U.S. patent application number 09/795518 was filed with the patent office on 2001-12-20 for fine denier yarn from poly (trimethylene terephthalate).
Invention is credited to Howell, James M., London, Joe Forrest JR., Watkins, Michelle H..
Application Number | 20010053442 09/795518 |
Document ID | / |
Family ID | 24065378 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010053442 |
Kind Code |
A1 |
Howell, James M. ; et
al. |
December 20, 2001 |
Fine denier yarn from poly (trimethylene terephthalate)
Abstract
Fine denier poly(trimethylene terephthalate) feed yarns and
drawn yarns wherein the drawn yarns are characterized by a denier
per filament less than 1.5 and are drawn such that the actual draw
ratio is within 10 percent of the predicted draw ratio determined
according to: [(elongation to break of the feed
yarn)+115]/[(elongation to break of the drawn yarn)+115)] are
disclosed.
Inventors: |
Howell, James M.;
(Greenville, NC) ; London, Joe Forrest JR.;
(Greenville, NC) ; Watkins, Michelle H.;
(Waynesboro, VA) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY
LEGAL DEPARTMENT - PATENTS
1007 MARKET STREET
WILMINGTON
DE
19898
US
|
Family ID: |
24065378 |
Appl. No.: |
09/795518 |
Filed: |
February 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09795518 |
Feb 28, 2001 |
|
|
|
09518759 |
Mar 3, 2000 |
|
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Current U.S.
Class: |
428/364 |
Current CPC
Class: |
Y10T 428/2969 20150115;
D01F 6/62 20130101; Y10T 428/2913 20150115 |
Class at
Publication: |
428/364 |
International
Class: |
D02G 003/00 |
Claims
What is claimed is:
1. A drawn yarn made by the following process: (1) providing a
polyester polymer having an intrinsic viscosity of at least 0.80
dl/g comprising at least 85 mole % poly(trimethylene terephthalate)
wherein at least 85 mole % of repeating units consist of
trimethylene units; (2) spinning the polyester polymer by
melt-extruding the polyester polymer at a temperature between about
255.degree. C. and 275.degree. C. to form a partially oriented feed
yarn; (3) preparing a drawn yarn from the partially oriented feed
yarn, wherein said drawn yarn has the following characteristics:
(a) a denier per filament less than about 1.0; and (b) an actual
draw ratio within 10 percent of a predicted draw ratio, wherein the
predicted draw ratio is determined according to: [(elongation to
break of the feed yarn)+115]/[(elongation to break of the drawn
yarn)+115)].
2. The drawn yarn of claim 1, wherein the actual draw ratio is
within 5 percent of the predicted draw ratio.
3. The drawn yarn of claim 1, wherein the actual draw ratio is
within 3 percent of the predicted draw ratio.
4. The drawn yarn of claim 1, wherein the spinning temperature is
between 260.degree. C. and 270.degree. C.
5. The drawn yarn of claim 1, wherein the spinning temperature is
at least 265.degree. C.
6. The drawn yarn of claim 1, wherein the polyester is
melt-extruded on a spinneret having orifices between about 0.12 to
0.38 mm in diameter.
7. The drawn yarn of claim 1 wherein the polyester polymer has an
intrinsic viscosity of at least 0.90 dl/g.
8. The drawn yarn of claim 1 wherein the polyester polymer has an
intrinsic viscosity of at least 1.00 dl/g.
9. The drawn yarn of claim 1 wherein the fine denier partially
oriented feed yarn has a denier per filament less than 2.
10. The drawn yarn of claim 1 wherein the fine denier partially
oriented feed yarn has a denier per filament less than 1.5.
11. The drawn yarn of claim 1 wherein the fine denier partially
oriented feed yarn has a denier per filament less than 1.0.
12. The drawn yarn of claim 9, wherein the actual draw ratio is
within 5 percent of the predicted draw ratio.
13. The drawn yarn of claim 10, wherein the actual draw ratio is
within 5 percent of the predicted draw ratio.
14. The drawn yarn of claim 9, wherein the actual draw ratio is
within 3 percent of the predicted draw ratio.
