyed on a continuous range dyer into medium yellow carpets.
- the soiling test was conducted on each carpet sample using a Vetterman drum.
- the base color of the sample was measured using the hand held color measurement instrument sold by Minolta Corporation as “Chromameter” model CR-210. This measurement was the control value.
- the carpet sample was placed in Vetterman drum. Two hundred grams (200 g) of clean nylon 101 Zytel nylon beads and fifty grams (50 g) of dirty beads (by DuPont Canada, Mississauga, Ontario) were placed on the sample.
- the dirty beads were prepared by mixing ten grams (10 g) of AATCC TM-122 synthetic carpet soil (by Manufacturer Textile Innovators Corp. Windsor, N.C.) with one thousand grams (1000 g) of new Nylon 101 Zytel beads.
- the sample was placed back in the drum, fifty grams (50 g) of soiled bead mixture was discarded and fifty grams (50 g) of new dirty beads were added into the drum.
- the filaments were spun through a spinneret capillary as shown in FIG. 3 having three tapered arms (lobes) which were essentially symmetrical.
- the filaments were spun through a spinneret capillary as shown in FIG. 4 .
- Filaments having a hollow trilobal cross section as described by this invention, as shown in FIG. 1B were made using the above-described process.
- the filaments were spun through a spinneret capillary as shown in FIG. 2 .
- the dimensions A 1 , A 2 , A 3 , B 1 , B 2 , B 3 , C used to produce Invention Example 1 are as set forth in Table 1.
- the filament had an exterior modification ratio of 1.66, a tip ratio of 2.6, an apex ratio of 1.08.
- the central void occupied about 5.3 percent of the cross sectional area of the filament.
- Filaments having a hollow trilobal cross section as described by this invention, as shown in FIG. 1 C were made using the above-described process.
- the filaments were spun through a spinneret capillary as shown in FIG. 2 .
- the dimensions A 1 , A 2 , A 3 , B 1 , B 2 , B 3 , C used to produce Invention Example 2 are as set forth in Table 1.
- the filament had an exterior modification ratio of 1.88, a tip ratio of 3.5, an apex ratio of 1.33.
- the central void occupied about ten percent (10%) of the cross sectional area of the filament.
- Examples 1 and 2 demonstrate distinctly different and lower “Glitter” in the final carpet than do Comparative Examples A and B.
- the filament and yarn of the present invention is useful as a carpet yarn having more “wool-like” appearance when made into carpet than yarns of the prior art having similar bulk, soiling and cleaning characteristics.
- the filament of the invention is also smoother (i.e., with rounded tips and without sharply defined cusps) and therefore less prone to soiling than other known high bulk trilobal fibers that can otherwise impart similar aesthetics to a carpet made therefrom, as is clearly supported by the soiling data in Table 2.
- a carpet constructed from yarn of the present invention therefore retains its appearance longer in service than carpets made from yarn of the prior art.
- the invention provides a surprisingly low glitter yarn that can produce carpets of comparable bulk to carpets made from such high glitter yarns as the solid trilobal cross section filaments(Comparative Example A).
Abstract
Description
- This application is a U.S. Utility patent application claiming priority to provisional application no. 60/523,870, filed Nov. 19, 2003 and provisional application no. 60/523,871, filed Nov. 19, 2003.
- 1. Field of the Invention
- The present invention relates to a spinneret plate for producing a bulked continuous filament having an exterior configuration of three smoothly contoured sides with an inwardly extending depressed region located adjacent each tip of each side and with a convex, generally delta-shaped, six-sided central void extending therethrough.
- 2. Description of the Prior Art
- While carpet yarns having relatively high levels of “glitter” have become fashionable there nevertheless remains a substantial demand for yarns which provide a lower glitter, more wool-like appearance with superior soil hiding, and which cover more surface area with lower face weights.
- “Glitter” is the property of the yarn relating to the yarn's ability to reflect incident light. The amount of glitter exhibited by a yarn is a measure of the relative fraction of light that is reflected by the yarn. “Bulk” is the property of the yarn, which most closely correlates to surface coverage ability of a given yarn.
