U.S. patent application number 10/282083 was filed with the patent office on 2003-05-22 for method of fabricating a non-hollow fiber having a regular polygonal cross-section.
This patent application is currently assigned to INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE. Invention is credited to Chen, Lien-Tai, Chen, Ting-Tsiu, Hu, Wei.
Application Number | 20030096114 10/282083 |
Document ID | / |
Family ID | 21679604 |
Filed Date | 2003-05-22 |
United States Patent
Application |
20030096114 |
Kind Code |
A1 |
Chen, Lien-Tai ; et
al. |
May 22, 2003 |
Method of fabricating a non-hollow fiber having a regular polygonal
cross-section
Abstract
Fibers or filaments made by using a spinneret orifice having a
regular polygonal cross-section. Melt-spinnable thermoplastic
polymer is melted and extruded through a spinneret orifice having a
regular polygonal cross-section to form molten filaments. The
molten filaments are then solidified, and optionally are
subsequently subjected to stretching and false twisting
processes.
Inventors: |
Chen, Lien-Tai; (Taoyuan,
TW) ; Chen, Ting-Tsiu; (Hsinchu, TW) ; Hu,
Wei; (Hsinchu, TW) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
WASHINGTON
DC
20037
US
|
Assignee: |
INDUSTRIAL TECHNOLOGY RESEARCH
INSTITUTE
|
Family ID: |
21679604 |
Appl. No.: |
10/282083 |
Filed: |
October 29, 2002 |
Current U.S.
Class: |
428/397 ;
428/365; 442/192; 442/195; 442/309; 442/334; 442/335; 442/337 |
Current CPC
Class: |
D01F 6/62 20130101; D04H
3/011 20130101; Y10T 442/3089 20150401; Y10T 442/611 20150401; D04H
1/435 20130101; D01F 6/06 20130101; Y10T 428/2973 20150115; Y10T
442/608 20150401; Y10T 442/609 20150401; D04B 1/14 20130101; D04H
1/4291 20130101; D10B 2321/022 20130101; D10B 2401/041 20130101;
D03D 15/283 20210101; D10B 2331/04 20130101; Y10T 428/2915
20150115; D04H 1/4334 20130101; D04H 3/16 20130101; Y10T 442/431
20150401; D01D 5/253 20130101; D01F 6/60 20130101; Y10T 442/68
20150401; D10B 2331/02 20130101; D04H 1/43912 20200501; D10B
2321/02 20130101; Y10T 442/3114 20150401; D03D 15/37 20210101 |
Class at
Publication: |
428/397 ;
428/365; 442/334; 442/335; 442/337; 442/309; 442/192; 442/195 |
International
Class: |
D03D 015/00; D04B
001/14; D04B 007/00; D04B 021/14; D04H 001/00; D04H 003/00; D04H
005/00; D04H 013/00; D02G 003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 29, 2001 |
TW |
90126697 |
Claims
What is claimed is:
1. A method of fabricating a non-hollow fiber having regular
polygonal cross-section, comprising the following steps: melting a
thermoplastic polymer; extruding the melted polymer through a
spinneret orifice having a regular polygonal cross-section to form
molten filaments; and solidifying the molten filaments to form the
non-hollow fiber having regular polygonal cross-section.
2. The method as claimed in claim 1, further comprising the steps
of stretching and false twisting the solidified filaments.
3. The method as claimed in claim 1, wherein the fabricated fiber
has a regular rectangular cross-section.
4. The method as claimed in claim 1, wherein the fabricated fiber
has a regular triangular cross-section.
5. The method as claimed in claim 1, wherein the plastic polymer is
selected from the group consisting of polyester, polyamide and
polyolefin.
6. The method as claimed in claim 5, wherein the polyester is
poly(ethylene terephthalate).
7. The method as claimed in claim 5, wherein the polyamide is Nylon
6 or Nylon 66.
8. The method as claimed in claim 5, wherein the polyolef in is
polypropylene.
9. The method as claimed in claim 1, wherein the melting is
performed at a temperature between 150-300.degree. C.
10. A non-hollow fiber having regular polygonal cross-section
fabricated by the method as claimed in claim 1.