15. A fine denier undrawn partially oriented feed yarn made by the
process comprising providing a polyester polymer comprising at
least 85 mole % poly(trimethylene terephthalate) wherein at least
85 mole % of repeating units consist of trimethylene units, and
wherein said polymer has an intrinsic viscosity of at least 0.80
dl/g, and spinning the polyester polymer by melt-extruding the
polyester polymer at a spinning temperature between about
255.degree. C. and about 275.degree. C. to form a fine denier
undrawn partially oriented feed yarn, wherein the fine denier
undrawn partially oriented feed yarn has a denier per filament less
than 2.
16. The fine denier feed yarn of claim 15, wherein the denier per
filament is less than 1.5.
17. The fine denier feed yarn of claim 15, wherein the denier per
filament is less than 1.0.
18. The fine denier feed yarn of claim 15, wherein the polymer has
an intrinsic viscosity of at least 0.90 dl/g.
19. The fine denier feed yarn of claim 15, wherein the polymer has
an intrinsic viscosity of at least 1.00 dl/g.
20. A drawn yarn prepared from a polyester polymer having an
intrinsic viscosity of at least 0.80 dl/g comprising at least 85
mole % poly(trimethylene terephthalate) wherein at least 85 mole %
of repeating units consist of trimethylene units, wherein the drawn
yarn has a denier per filament less than about 1.0.
Description
PRIORITY
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 09/518,759, filed Mar. 3, 2000, which is incorporated
herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to very fine denier polyester
yarn made from poly(trimethylene terephthalate) fibers.
BACKGROUND OF THE INVENTION
[0003] Polyester yarns having very fine denier are highly desirable
for manufacturing fabrics used in the garment industry. Such yarns
are desirable because they yield a light-weight material having
excellent properties such as softness. The softness of a yarn and
fabric is a measure of how soft a material feels to the touch. A
yarn and fabric used for many clothing apparel items require a high
degree of softness.
[0004] Very fine denier polyester fibers currently known in the art
are made using polyethylene terephthalate. Such yarns provide
softness suitable for many garments such as, e.g., dresses, jackets
and other ladies' apparel. However, because polyethylene
terephthalate has a high Young's modulus, the maximum softness
achieved is not suitable for garments requiring ultra-soft
touch.
[0005] There is therefore a need in the art for very fine denier
polyester yarns having superior softness quality. Theoretically,
polyester yarns made from a polymer having a low Young's modulus
should yield the desirable properties. However, attempts to
commercially manufacture such a fine denier polyester yarn from
poly(trimethylene terephthalate) have not been successful due to
various manufacturing problems. For example, when attempting to
make very fine denier yarns from poly(trimethylene terephthalate),
excessive breaks in the fibers have been experienced. Further, it
was thought in the prior art that the tenacity of poly(trimethylene
terephthalate) was too low to successfully make a very fine denier
yarn.
SUMMARY OF THE INVENTION
[0006] The present invention comprises a drawn yarn made from a
partially oriented feed yarn, said feed yarn made from a polyester
polymer melt-extruded at a spinning temperature between about
255.degree. C. and 275.degree. C., wherein said polymer comprises
at least 85 mole % poly(trimethylene terephthalate) wherein at
least 85 mole % of repeating units consist of trimethylene units,
and wherein said polymer has an intrinsic viscosity of at least
0.80 dl/g, and wherein said drawn yarn has the following
characteristics:
[0007] (a) a denier per filament less than about 1.5; and
[0008] (b) an actual draw ratio within 10 percent of a predicted
draw ratio, wherein the predicted draw ratio is determined
according to: [(elongation to break of the feed
yarn)+115]/[(elongation to break of the drawn yarn)+115)].
[0009] The present invention further comprises a process for making
a drawn yarn from a partially oriented feed yarn, comprising the
steps:
[0010] (a) extruding a molten polyester polymer at a temperature
between about 255.degree. C. and about 275.degree. C. through a
spinneret to form filaments, wherein said polymer comprises at
least 85 mole % poly(trimethylene terephthalate) wherein at least
85 mole % of repeating units consist of trimethylene units, and
wherein said polymer has an intrinsic viscosity of at least 0.80
dl/g;
[0011] (b) cooling the filaments by exposing them to a flow of
quench air;
[0012] (c) coating the filaments with a spin finish;
[0013] (d) heating the filaments to a temperature greater than the
glass transition temperature of the filaments, but less than
200.degree. C., prior to drawing the filaments; and
[0014] (e) drawing the filaments between a set of feed rolls to
produce a denier per filament less than about 1.5 and an actual
draw ratio within 10 percent of a predicted draw ratio, wherein the
predicted draw ratio is determined according to: [(elongation to
break of the feed yarn)+115]/[(elongation to break of the drawn
yarn)+115)].