- U.S. Pat. No. 3,329,553 (Sims et al.) discloses a trilobal filament having a void fraction in the range from ten to sixty-five percent (10-65%). This reference teaches that void ratio is correlated with bulk in that the higher the void ratio the greater the bulk.
- U.S. Pat. No. 6,048,615 (Lin, RD-7395), assigned to the assignee of the present invention, discloses a trilobal filament with concave-sided voids formed from a thermoplastic synthetic polymer. This yarn exhibits excellent durability and good soiling resistance, but has relatively high glitter.
- U.S. Pat. Nos. 5,108,838 and 5,176,926 (both to Tung), both assigned to the assignee of the present invention, disclose a solid trilobal filament formed from a thermoplastic synthetic polymer material which exhibits low glitter. The structure of this yarn provides less bulk and is somewhat less effective in hiding soil than the current invention.
- U.S. Pat. No. 5,380,592 (Tung), assigned to the assignee of the present invention, discloses a trilobal cross-section with three voids which improve bulk and soil hiding compared to the solid cross-section trilobal filament discussed immediately above. However, this yarn is still somewhat vulnerable to soiling owing to the channels or “cusps” in the sides. Filaments of this yarn are also more subject to discontinuity in the spinning process owing to the complexity of the spinneret used to form the yarn. Open voids may occur in individual filaments, resulting in severe dyeability differences from filament to filament.
- In view of the foregoing it is believed advantageous to provide a spinneret for forming synthetic filaments which is conducive to a stable spinning process that is consistent along the length of the filament and that produces filaments that are easily bulked, exhibit a relatively low glitter, and are contoured to resist soil accumulation.
- The present invention is directed to a spinneret plate for producing a thermoplastic synthetic polymer filament having a three-sided exterior configuration wherein each side exhibits a smoothly curved contour having an inwardly extending depressed region disposed adjacent to each tip of each side. The filament has a generally delta-shaped void with a geometric center and three major apices extending centrally and axially therethrough. Each side of the void is convex in shape and has a first and a second end. Each side of the void is formed from two facets that meet to define a minor apex intermediate the first and second end of each side.
- The spinneret plate has a cluster of three Y-shaped orifices centered about a central point. Each Y-shaped orifice has three linear legs meeting at a junction point corresponding to a major apex of the void. One leg of each orifice extends radially outwardly from the junction point, the axis of that one leg aligning with a radius extending outwardly from the central point. The axes of each of the other two legs of each orifice project toward an apex point disposed intermediate adjacent orifices, each intermediate point corresponding to a minor apex of the void. The radially outwardly extending leg of each Y-shaped orifice is wider than the other legs of the Y-shaped orifice.
- The invention will be more fully understood from the following detailed description, taken in connection with the accompanying drawings, which form a part of this application and in which:
-
FIG. 1 is a cross sectional view of a bulked continuous filament in accordance with the present invention; -
FIG. 2 is a view of the bottom surface of a spinneret plate having a cluster of orifices formed therein for producing the filament shown inFIG. 1 ; -
FIG. 3 is a view of the bottom surface of a spinneret plate used for spinning the filaments of Comparative Example 1; and -
FIG. 4 is a view of the bottom surface of a spinneret plate used for spinning the filaments of Comparative Example 2. - Throughout the following detailed description similar reference numerals refer to similar elements in all Figures of the drawings.
