U.S. patent application number 11/300952 was filed with the patent office on 2006-05-04 for polyester monofilaments.
Invention is credited to Kenneth B. Atwood, Anne-Marie Coffin, John D. Feathers, Richard Allen Hayes, Charles F. Nelson.
Application Number | 20060093819 11/300952 |
Document ID | / |
Family ID | 33097570 |
Filed Date | 2006-05-04 |
United States Patent
Application |
20060093819 |
Kind Code |
A1 |
Atwood; Kenneth B. ; et
al. |
May 4, 2006 |
Polyester monofilaments
Abstract
The present invention provides monofilaments coated with certain
adhesive layers and methods to produce the coated filaments. Also
provided are fabrics formed from the monofilaments. The coated
monofilaments and fabrics provide improved adhesion with additional
coating top layers.
Inventors: |
Atwood; Kenneth B.;
(Hendersonville, TN) ; Coffin; Anne-Marie;
(Monroe, NJ) ; Feathers; John D.; (Vienna, WV)
; Hayes; Richard Allen; (Brentwood, TN) ; Nelson;
Charles F.; (Parkersburg, WV) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY;LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
33097570 |
Appl. No.: |
11/300952 |
Filed: |
December 15, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10407574 |
Apr 4, 2003 |
|
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11300952 |
Dec 15, 2005 |
|
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Current U.S.
Class: |
428/364 |
Current CPC
Class: |
Y10T 428/2913 20150115;
Y10T 442/641 20150401; Y10T 428/2969 20150115; Y10T 428/2964
20150115; Y10T 428/2933 20150115; D01F 8/10 20130101; D06N 3/04
20130101; Y10T 428/2929 20150115; D01F 8/14 20130101; Y10T 442/2861
20150401; Y10T 428/2924 20150115; D06N 3/183 20130101; D01D 11/06
20130101 |
Class at
Publication: |
428/364 |
International
Class: |
D02G 3/00 20060101
D02G003/00 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. A monofilament comprising a polyester core and a core coating,
wherein said core coating comprises a vinylidene chloride
copolymer, and wherein said vinylidene chloride copolymer comprises
35 to 96 weight percent vinylidene chloride, from about 3.5 to
about 64.5 weight percent of an acrylic ester, and from about 0.5
to about 25 weight percent of itaconic acid based on weight of
copolymer.
5. The monofilament of claim 4 wherein said vinylidene chloride
copolymer comprises about 75 to about 95 weight percent vinylidene
chloride, about 4 to about 20 weight percent of an acrylic ester,
and about 1 to about 5 weight percent of itaconic acid based on
weight of copolymer.
6. The monofilament of claim 4 wherein said acrylic ester is
selected from alkyl esters of acrylic acid or methacrylic acid with
1 to 18 carbon atoms in the alkyl group.
7. The monofilament of claim 4 wherein said vinylidene chloride
copolymer is blended with a polyacrylate ester.
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. (canceled)
13. A textile fabric comprising the polyester monofilament of claim
4.
14. A textile fabric comprising a polyester monofilament and a
fabric coating of a vinylidene chloride.
15. The textile fabric of claim 14 wherein the polyester
monofilament comprises a polyester core and a core coating, said
core coating comprising a vinylidene chloride copolymer.
16. The textile fabric of claim 14 wherein said vinylidene chloride
copolymer comprises from about 35 to about 96 weight percent
vinylidene chloride and from about 4 to about 65 weight percent of
at least one other polymerizable olefin monomer based on weight of
copolymer.
17. The textile fabric of claim 14 wherein said vinylidene chloride
copolymer comprises about 35 to about 96 weight percent vinylidene
chloride, about 3.5 to about 64.5 weight percent of an acrylic
ester, and about 0.5 to about 25 weight percent of itaconic acid
based on weight of copolymer.
18. The textile fabric of claim 14 wherein said vinylidene chloride
copolymer comprises about 75 to about 95 weight percent vinylidene
chloride, about 4 to about 20 weight percent of an acrylic ester,
and about 1 to about 5 weight percent of itaconic acid based on
weight of copolymer.
19. The textile fabric of claim 18 wherein said acrylic ester is
selected from alkyl esters of acrylic acid or methacrylic acid with
1 to 18 carbon atoms in the alkyl group.