11. The non-hollow fiber as claimed in claim 10, having a fineness
of 0.5-5 d.p.f.
12. A fabric made by the non-hollow fiber as claimed in claim
10.
13. The fabric as claimed in claim 12 in the form of woven fabric,
knitted fabric or non-woven fabric.
14. The fabric as claimed in claim 13, having an lightness value
(L) higher than 95 and the windproof coefficient is at least 15%
higher than that of a fiber having a round cross-section.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of fabricating a
non-hollow fiber having a regular polygonal cross-section. In
particular, the present invention relates to a method of
fabricating a non-hollow fiber having a regular rectangular or
regular triangular cross-section. The present invention also
relates to a fabric manufactured by the fibers, which demonstrates
good windproof characteristic and brightness.
[0003] 2. Description of the Related Art
[0004] Many efforts have been made to improve the characteristics
of synthetic filaments or fibers so as to provide fabrics or
textiles having good performances and functions, such as
moisture-absorbing properties, sweat-expelling properties,
antistatic properties, sustained release characteristics,
antibacterial properties, thermal insulation, windproof
characteristics and brightness.
[0005] U.S. Pat. No. 5,057,368 issued to Largman et al, discloses
trilobal or quardrilobal filaments useful in such diverse
applications such as filtering, wicking, insulating and other
applications.
[0006] U.S. Pat. No. 5,279,879 issued to Goodall et al, discloses
hollow synthetic filaments having a four sided cross-section and
four substantially equispaced continuous voids. The filaments are
especially suitable for making carpets which demonstrate improved
soil-resistance.
[0007] Fabrics or textiles in which the filaments or yarns are
woven in a dense structure are suitable for manufacturing clothes
that require good windproof characteristics. Such clothes are
conventionally made of ultra-fine filaments. The need for
ultra-fine filaments inevitably increases the cost of the
clothes.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is therefore to provide
fabrics or textiles that demonstrate superior windproof
characteristics, and can be made at a lower cost.
[0009] To attain the object, the invention provides non-hollow
fibers or filaments having regular polygonal cross-section. As the
fibers or filaments are solid and have equilateral sides in
cross-section, the fibers or filaments can be arranged in a denser
manner when woven, and thus the resulting fabrics or clothes have
superior windproof characteristics.
[0010] According to another aspect of the inventions as there is no
need to use ultra-fine filaments, the production cost of
manufacturing windproof clothes is significantly reduced.
[0011] According to a further aspect of the invention, as the
filaments or yearns can be woven in a more dense manner, the heat
insulating properties and the brightness of the woven fabrics or
textiles are also significantly improved.
[0012] The fibers or filaments of the present invention are made by
using a spinneret orifice having a regular polygonal
cross-section.
[0013] Specifically, the fibers or filaments of the invention are
made by melting a thermoplastic polymer; extruding the melted
polymer through a spinneret orifice having a regular polygonal
cross-section to form molten filaments; and solidifying the molten
filaments. Usually, the solidified filaments are subsequently
subjected to stretching and false twisting processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention can be more fully understood by
reading the subsequent detailed description in conjunction with the
examples and references made to the accompanying drawing,
wherein:
[0015] FIG. 1 is a photo showing the cross-section of the
non-hollow rectangular cross-sectional filaments made in example 1;
and
[0016] FIG. 2 is a photo showing the cross-section of the
non-hollow triangular cross-sectional filaments made in example
3.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The fibers or filaments of the invention are non-hollow
fibers and filaments having regular polygonal cross-section. The
preferred filaments of the invention are those that have regular
rectangular or regular triangular cross-section, although the
invention is not limited to the preferred filaments.
[0018] The term "regular polygonal" indicates that each side of the
polygon has equal length, that is, is a regular polygonal.
[0019] The filaments are prepared by spinning molten polymer
through spinneret capillaries or orifices designed to provide the
desired configuration of the cross-section of the filaments. That
is, the orifices are designed and formed in a configuration having
a corresponding regular polygonal cross-section.
[0020] The filaments may be prepared from synthetic thermoplastic
polymers melt-spinnable. Examples of these polymers include but are
not limited to polyester, polyamide and polyolefin.