-
FIG. 1 is a cross section view of a bulked continuous filament generally indicated byreference character 10 in accordance with the present invention. Alongitudinal axis 12 extending through thefilament 10 serves its geometric center. The distance from theaxis 12 to the point(s) on the exterior contour of thefilament 10 closest to the axis defines the minor radius (R1) of the filament. A major radius (R2) is defines the distance from theaxis 12 to the point(s) on the exterior contour of the filament that lie farthest therefrom. - Each
filament 10 has a generally three-sided exterior configuration formed fromsides 14A, 14B and 14C. The side 14 A is defined by a smoothly curved contour extending between a firstrounded tip 16A and a second rounded tip 16B. The side 14B is defined by a smoothly curved contour extending between the second rounded tip 16B and a thirdrounded tip 16C. Theside 14C is defined by a smoothly curved contour extending between the third rounded tip 16B and the roundedfirst tip 16A. The distance from a respective center of generation 18A, 18B, 18C to eachrounded tip FIG. 1 for clarity of illustration). - Each
exterior side 14A, 14B, 14C has a first inwardly extendingdepressed region 22 disposed near one tip and a second inwardly extendingdepressed region 24 disposed near the other tip. By “depressed region” it is meant that the contour of the filament in that region extends inwardly toward theaxis 12 of the filament. Theintermediate region 26 of eachside 14A, 14B, 14C (i.e., the region between thedepressed regions axis 12. Eachexterior side 14A, 14B, 14C of thefilament 10 thus exhibits a generally “wavy” configuration having two concave regions (i.e., thedepressed regions 22, 24) and three convex regions (i.e., the bowedintermediate region 26 and therounded regions 28 disposed near each rounded tip of each side). - In general a
filament 10 in accordance with the present invention has an exterior modification ratio (R2/R1) in the range from about 1.4 to about 2.0, and more particularly in the range from about 1.6 to about 1.8. In addition, the ratio of the major radius (R2) to the tip radius (R3) defines a tip ratio (R2/R3) in the range from about 2.0 to about 4.0, and more particularly in the range from about 2.0 to about 3.0. - The
filament 10 has a void 30 extending centrally and axially therethrough. Theaxis 12 defines the geometric center of the void. Thecentral void 30 is a generally “delta-shaped” opening having three generally convexmajor sides major sides major apices side discernable facets facets facets minor apex major side major apices geometric center 12 of the void 30 while theminor apices - The void 30 may occupy from about four percent (4%) to about twenty-five percent (25%), and more particularly from about four percent (4%) to about fifteen percent (15%), of the cross sectional area of the
filament 10. - In accordance with the present invention the
central void 30 is oriented within thefilament 10 such that eachmajor apex proximal side 14A, 14B, 14C of thefilament 10, while eachminor apex rounded tip - These relationships are exemplified in
FIG. 1 by theradial reference line 42 extending from theaxis 12 of thefilament 10 through the major apex 34C and apoint 44 disposed substantially midway along theintermediate region 26 of theside 14C. Similar reference lines, omitted for clarity, may be drawn through the othermajor apices filament 10. The alignment of the minor apices and the rounded tip of the filament is exemplified inFIG. 1 by aradial reference line 46 extending from theaxis 12 of thefilament 10 through the minor apex 40C and therounded tip 16C of the filament. Similar reference lines, again omitted for clarity, may be drawn through theminor apices rounded tips 16A, 16B of the filament. - A filament in accordance with the present invention is a bulked continuous filament prepared using a synthetic, thermoplastic melt-spinnable polymer. Suitable polymers include polyamides, polyesters, and polyolefins. The polymer is first melted and then is extruded (“spun”) through a
spinneret plate 50 having appropriately sized orifices therein (to be described hereinafter) under conditions which vary depending upon the individual polymer thereby to produce afilament 10 having the desired denier, exterior modification ratio, tip ratio, apex ratio and void percentage. The filaments are subsequently quenched by air flowing across them at a flow rate of between 1.2-1.8 ft/sec (0.36 to 0.55 m/sec). Void percentage can be increased by more rapid quenching and increasing the melt viscosity of thermoplastic melt polymers, which can slow the flow allowing sturdy pronounced molding to occur. - A plurality of
filaments 10 are gathered together to form a yarn. Drawing and bulking of the combined filaments is performed by any method known in the art, with the preferred operating condition described below in the examples provided. - Owing to the particular desired properties of the filaments 10 a yarn formed therefrom is believed to be particularly advantageous for tufting [with other types of yarn(s), if desired] into carpet having especially desirable properties. If desired, the yarn could include other forms of filament(s).