[0015] The present inventions further comprises a fine denier feed
yarn made from a polyester polymer melt-extruded at a spinning
temperature between about 255.degree. C. and about 275.degree. C.,
wherein said polymer comprises at least 85 mole % poly(trimethylene
terephthalate) wherein at least 85 mole % of repeating units
consist of trimethylene units, and wherein said polymer has an
intrinsic viscosity of at least 0.80 dl/g, and wherein said fine
denier feed yarn has a denier per filament less than about 2.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic diagram of an exemplary spinning
position for making the very fine denier poly(trimethylene
terephthalate) yarns of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention provides a very fine denier polyester
drawn yarn made from poly(trimethylene terephthalate) and a feed
yarn and process for making the same. The very fine denier feed
yarn of the present invention is a multifilament yarn wherein the
denier per filament is less than about 2 dpf (2.22 dtex/filament).
Preferably, the denier per filament of the feed yarn is less than
1.5 dpf (1.67 dtex/filament) and, most preferably, the denier per
filament is less than I dpf (1.11 dtex/filament). The very fine
denier drawn yarn of the present invention is a multifilament yarn
wherein the denier per filament is less than about 1.5 dpf (1.67
dtex/filament). Preferably, the denier per filament is less than 1
dpf (1.1 dtex/filament). The feed yarns (and consequently, the
drawn yarns) are made from a polyester polymer, wherein said
polymer comprises at least 85 mole % poly(trimethylene
terephthalate) wherein at least 85 mole % of repeating units
consist of trimethylene units, and wherein said polymer has an
intrinsic viscosity of at least 0.80 dl/g. Preferably, the
intrinsic viscosity is at least 0.90 dl/g and, most preferably, it
is at least 1.00 dl/g. Partially oriented feed yarn is made using
conventional melt-spinning techniques, at a spinning temperature of
about 255.degree. C. to about 275.degree. C. Molten polymer is
extruded through spinneret orifices of diameter from about 0.12 mm
to about 0.38 mm. The yarns of the present invention are drawn such
that actual draw ratio is within ten percent of the predicted draw
ratio. This requirement is satisfied if the draw ratio difference,
.DELTA.DR, is less than ten percent. The draw ratio difference,
.DELTA.DR, as defined herein is defined according to equation (I):
1 DR = DR P - DR A DR A 10 % , ( I )
[0018] where DR.sub.A is the actual draw ratio, and DR.sub.P is the
predicted draw ratio. The predicted draw ratio, DR.sub.P is defined
according to equation (II): 2 DR P = E B ( F Y ) + 115 E B ( D Y )
+ 115 , ( II )
[0019] where, E.sub.B(F.sub.Y) is the elongation to break of the
partially oriented feed yarn and E.sub.B(D.sub.Y) is the elongation
to break of the drawn yarn. Preferably, the actual draw ratio is
within five percent of the predicted draw ratio and, most
preferably, it is within three percent.
[0020] As shown in FIG. 1, molten streams 20 of poly(trimethylene
terephthalate) polymer are extruded through orifices in spinneret
22 downwardly into quench zone 24 supplied with radially or
transversely directed quenching air. The diameter and quantity of
orifices in spinneret 22 may be varied depending upon the desired
filament size and the number of filaments in the multifilament yarn
of the present invention. Further, the temperature of molten
streams 20 is controlled by the spin block temperature, which is
also known as the spinning temperature. It has been found that an
orifice diameter of about 0.12 mm to about 0.38 mm can be used to
produce the very fine filament yarns of the present invention.
Further, a spinning temperature between about 255.degree. C. and
275.degree. C. is required to make the very fine denier yarns of
the present invention. Preferably, the spinning temperature is
between about 260.degree. C. and 270.degree. C. and, most
preferably, the spinning temperature is maintained at 265.degree.
C.
[0021] Streams 20 solidify into filaments 26 at some distance below
the spinneret within the quench zone. Filaments 26 are converged to
form multifilament yarn 28. A conventional spin-finish is applied
to yarn 28 through a metered application or by a roll application
such as finish roll 32. Yam 28 next passes in partial wraps about
godets 34 and 36 and is wound on package 38. The filaments may be
interlaced if desired, as by pneumatic tangle chamber 40.