[0021] Polyesters that are suitable for use in this invention are
those derived from the condensation f aromatic and cycloaliphatic
dicarboxylic acids and may be cycloaliphatic, aliphatic or aromatic
polyesters. Examples or these polyesters are poly(ethylene
terephthalate), poly(cyclohexylenedimethylene terephthalate),
poly(lactide), poly(butylenes terephthalate), poly(glycolic acid)
and poly(ethylene adipate). Among these, poly(ethylene
terephthalate) is preferred. Other examples of suitable polyesters
are those mentioned in U.S. Pat. Nos. 4,454,196, 4,410,073 and
4,359,557 incorporated herein for references.
[0022] Polyamides of the above description are well known in this
art and include, for example nylon 6 (poly(6-aminohexanoic acid)),
nylon 66 (poly(hexamethyleneadipamide)), nylon 4
(poly(4-aminobutyric acid)), nylon 11 (poly(11-amino-undecanoic
acid) and the like. The preferred polyamides are nylon 6 and nylon
66. Other examples of suitable polyamides can be seen from "Textile
fiber handbook", 5.sup.th edition, Trowbridge GB (1984), pp
19-20.
[0023] Examples of polyolefin that can be used in this invention as
raw material include, but are not limited to polyethylene,
polypropylene, polyisobutene, poly(4-methyl-1-pentene),
poly(3-methyl-1-butene), and poly(1-hexene). Among these
polyolefins, polypropylene is preferred. Other examples of useful
polyolefins can be found from U.S. Pat. Nos. 4,137,391, 4,562,869,
4,567,092 and 4,559,862 included herein for reference. Also, a
blend of the above-mentioned polymers is also suitable for use
according to the present invention.
[0024] The manufacturing method of the fibers or filaments of the
invention are substantially the same as conventional melt spinning
techniques except that a spinneret orifice having a configuration
sufficient to provide a fiber having regular polygonal
cross-section is used. The raw material, ie., the plastic polymers
is melted and is extruded through the spinneret to form molten
filaments. The melting temperature is usually between
150-300.degree. C. depending on the melting point of the polymer
used and the type of the spinneret selected. For example, if
polyethylene terephthalate is used as raw material, it is heated to
270-300.degree. C. to melt, and if polypropylene is used, the
melting temperature is preferably between 200-280.degree. C.
[0025] In the melt spinning process, the molten polymer is extruded
into air or other gas, or into a suitable liquid to cool and
solidify the molten filaments. Usually, the solidifying process is
conducted by using quenching gases, for example chilled air, at a
temperature of about 10-25.degree. C. The temperature and the
velocity of the quenching air blown to the molten filaments may
vary depending on the polymer used and the desired properties of
the filament. Usually, the filaments are also lubricated with oil
at about 100-120 cm from the orifice of the spinneret so as to
facilitate the solidifying process. The oil amount (OPU, oil per
unit) used is about 0.5-0.8% and may vary depending on the polymer
used and other spinning conditions. Before being taken up, the
filaments may be subjected to further processing such as stretching
and false twisting to increase their bulk. Note that in the
stretching and false twisting process, it is important to maintain
the regular polygonal cross-section of the filaments. This can
usually be attained by properly adjusting the machine used for
performing these operations.
[0026] The fibers or filaments produced by the above process have a
solid and regular polygonal cross-section and have a fineness of
0.5-5 dpf (denier per filament). The fibers of the invention can be
employed in many applications, and are not limited to the
fabrication of woven, non-woven, and knitted fabrics or clothes.
The fibers of the invention are particularly suited for use in the
fabrication of fabrics or textiles that require superior wind
proofing, brightness and heat insulation.
[0027] The following examples are presented to further illustrate
the invention and are not to be construed as limitations
thereon.