-
FIG. 2 illustrates aspinneret plate 50 useful for producing afilament 10 in accordance with the invention. - The
spinneret plate 50 is a relatively massive member having an upper surface (not shown) and abottom surface 52. As is well appreciated by those skilled in the art a portion of the upper surface of the spinneret plate is provided with a bore recess (not shown) whereby theplate 50 is connected to a source of polymer. Depending upon the rheology of the polymer being extruded the lower margins of the bore recess may be inclined to facilitate flow of polymer from the supply to the spinneret plate. - A plurality of capillary openings each generally indicated by the
reference character 54 extends through theplate 50 from the recessed upper surface to thebottom surface 52. Eachcapillary opening 54 serves to form one filament. Only onesuch capillary opening 54 is illustrated inFIG. 2 . The number of capillary openings provided in a given plate thus corresponds to the number of filaments being gathered to form a predetermined number of yarn(s). As noted, additional filaments (if used) may be incorporated into the yarn in any convenient manner. - As best seen in
FIG. 2 , in the present invention eachcapillary opening 54 is itself defined by a cluster of three orifices 56-1, 56-2 and 56-3 centered symmetrically about acentral point 58. - Each orifice 56-1, 56-2 and 56-3 is a generally “Y”-shaped opening comprising three
linear legs leg longitudinal axis axes axes legs junction point 68. The junction points 68 are spaced adistance 70 from thecenter point 58 of the cluster. - The orifices 56-1, 56-2 and 56-3 are arranged with respect to each other such that one leg of each orifice 56-1, 56-2 and 56-3, e.g., the
leg 62A, extends from thejunction point 68 in a radially outward direction relative to thecentral point 58. Stated alternatively, the radially outwardly extendingleg 62A of each orifice 56-1, 56-2 and 56-3 is oriented such that itsaxis 64A aligns with aradius 70 extending outwardly from thecentral point 58. Eachjunction point 68 of the orifices 56-1, 56-2, 56-3 respectively corresponds to amajor apex void 30 of the filament being spun. - The other two
legs axes apex point 72 disposed intermediate adjacent orifices. Extensions of each of theaxes legs apex point 72. Eachapex point 72 corresponds to a respectiveminor apex void 30 of the filament being spun. The ends of the confrontinglegs gap gaps legs legs - The width dimensions of the
legs radially extending leg 62A (indicated by the reference character B1) is wider than the width dimensions (indicated by the reference characters B2, B3) of theother legs - The spinneret plate may be fabricated in any appropriate manner, as by using the laser technique disclosed in U.S. Pat. No. 5,168,143, (Kobsa et al., QP-4171-A), assigned to the assignee of the present invention.
- The following Table presents the magnitudes of the various dimensions Al, A2, A3, B1, B2, B3, and C used to fabricate filaments having the cross section illustrated in
FIG. 1 used in invention Example 1 and Invention Example 2. The dimensions are in inches, with the corresponding metric measurement given parenthetically in centimeters.TABLE 1 A1, A2, A3 B1 B2, B3 C 0.0153 0.0073 0.0061 0.0186 (Invention Example 1) (0.0389) (0.019) (0.015) (0.047) 0.0214 0.0052 0.0044 0.0247 (Invention Example 2) (0.054) (0.013) (0.011) (0.062) - Trilobal cross sections with voids (hollow filament) have been practiced in the past [e.g., U.S. Pat. 6,048,615 (Lin)]. However, hollow filament yarns are difficult to make because of cross section shape control. Void percent and exterior modification ratio are both sensitive to polymer viscosity and quench air flow. As is well understood by one skilled in the art, without tight control of these parameters, lack of cross section shape uniformity can result in streaks when the yarns are finally tufted into a carpet.
- The combination of the three orifices taken together with the enlarged width dimension (B1) of the radially outwardly extending leg of each orifice causes polymer streams emanating from each orifice to converge, thus producing surprisingly stable polymer flow that is less prone to filament breakage and process interruption than the more complicated spinnerets of the prior art.
- The stable polymer flow provided by the use of the spinneret in accordance also results in surprising robustness of cross section formation in the spinning process. The fiber cross section shape is measurably less sensitive to quench airflow, and thus provides a distinct advantage versus the prior art as a result of the greater consistency of shape provided along the length of the formed filaments and yarns made therefrom.