[0022] The partially oriented poly(trimethylene terephthalate)
yarns are then drawn using conventional drawing equipment, such as
a Barmag DW48. According to the present invention, the yarns are
drawn such that the draw ratio difference, ADR, is less than ten
percent, as described above.
[0023] The very fine filament yarns of the present invention are
suitable for warp drawing, air jet texturing, false-twist
texturing, gear crimping, and stuffer-box crimping, for example.
The yarns of the present invention may be used to make any fabrics
which could be made from very fine denier polyethylene
terephthalate yarns, such as disclosed in U.S. Pat. No. 5,250,245,
which is incorporated herein by reference in its entirety. Tows
made from these filament may also be crimped, if desired, and cut
into staple and flock. The fabrics made from these improved yarns
may be surface treated by conventional sanding and brushing to give
suede-like tactility. The filament surface frictional
characteristics may be changed by selection of cross-section,
delusterant, and through such treatments as alkali-etching. The
improved combination of filament strength and uniformity makes
these filaments especially suited for end-use processes that
require fine filament yarns without broken filaments (and yarn
breakage) and uniform dyeing with critical dyes.
[0024] The fine filament yarns of the present invention are
especially suitable for making high-end density moisture-barrier
fabrics, such as rainwear and medical garments. The surface of the
knit and woven fabrics can be napped (brushed or sanded). To reduce
the denier even further, the filaments may be treated (preferably
in fabric form) with conventional alkali procedures. The fine
filament yarns of the present invention may be co-mingled on-line
in spinning or off-line with higher denier polyester (or nylon)
filaments to provide for cross-dyed effects and/or mixed shrinkage
post-bulkable potential, where the bulk may be developed off-line,
such as over feeding in the presence of heat while beaming/slashing
or in fabric form, such as in the dye bath. The degree of interlace
is selected based on the textile processing needs and final desired
yarn/fabric aesthetics. Because of the low Young's modulus of
poly(trimethylene terephthalate), the very fine denier yarns of the
present invention are especially suitable for fabrics where
softness is important.
[0025] Measurements discussed herein were made using conventional
U.S. textile units, including denier, which is a metric unit. The
dtex equivalents for denier are provided in parentheses after the
actual measured values. Similarly, tenacity and modulus
measurements were measured and reported in grams per denier ("gpd")
with the equivalent dN/tex value in parentheses.
TEST METHODS
[0026] The physical properties of the partially oriented
poly(trimethylene terephthalate) yarns reported in the following
examples were measured using an Instron Corp. tensile tester, model
no. 1122. More specifically, elongation to break, E.sub.B, and
tenacity were measured according to ASTM D-2256.
[0027] Boil off shrinkage ("BOS") was determined according to ASTM
D 2259 as follows: a weight was suspended from a length of yarn to
produce a 0.2 g/d (0.18 dN/tex) load on the yarn and measuring its
length, L.sub.1. The weight was then removed and the yarn was
immersed in boiling water for 30 minutes. The yarn was then removed
from the boiling water, centrifuged for about a minute and allowed
to cool for about 5 minutes. The cooled yarn is then loaded with
the same weight as before. The new length of the yarn, L.sub.2, was
recorded. The percent shrinkage was then calculated according to
equation (III), below: 3 Shrinkage ( % ) = L 1 - L 2 L 1 .times.
100 ( III )
[0028] Dry heat shrinkage ("DHS") was determined according to ASTM
D 2259 substantially as described above for BOS. L.sub.1 was
measured as described, however, instead of being immersed in
boiling water, the yarn was placed in an oven at about 160.degree.
C. After about 30 minutes, the yarn was removed from the oven and
allowed to cool for about 15 minutes before L.sub.2 was measured.
The percent shrinkage was then calculated according to equation
(III), above.
[0029] Intrinsic viscosity was measured in 50/50 weight percent
methylene chloride/triflouroacetic acid following ASTM D
4603-96.
EXAMPLE I
Polymer Preparation
Polymer Preparation 1
[0030] Poly(trimethylene terephthalate) polymer was prepared using
batch processing from dimethylterephthalate and 1,3-propanediol. A
40 lb (18 kg) horizontal autoclave with an agitator, vacuum jets
and a monomer distillation still located above the clave portion of
the autoclave was used. The monomer still was charged with 40 lb
(18 kg) of dimethyl terephthalate and 33 lb (15 kg) of
1,3-propanediol. Sufficient lanthanum acetate catalyst was added to
obtain 250 parts per million ("ppm") lanthanum in the polymer.