EXAMPLE 1
The Preparation of Fibers Having Regular Rectangular Cross-Section
(1)
[0028] A melt dope containing R-PET (intrinsic viscosity=0.64,
Shinkong Synthetic Fibers Corporation) was prepared by melting the
polymer at 280.degree. C. The melt was then spun at 32.8
grams/minute through a spinneret having regular rectangular
orifice. The filaments extruded from the orifice were then cooled
by blowing with a quenching air of 16.1.degree. C. at 0.44
meter/sec. velocity. After quenching, the filaments were treated
with an aqueous liquid containing 10% oil by contacting an
applicator located at a distance of 110 cm from the orifice so as
to facilitate the solidifying of the hot filaments. The oil per
unit of the treatment was 0.6%. The cooled and solidified filaments
were then taken up by passing through a pair of driven take-up
rolls at a speed of 3000 meter/minute. The obtained yarn bundles
are 100 denier, and 24 filaments per yarn bundle. The strength
(gram/denier) and the elongation (%) of the yarn bundles were first
tested. The yarn bundles were then subjected to stretching and
false twisting, and tested for their strength and elongation. The
results are summarized in Table 1 below. The cross-section of the
resulting fiber is shown in FIG. 1.
EXAMPLE 2
The Preparation of Fibers Having Regular Rectangular Cross-Section
(1)
[0029] A melt dope containing PET (intrinsic viscosity=0.64) was
prepared by melting the polymer at 280.degree. C. The melt was then
spun at 65.6 grams/minute through a spinneret having regular
rectangular orifice. The filaments extruded from the orifice were
then cooled by blowing with a quenching gas of 16.1.degree. C. at
0.44 meter/sec. velocity. After quenching, the filaments were
treated with an aqueous liquid containing 10% oil by contacting an
applicator located at a distance of 110 cm from the orifice so as
to facilitate the solidifying of the hot filaments. The oil per
unit of the treatment was 0.6%. The cooled and solidified filaments
were then taken up by passing through a pair of driven take-up
rolls at a speed of 3000 meter/minute. The obtained yarn bundles
are 200 denier, and 24 filaments per yarn bundle. The strength
(gram/denier) and the elongation (%) of the yarn bundles were first
tested. The yarn bundles were then subjected to stretching and
false twisting, and tested for their strength and elongation. The
results are summarized in Table 1 below. The cross-section of the
resulting fiber is shown in FIG. 1.
COMPARATIVE EXAMPLE 1
The Preparation of Fibers Having Round Cross-Section (1)
[0030] A melt dope containing R-PET (intrinsic viscosity=0.64) was
prepared by melting the polymer at 280.degree. C. The melt was then
spun at 31.8 grams/minute through a spinneret having round orifice.
The filaments extruded from the orifice were then cooled by blowing
with a quenching gas of 16.1.degree. C. at 0.44 meter/sec.
velocity. After quenching, the filaments were treated with an
aqueous liquid containing 10% oil by contacting an applicator
located at a distance of 110 cm from the orifice so as to
facilitate the solidifying of the hot filaments. The oil per unit
of the treatment was 0.6%. The cooled and solidified filaments were
then taken up by passing through a pair of driven take-up rolls at
a speed of 3000 meter/minute. The obtained yarn bundles are 100
denier, and 24 filaments per yarn bundle. The strength
(gram/denier) and the elongation (%) of the yarn bundles were first
tested. The yarn bundles were then subjected to stretching and
false twisting, and tested for their strength and elongation. The
results are summarized in Table 1 below.
COMPARATIVE EXAMPLE 2
The Preparation of Fibers Having Round Cross-Section (2)
[0031] A melt dope containing R-PET (intrinsic viscosity=0.64) was
prepared by melting the polymer at 280.degree. C. The melt was then
spun at 65.1 grams/minute through a spinneret having round orifice.
The filaments extruded from the orifice were then cooled by blowing
with a quenching gas of 16.1.degree. C. at 0.44 meter/sec.
velocity. After quenching, the filaments were treated with an
aqueous liquidcontaining 10% oil by contacting an applicator
located at a distance of 110 cm from the orifice so as to
facilitate the solidifying of the hot filaments. The oil per unit
of the treatment was 0.6%. The cooled and solidified filaments were
then taken up by passing through a pair of driven take-up rolls at
a speed of 3000 meter/minute. The obtained yarn bundles are 200
denier, and 24 filaments per yarn bundle. The strength
(gram/denier) and the elongation (%) of the yarn bundles were first
tested. The yarn bundles were then subjected to stretching and
false twisting, and tested for their strength and elongation. The
results are summarized in Table 1 below.