- In addition, the disclosed spinneret plate is especially useful in the manner of producing the disclosed filament cross-section because it is simpler and less expensive to produce than previous hollow filament spinnerets.
- Spinning Process:
- Nylon 6,6 filaments having various cross-sections were produced for Comparative Examples A and B and for Invention Examples 1 and 2 from appropriately configured spinnerets, each with one hundred thirty-six (136) capillaries.
- The nylon 6,6 polymer used for all of the examples was a bright polymer. The polymer spin dope did not contain any delusterant and had a relative viscosity (RV) of sixty-eight plus/minus approximately three units (68, +/−˜3 units). The polymer temperature before the spinning pack was controlled at about two hundred ninety plus/minus one degree Centigrade (290, +/−1° C.). The spinning throughput was seventy pounds (70 lbs; 31.8 kg) per hour.
- The relative viscosity (RV) was measured by dissolving 5.5 grams of nylon 6,6 polymer in fifty cubic centimeters (50 cc) of formic acid. The RV is the ratio of the absolute viscosity of the nylon 66/formic acid solution to the absolute viscosity of the formic acid. Both absolute viscosities were measured at twenty-five degrees Centigrade (25° C.).
- The polymer was extruded through the different spinnerets and divided into two (2) sixty-eight filament (68) segments. The capillary dimensions for the spinnerets are described below. The molten fibers were then rapidly quenched in a chimney, where cooling air at about nine degrees Centigrade (−9° C.) was blown past the filaments at three hundred cubic feet per minute [300 cfm (732 m/min)] through the quench zone. The filaments were then coated with a lubricant for drawing and crimping. The coated yarns were drawn at 2197 yards per minute (2.75 x draw ratio) using a pair of heated draw rolls. The draw roll temperature was one hundred ninety degrees Centigrade (190° C.). The filaments were then forwarded into a dual-impingement hot air bulking jet similar to that described in Coon, U.S. Pat. No. 3,525,134 (Coon, assigned to the assignee of the present invention) to form two (2) twelve hundred five denier (1205 denier, 1340 decitex), 17.7 denier per filament (dpf) yarns (19 decitex per filament). The temperature of the air in the bulking jet was two hundred twenty degrees Centigrade (220° C.).
- The spun, drawn, and crimped bulked continuous filament (BCF) yarns were cable-twisted to 3.2 turns per inch (tpi) on a cable twister and heat-set on a Superba heat-setting machine at setting temperature of two hundred sixty degrees Farenheit (265° F.; 129.4° C.).
- The yarns were then tufted into twenty-eight ounce per square yard (28 oz/sq. yd; 949 g/sq. meter) having 0.21875 inch [{fraction (7/32)}″, 0.56 cm] pile height loop pile carpets on a {fraction (1/10)} inch gauge (0.254 cm) loop pile tufting machine. The tufted carpets were dyed on a continuous range dyer into medium yellow carpets.
- Test Methods:
- Each carpet sample produced from the yarns of Comparative Examples A and B and Invention Examples 1 and 2 was subjected to the following tests.
- Carpet Glitter and Bulk Ratings. The degrees of bulk and glitter for different cut-pile carpet samples were visually compared in a side-by side comparison without knowledge of which carpets were made with which yarns. The carpets were examined by a panel of five (5) experienced examiners each familiar with carpet construction and surface texture. The glitter value was measured by the examiners on a scale of “1” to “5”, with “5” being the most glitter. The glitter rating for each sample was averaged and the samples given a rating of low, medium or high glitter based on the average rating. Carpet bulk was rated in the same manner. The glitter and bulk results are reported in Table 2.
- Soiling Test:
- The soiling test was conducted on each carpet sample using a Vetterman drum.
- The base color of the sample was measured using the hand held color measurement instrument sold by Minolta Corporation as “Chromameter” model CR-210. This measurement was the control value.