Parts per million is used herein to mean micrograms per gram. In
addition, tetraisopropyl titanate polymerization catalyst was added
to the monomer to obtain 30 ppm titanium in the polymer. The
temperature of the still was gradually raised to 245.degree. C. and
approximately 13.5 lb (6.2 kg) of methanol distillate were
recovered.
[0031] An amount of phosphoric acid in 1,3-propanediol solution to
obtain about 160 ppm phosphorous in the polymer was added to the
clave. If delustered polymer was desired, then a 20 percent by
weight ("wt. %") slurry of titanium dioxide (TiO.sub.2) in
1,3-propanediol solution was added to the clave in an amount to
give 0.3 wt. % in polymer. The ingredients were agitated and well
mixed and polymerized by increasing the temperature to 245.degree.
C., reducing pressure to less than 3 millimeters of mercury (less
than 400 Pa) and agitating for a period of four to eight hours.
With polymer molecular weight at the desired level, polymer was
extruded through a ribbon or strand die, quenched, and cut into a
flake or pellet size suitable for remelt extrusion or solid state
polymerizing. Polymer intrinsic viscosity ("IV") in the range of
0.60 dl/g to 1.00 dl/g was produced by this method.
[0032] The polymer made by this process (with TiO2) was used in
Example II-3. The polymers used in Examples II-5, II-6, II-7, II-8,
II-9, III-13 and III-14 were made in substantially the same manner,
except that TiO.sub.2 was not added, and had the same IV. The
polymers for Examples II-10 and III-15 were made in the same way,
but had a slightly higher IV and did contain TiO.sub.2.
Polymer Preparation 2
[0033] Higher molecular weight polymer (IV>1.00 dl/g) for
Examples II-2, III-11 and III-12 was produced by solid state
polymerizing polymer chip or flake (made in the same way as
described above) in a fluidized bed polymerizer. The polymer of
Example III-11 included TiO.sub.2, whereas the others did not.
Crystallized and dried polymer was charged to a fluidized bed
reactor continually agitated and purged with dry, inert gas and
maintained at a temperature of 200.degree. C. to 220.degree. C. for
up to 10 hours to produce polymer with IV up to 1.40.
Polymer Preparation 3
[0034] Poly(trimethylene terephthalate) polymer for use in Example
II-4 was prepared from terephthalic acid and 1,3-propanediol using
a two vessel process utilizing an esterification vessel ("reactor")
and a polycondensation vessel ("clave"), both of jacketed,
agitated, deep pool design. 428 lb (194 kg) of 1,3-propanediol and
550 lb (250 kg) of terephthalic acid were charged to the reactor.
Esterification catalyst (monobutyl tin oxide at a level of 90 ppm
Sn (tin)) was added to the reactor to speed the esterification when
desired. The reactor slurry was agitated and heated at atmospheric
pressure to 210.degree. C. and maintained while reaction water was
removed and the esterification was completed. At this time the
temperature was increased to 235.degree. C., a small amount of
1,3-propanediol was removed and the contents of the reactor were
transferred to the clave.
[0035] With the transfer of reactor contents, the clave agitator
was started and 91 grams of tetraisopropyl titanate was added as a
polycondensation catalyst. If titanium dioxide was desired in the
polymer, a 20% slurry in 1,3-propanediol was added to the clave in
an amount to give 0.3 wt. % in polymer. The process temperature was
increased to 255.degree. C. and the pressure was reduced to 1 mm Hg
(133 Pa). Excess glycol was removed as rapidly as the process would
allow. Agitator speed and power consumption were used to track
molecular weight build. When the desired melt viscosity and
molecular weight were attained, clave pressure was raised to 150
psig (1034 kPa gauge) and clave contents were extruded to a cutter
for pelletization.
[0036] TiO.sub.2 was added in the same amount and in the same way
as in Polymer Preparation 1.
Polymer of Example II-1
[0037] Batch poly(trimethylene terephthalate) polymer having the
properties described in Table 1 and 0.3 weight % TiO.sub.2 was used
for Example II-1.