1 TABLE 1 Before After stetching stetching Example (1) 103d
Strength (g/d) Elongation (%) 68.21d Strength (g/d) Elongation (%)
Regular Average 2.54 115.26 Average 4.69 36.88 rectangular Standard
0.27 13.94 Standard 0.15 4.06 derivation derivation variation 10.60
12.09 variation 3.25 11.0 Example (2) 197.93d Strength (g/d)
Elongation (%) 135.08d Strength (g/d) Elongation (%) Regular
Average 2.29 123.87 Average 3.79 39.60 rectangular Standard 0.15
10.69 Standard 0.18 5.16 derivation derivation variation 6.65 8.63
variation 4.75 13.03 Comparative example (1) 98.73d Strength (g/d)
Elongation (%) 67.8d Strength (g/d) Elongation (%) Round Average
2.48 114.99 Average 4.57 40.81 Standard 0.12 6.07 Standard 0.09
2.30 derivation derivation variation 4.74 5.28 variation 1.97 5.64
Comparative example (2) 201d Strength (g/d) Elongation (%) 124.6d
Strength (g/d) Elongation (%) Round Average 2.41 143.88 Average
4.49 38.44 Standard 0.13 10.00 Standard 0.19 3.08 derivation
derivation variation 5.25 6.95 variation 4.18 8.01 Note: d:
denier
EXAMPLE 3
The Preparation of Fibers Having Regular Triangular Cross-Section
(2)
[0032] A melt dope containing R-PET (intrinsic viscosity=0.64) was
prepared by melting the polymer at 280.degree. C. The melt was then
spun at 32.8 grams/minute through a spinneret having round orifice.
The filaments extruded from the orifice were then cooled by blowing
with a quenching air of 16.1.degree. C. at 0.44 meter/sec.
velocity. After quenching, the filaments were treated with an
aqueous liquid containing 10% oil by contacting an applicator
located at a distance of 110 cm from the orifice so as to
facilitate the solidifying of the hot filaments. The oil per unit
of the treatment was 0.6%. The cooled and solidified filaments were
then taken up by passing through a pair of driven take-up rolls at
a speed of 3000 meter/minute. The obtained yarn bundles are 100
denier, and 24 filaments per yarn bundle. The strength
(gram/denier) and the elongation (%) of the yarn bundles were first
tested. The yarn bundles were then subjected to stretching and
false twisting. The cross-section of the resulting fiber is shown
in FIG. 2.
[0033] The fibers obtained respectively from example 1 and
comparative example 1 were woven into fabrics. Sample fabrics were
prepared and the wind resistance coefficient (WRC) of the sample
fabrics were tested. The test results are indicated Table 2
below.
2TABLE 2 flow rate (1/min) of WRC (comparative wind (mmH.sub.2O)
WRC (example) (mmH.sub.2O) example 1) (mmH.sub.2O) 10 3.4 2.1 20
6.8 4.9 40 10.5 10.7 60 18.4 18.3 80 30.5 22.4
[0034] As can be seen from Table 2, the wind resistance coefficient
of the fabrics made by the fibers of the invention is about 15%
higher than that of the fabrics made by conventional fibers which
have a round cross-section.
[0035] The lightness (L) of the sample fabrics made by the fibers
of example 1 and comparative example 1 were also tested. The tested
data shows that the L value of sample fabrics of example 1 is 93.84
while the L value of the fabrics of comparative example 1 is 92.45.
It is indicative from the data as shown above that the fibers of
the present invention have almost the same mechanical
characteristics as conventional fibers, but the windproof
characteristics, brightness and heat insulation are superior to
conventional fibers.
[0036] While the invention has been described by way of example and
in terms of the preferred embodiments, it is to be understood that
the invention is not limited to the disclosed embodiments. To the
contrary, it is intended to cover various modifications and similar
arrangements (as would be apparent to those skilled in the art).
Therefore, the scope of the appended claims should be accorded the
broadest interpretation so as to encompass all such modifications
and similar arrangements.
* * * * *