20. The textile fabric of claim 14 wherein said vinylidene chloride
copolymer is blended with a polyacrylate ester.
21. The textile fabric of claim 14 comprising a second coating,
said second coating being selected from the group consisting of
fluorinated surfactants.
22. The textile fabric of claim 14 comprising a second coating,
said second coating being selected from the group consisting of
polyolefins, cyclic olefin polymers, modified polyolefins,
polyolefin copolymers, glycidyl esters of unsaturated acids,
ionomers, ethylene/vinyl copolymers, ethylene/vinyl chloride
copolymers, ethylene/vinyl acetate copolymers, ethylene/acrylic
acid copolymers, ethylene/methacrylic acid copolymers,
ethylene/vinyl alcohol copolymers, poly(vinyl alcohol), poly(vinyl
alcohol-cobutyral), polyurethanes, thermoplastic polyurethanes,
polyvinyl chloride, polyvinylidene chloride copolymers, liquid
crystalline polymers, fluorinated polymers, polyamides, polyimides,
polyphenylene sulfide, polyphenylene oxide, polysulfones,
polyethersulfones, rubbers, polycarbonate, polyacrylates, terpene
resins, polyacetal, styrene/acrylonitrile copolymers,
styrene/maleic anhydride copolymers, styrene/maleimide copolymers,
coumarone/indene copolymers, and combinations thereof.
23. A process for producing a polyester monofilament comprising a
polyester core and a vinylidene chloride copolymer coating, said
process comprising: providing a polyester monofilament and
depositing onto said polyester monofilament a vinylidene chloride
copolymer to form said coating, drawing coated polyester
monofilament to a draw ratio from about 3.0:1 to about 6.5:1 at a
temperature up to about 250.degree. C.
24. The process of claim 23, wherein the polyester monofilament is
drawn at a temperature up to about 100.degree. C. to a length
corresponding to a draw ratio of about 3.0:1 to about 4.5:1.
25. The process of claim 23 wherein, following said drawing, the
polyester monofilament is allowed to relax to about 30 percent of
its drawn length.
26. The process of claim 23, further comprising depositing onto
said coated polyester monofilament a second coating.
27. A process for producing a textile fabric comprising providing a
textile fabric made from polyester monofilament, depositing onto
said polyester monofilament textile fabric a vinylidene chloride
copolymer to form a coating, and subjecting coated fabric to a
temperature up to about 250.degree. C.
28. The process of claim 27 wherein after coating is applied, a
vacuum is applied across the fabric and coated fabric is subjected
to a temperature up to about 250.degree. C.
29. The process of claim 27 wherein after coating is applied, a
pressure is applied across the fabric and coated fabric is
subjected to a temperature up to about 250.degree. C.
30. The process of claim 28 wherein the textile fabric comprises a
woven polyester monofilament textile fabric.
31. The process of claim 28 comprising depositing onto one or more
first coatings of a vinylidene chloride copolymer, and a second
coating, the second coating being applied after subjecting fabric
to temperature up to about 250.degree. C. for sufficient time to
dry first coating of vinylidene chloride copolymer.
32. The process of claim 29 wherein the textile fabric comprises a
woven polyester monofilament textile fabric.
33. The process of claim 29 comprising depositing onto one or more
first coatings of a vinylidene chloride copolymer, and a second
coating, the second coating being applied after subjecting fabric
to temperature up to about 250.degree. C. for sufficient time to
dry first coating of vinylidene chloride copolymer.
Description
BACKGROUND OF THE INVENTION
[0001] Polymeric monofilaments are used as reinforcements for
rubbers, in fishing lines, in toothbrush bristles, in paintbrush
bristles and the like. In addition, woven fabrics produced from
monofilaments are used, for example, in industrial belts and paper
machine clothing.
[0002] Polyester monofilaments offer high strength and good
dimensional stability. For example, U.S. Pat. No. 3,051,212 and
U.S. Pat. No. 3,869,427 disclose the use of polyester monofilaments
as reinforcements for rubber articles. The use of polyester
monofilaments to make fabric for processing and drying wet pulp to
make paper is described in U.S. Pat. No. 3,858,623, U.S. Pat. No.
4,071,050, U.S. Pat. No. 4,374,960, U.S. Pat. No. 5,169,499, U.S.