EXAMPLE II
[0038] Several samples of poly(trimethylene terephthalate) polymer,
prepared as described in Example I, were spun into partially
oriented filaments, using a conventional remelt single screw
extrusion process and conventional polyester fiber melt-spinning
(S-wrap) process, as illustrated in FIG. 1. The spinning conditions
and properties for the resulting partially oriented yarns are set
forth in Table I. The starting polymers had varying intrinsic
viscosities, as indicated in Table I. The polymer was extruded
through spinneret orifices having a diameter of about 0.23 mm. The
spin block temperature was varied to obtain the polymer
temperatures indicated in Table I. The filamentary streams leaving
the spinneret were quenched with air at 21.degree. C. and collected
into bundles of filaments. Spin finish was applied in the amounts
indicated in Table I, and the filaments were interlaced and
collected as multi-filament yarn.
[0039] Each of the partially oriented yarns spun in this example
was suitable as a very fine denier feed yarn for making drawn yarns
according to the present invention, as illustrated in Example IV.
Yam item "II-10" was suitable as a very fine denier direct-use
partially oriented yarn in some applications. Such a fine denier
partially oriented poly(trimethylene terephthalate) yarn may be
woven or knit into end use fabrics without further drawing.
1 TABLE I Spinning Conditions Winding Spun Yarn Properties Speed,
Temp, # of Speed, Yarn Denier Per Ten., g/d Mod, DHS, BOS, Id. IV
m/m .degree. C. Finish, % Fils. m/m Denier (dtex) Filament (dtex)
(dN/tex) E.sub.B, % g/d (dN/tex) % % II-1 1.04 1829 254 0.60 100
1808 107(119) 1.07(1.19) 2.47(2.18) 128 18.6(16.4) -- 52 II-2 1.2
2743 275 0.50 100 2680 95(106) 0.95(1.06) 2.98(2.63) 83 20.2(17.8)
-- 42 II-3 0.88 2743 270 0.50 100 2706 96(107) 0.96(1.07) 2.7(2.38)
98 20.1(17.7) 41 43 II-4 0.88 2746 270 0.50 200 2670 201(223)
1.01(1.11) 2.73(2.41) 91 22.8(20.1) 28 38 II-5 0.88 3200 265 0.60
100 3100 112(124) 1.12(1.24) 2.85(2.52) 82 17.0(15.0) -- 36 II-6
0.88 3200 265 0.60 100 3100 150(167) 1.50(1.67) 2.77(2.44) 81
17.7(15.6) -- 36 II-7 0.88 3200 265 0.60 100 3155 113(126)
1.13(1.26) 2.78(2.45) 83 18.8(16.6) -- 40 II-8 0.88 3200 265 1.00
100 3164 153(170) 1.53(1.70) 2.73(2.41) 75 20.5(18.1) -- 39 II-9
0.88 4115 265 0.60 100 4042 88(98) 0.88(0.98) 3.29(2.90) 60
21.7(19.2) -- 31 II-10 0.92 4115 265 0.50 100 4042 84(93)
0.84(0.93) 3.15(2.78) 63 24.5(21.6) -- 25
EXAMPLE III
[0040] This example showed the spinning parameters used to spin
additional samples of poly(trimethylene terephthalate) polymer into
partially oriented filaments. The polymers used in this example
were prepared as described in Example I. The spinning conditions
and properties for the resulting partially oriented feed yarns are
set forth in Table II. As with the feed yarns from Example II, the
partially oriented yarns spun in this example were suitable for
making very fine denier drawn yarns. Yarn item "III-15" was also
suitable as a very fine denier direct-use partially oriented
yarn.
2 TABLE II Spinning Conditions Winding Spun Yarn Properties Speed,
Temp, # of Speed, Yarn Denier Per Ten., g/d Mod, DHS, BOS, Id. IV
m/m .degree. C. Finish, % Fils. m/m Denier (dtex) Filament (dtex)
(dN/tex) E.sub.B, % g/d (dN/tex) % % III-11 1.05 2743 270 0.40 100
2670 96(107) 0.96(1.07) 2.79(2.46) 91 22.7(20.0) 30 37 III-12 1.05
2743 270 0.40 100 2670 95(106) 0.95(1.06) 3.07(2.71) 81 23.4(20.7)
25 29 III-13 0.88 3658 265 1.00 100 3612 137(152) 1.37(1.52)
2.96(2.61) 68 20.7(18.3) -- 30 III-14 0.88 4115 265 1.00 100 4078
123(137) 1.23(1.37) 2.87(2.53) 62 20.1(17.7) -- 17 III-15 0.92 4115
265 0.50 100 4042 78(87) 0.78(0.87) 3.27(2.89) 66 24.4(21.5) --
27
EXAMPLE IV
[0041] The partially oriented feed yarns from Example II were drawn
at a speed of 400 meters per minute ("mpm") over a heater plate at
varying temperatures, with varying draw ratios. The drawing
parameters and drawn yarn properties are provided in Table III. As
shown in Table III, the yarns of the present invention were drawn
such that ADR is less than ten percent.