- The carpet sample was placed in Vetterman drum. Two hundred grams (200 g) of clean nylon 101 Zytel nylon beads and fifty grams (50 g) of dirty beads (by DuPont Canada, Mississauga, Ontario) were placed on the sample. The dirty beads were prepared by mixing ten grams (10 g) of AATCC TM-122 synthetic carpet soil (by Manufacturer Textile Innovators Corp. Windsor, N.C.) with one thousand grams (1000 g) of new Nylon 101 Zytel beads. Sixteen to seventeen hundred grams (1600-1700 g) of ceramic cylindrical shaped beads [110 to 130 ½″ diameter x ½″ length small beads and twenty-five to thirty-five (25 to 35) ¾″ diameter, ¾″ length (1.91 cm diameter, 1.91 cm length) large beads were added into the Vetterman drum. The Vetterman drum was run for five hundred (500) cycles and the sample removed.
- The color of the sample was again measured and the color change versus the control value (delta E) owing to soiling was recorded as an “As Soiled” value [note: This interim result is not reported in Table 2]. The sample was vacuumed four (4) times in both the length and width directions and the color was again measured and the color change versus control value (delta E) after vacuuming was recorded as an “As Cleaned” value [note: This interim result is not reported in Table 2].
- The sample was placed back in the drum, fifty grams (50 g) of soiled bead mixture was discarded and fifty grams (50 g) of new dirty beads were added into the drum.
- The procedure described above was repeated for three additional five hundred (500) cycle runs.
- After a total of two thousand (2000) cycles, the color of the sample versus the control value (delta E) “As Soiled” was measured and reported. The color change versus the control value after vacuuming (the “As Cleaned” value) was measured and recorded. These measurements (i.e., the “As Soiled” and the “As Cleaned” values taken after two thousand cycles) are reported in Table 2 in the columns “As Soiled” and “As Cleaned”, respectively. Samples with a high value of delta E perform worse than samples with low delta E value.
- Comparative Example A
- Filaments having a trilobal cross-section as disclosed in U.S. Pat. No. 4,492,731 (Bankar et al.), assigned to the assignee of the present invention, were made using the above-described spinning process. The filaments were spun through a spinneret capillary as shown in
FIG. 3 having three tapered arms (lobes) which were essentially symmetrical. - Comparative Example B
- Filaments having a hollow trilobal cross section as disclosed in U.S. Pat. No. 6,048,615 (Lin), assigned to the assignee of the present invention, were made using the above-described spinning process. The filaments were spun through a spinneret capillary as shown in
FIG. 4 . - Invention Example 1
- Filaments having a hollow trilobal cross section as described by this invention, as shown in
FIG. 1B , were made using the above-described process. The filaments were spun through a spinneret capillary as shown inFIG. 2 . The dimensions A1, A2, A3, B1, B2, B3, C used to produce Invention Example 1 are as set forth in Table 1. - The filament had an exterior modification ratio of 1.66, a tip ratio of 2.6, an apex ratio of 1.08. The central void occupied about 5.3 percent of the cross sectional area of the filament.
- Invention Example 2
- Filaments having a hollow trilobal cross section as described by this invention, as shown in
FIG. 1 C were made using the above-described process. The filaments were spun through a spinneret capillary as shown inFIG. 2 . The dimensions A1, A2, A3, B1, B2, B3, C used to produce Invention Example 2 are as set forth in Table 1. - The filament had an exterior modification ratio of 1.88, a tip ratio of 3.5, an apex ratio of 1.33. The central void occupied about ten percent (10%) of the cross sectional area of the filament.
- The test results are summarized below in Table 2.
TABLE 2 Soiling Cross-section (ΔE) Soiling (ΔE) Example (exterior MR) As Soiled Cleaned Glitter Bulk Comp. A Solid trilobal 23.25 21.14 High High (2.6 MR) Comp. B Hollow trilobal N/A N/A High Medium (-.- MR) Inv. 1 1.66 17.94 16.71 Low Medium Inv. 2 1.88 21.17 19.86 Low High - As can be appreciated from Table 2, Examples 1 and 2 (having relatively “wavy” sides including two concave and three convex surfaces and a void shaped and oriented in the manner shown in
FIG. 1 ) demonstrate distinctly different and lower “Glitter” in the final carpet than do Comparative Examples A and B. The filament and yarn of the present invention is useful as a carpet yarn having more “wool-like” appearance when made into carpet than yarns of the prior art having similar bulk, soiling and cleaning characteristics. - The filament of the invention is also smoother (i.e., with rounded tips and without sharply defined cusps) and therefore less prone to soiling than other known high bulk trilobal fibers that can otherwise impart similar aesthetics to a carpet made therefrom, as is clearly supported by the soiling data in Table 2. A carpet constructed from yarn of the present invention therefore retains its appearance longer in service than carpets made from yarn of the prior art.
- To achieve high bulk with low glitter is generally believed to be difficult. The invention provides a surprisingly low glitter yarn that can produce carpets of comparable bulk to carpets made from such high glitter yarns as the solid trilobal cross section filaments(Comparative Example A).
- As a result of the configuration filaments in accordance with this invention and yarns formed therefrom are easily bulked and exhibit a relatively low glitter while the exterior contour resists soil accumulation.
Claims (2)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US10/991,469 US20050147788A1 (en) | 2003-11-19 | 2004-11-19 | Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void |
US11/173,267 US20060008548A1 (en) | 2003-11-19 | 2005-07-01 | Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void |
Applications Claiming Priority (3)
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US52387003P | 2003-11-19 | 2003-11-19 | |
US52387103P | 2003-11-19 | 2003-11-19 | |
US10/991,469 US20050147788A1 (en) | 2003-11-19 | 2004-11-19 | Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void |
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US11/173,267 Continuation-In-Part US20060008548A1 (en) | 2003-11-19 | 2005-07-01 | Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void |
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US20050147788A1 true US20050147788A1 (en) | 2005-07-07 |
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US10/991,469 Abandoned US20050147788A1 (en) | 2003-11-19 | 2004-11-19 | Spinneret plate for producing a bulked continuous filament having a three-sided exterior cross-section and a convex six-sided central void |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070128404A1 (en) * | 2005-12-06 | 2007-06-07 | Invista North America S.Ar.L. | Hexalobal cross-section filaments with three major lobes and three minor lobes |
US20100159186A1 (en) * | 2008-12-18 | 2010-06-24 | E. I. Du Pont De Nemours And Company | Poly-trimethylene terephthalate solid core fibrillation-resistant filament having a substantially triangular cross section, a spinneret for producing the filament, and a carpet made therefrom |
US20100159184A1 (en) * | 2008-12-18 | 2010-06-24 | E. I. Du Pont De Nemours And Company | Poly-trimethylene terephthalate solid core fibrillation-resistant filament having a substantially triangular cross section, a spinneret for producing the filament, and a carpet made therefrom |
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 |
US20120231207A1 (en) * | 2011-03-07 | 2012-09-13 | Moshe Rock | Textile fabric with high insulation to weight ratio |
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US6610903B1 (en) * | 1998-12-18 | 2003-08-26 | Kimberly-Clark Worldwide, Inc. | Materials for fluid management in personal care products |
US6838402B2 (en) * | 1999-09-21 | 2005-01-04 | Fiber Innovation Technology, Inc. | Splittable multicomponent elastomeric fibers |
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US20070128404A1 (en) * | 2005-12-06 | 2007-06-07 | Invista North America S.Ar.L. | Hexalobal cross-section filaments with three major lobes and three minor lobes |
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 |
US20100159186A1 (en) * | 2008-12-18 | 2010-06-24 | E. I. Du Pont De Nemours And Company | Poly-trimethylene terephthalate solid core fibrillation-resistant filament having a substantially triangular cross section, a spinneret for producing the filament, and a carpet made therefrom |
US20100159184A1 (en) * | 2008-12-18 | 2010-06-24 | E. I. Du Pont De Nemours And Company | Poly-trimethylene terephthalate solid core fibrillation-resistant filament having a substantially triangular cross section, a spinneret for producing the filament, and a carpet made therefrom |
US20120231207A1 (en) * | 2011-03-07 | 2012-09-13 | Moshe Rock | Textile fabric with high insulation to weight ratio |
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