3 TABLE III Drawing Predicted Draw Conditions Drawn Yarn Properties
Ratio Draw Heater Yarn Denier Denier Per Tenacity, g/d Modulus, g/d
DHS, BOS, Draw .DELTA.DR, Id. Ratio Plate .degree. C. (dtex)
Filament (dtex) (dN/tex) EB, % (dN/tex) % % Ratio % IV-1 1.40 130
78(87) 0.78(0.87) 2.98(2.63) 54 21.2(18.7) -- 13.3 1.44 2.86 1.50
73(81) 0.73(0.82) 3.21(2.83) 43 23.4(20.7) -- 13.9 1.54 2.67 1.52
73(81) 0.73(0.81) 3.21(2.83) 39 23(20.3) -- 14.0 1.58 3.95 IV-2 1.1
160 88(98) 0.88(0.98) 3.13(2.76) 57 24.5(21.6) 10 7.0 1.15 4.55 1.2
82(91) 0.82(0.91) 3.59(3.17) 50 23.7(20.9) 13 10.0 1.20 0.00 1.3
82(91) 0.81(0.90) 3.83(3.38) 38 30(26.5) 16 11.0 1.29 -0.77 1.4
75(83) 0.75(0.83) 4.06(3.58) 29 28(24.7) 16 13.0 1.38 -1.43 1.5
67(74) 0.67(0.74) 4.52(3.99) 27 29.3(25.9) 16 13.0 1.39 -7.33 IV-3
1.1 120 88(98) 0.88(0.98) 2.69(2.37) 70 22.4(19.8) 11 8.0 1.15 4.55
1.2 81(90) 0.81(0.90) 2.71(2.39) 51 23.4(20.7) 15 12.0 1.28 6.67
1.3 76(84) 0.76(0.84) 3.12(2.75) 45 25.6(22.6) 17 14.0 1.33 2.31
IV-4 1.1 120 186(207) 0.93(1.03) 2.54(2.24) 60 23.1(20.4) 13 10.0
1.18 7.27 1.2 173(192) 0.86(0.96) 2.84(2.51) 51 25.4(22.4) 16 14.0
1.24 3.33 1.3 161(179) 0.81(0.90) 2.73(2.41) 36 26.5(23.4) 18 15.0
1.36 4.62 IV-5 1.3 160 85(94) 0.85(0.94) 3.52(3.11) 36 -- -- --
1.30 0.00 IV-6 1.35 160 82(91) 0.82(0.91) 3.69(3.26) 30 -- -- --
1.35 0.00 IV-7 1.3 160 91(101) 0.91(1.01) 3.38(2.98) 34 25.4(22.4)
-- 10.6 1.33 2.31 1.35 87(97) 0.87(0.97) 3.77(3.33) 36 25.7(22.7)
-- 11.4 1.31 -2.96 1.4 84(93) 0.84(0.93) 3.83(3.38) 30 26.3(23.2)
-- 11.3 1.37 -2.14 1.45 81(90) 0.81(0.90) 3.97(3.5) 28 25.8(22.8)
-- 11.6 1.38 -4.83 IV-8 1.5 160 109(121) 1.09(1.21) 4.04(3.57) 25
24.1(21.3) -- 12.0 1.36 -9.33 IV-9 1.2 160 71(79) 0.71(0.79)
4.09(3.61) 36 28.4(25.1) -- 10.0 1.16 -3.33 1.25 72(80) 0.72(0.80)
3.95(3.49) 30 27.7(24.4) -- 10.8 1.21 -3.20 1.3 75(83) 0.75(0.83)
3.85(3.4) 26 24.3(21.4) -- 10.6 1.24 -4.62 IV-10 1.1 160 74(82)
0.74(0.82) 3.22(2.84) 40 24.6(21.7) -- 8.0 1.15 4.55 1.2 70(78)
0.70(0.78) 3.48(3.07) 30 25.9(22.9) -- 11.0 1.23 2.50
* * * * *