Pat. No. 5,169,711, U.S. Pat. No. 5,283,110, U.S. Pat. No.
5,297,590, U.S. Pat. No. 5,635,298, U.S. Pat. No. 5,692,938, U.S.
Pat. No. 5,885,709, and Kirk-Othmer Encyclopedia of Chemical
Technology (2nd Ed.) (Interscience) 1967, Vol. 14, pp. 503-508 and
the references cited therein. For example, linear poly(ethylene
terephthalate)s having inherent viscosities between 0.60 and 1.0
dL/g are known for use in the production of monofilaments.
Generally, it has been disclosed that the inherent viscosity is
greater than 0.70 dL/g. U.S. Pat. No. 3,051,212, U.S. Pat. No.
3,627,867, U.S. Pat. No. 3,657,191, U.S. Pat. No. 3,869,427, U.S.
Pat. No. 3,959,215, U.S. Pat. No. 3,959,228, U.S. Pat. No.
3,975,329, U.S. Pat. No. 4,016,142, U.S. Pat. No. 4,017,463, U.S.
Pat. No. 4,139,521, U.S. Pat. No. 4,374,960, U.S. Pat. No.
5,472,780, U.S. Pat. No. 5,635,298, U.S. Pat. No. 5,763,538, and
U.S. Pat. No. 5,885,709 disclose the use of high molecular weight,
linear polyesters for use in the manufacture of monofilaments. The
inherent viscosity of a polymer is an indicator of its molecular
weight.
[0003] For many end uses, hydrolysis resistance is desired.
Enhancement of hydrolysis resistance by reducing the content of
carboxyl end groups is disclosed, for example, in U.S. Pat. No.
3,051,212, U.S. Pat. No. 3,657,191, U.S. Pat. No. 4,139,521, U.S.
Pat. No. 4,374,961, U.S. Pat. No. 5,246,992, U.S. Pat. No.
5,378,537 and references cited therein. Hydrolysis stabilization
additives have also been disclosed. Generally, the hydrolysis
stabilization additives have been disclosed to function by reacting
with free polymeric carboxyl end groups. U.S. Pat. No. 3,051,212
and U.S. Pat. No. 4,374,960 disclose the use of diazomethane to
"cap" the polyester carboxyl end groups to enhance the hydrolysis
resistance. Carbodiimides are disclosed as polyester hydrolysis
stabilization additives in U.S. Pat. No. 3,193,522, U.S. Pat. No.
3,193,523, U.S. Pat. No. 3,975,329, U.S. Pat. No. 5,169,499, U.S.
Pat. No. 5,169,711, U.S. Pat. No. 5,246,992, U.S. Pat. No.
5,378,537, U.S. Pat. No. 5,464,890, U.S. Pat. No. 5,686,552, U.S.
Pat. No. 5,763,538, U.S. Pat. No. 5,885,709 and U.S. Pat. No.
5,886,088. Epoxides are disclosed as polyester hydrolysis
stabilization additives in U.S. Pat. No. 3,627,867, U.S. Pat. No.
3,657,191, U.S. Pat. No. 3,869,427, U.S. Pat. No. 4,016,142, U.S.
Pat. No. 4,071,504, U.S. Pat. No. 4,139,521, U.S. Pat. No.
4,144,285, U.S. Pat. No. 4,374,960, U.S. Pat. No. 4,520,174, U.S.
Pat. No. 4,520,175, and U.S. Pat. No. 5,763,538. Cyclic carbonates,
such as ethylene carbonate, are disclosed as hydrolysis
stabilization additives in U.S. Pat. No. 3,657,191, U.S. Pat. No.
4,374,960, and U.S. Pat. No. 4,374,961. U.S. Pat. No. 3,959,215
discloses the use of phenylene bisoxazolines for the stabilization
of polyesters. Aziridine compounds have been disclosed in the
production of low carboxyl polyesters in U.S. Pat. No. 3,959,228
and U.S. Pat. No. 5,763,538. U.S. Pat. No. 5,763,538 discloses the
use of keteneimines and isocyanates as polyester monofilament
hydrolysis stabilization additives.
[0004] Monofilaments having desired surface characteristics can be
prepared, for example, by the application of a coating to preformed
monofilaments or by the melt spinning of sheath-core bicomponent
monofilaments. Monofilaments can also be treated after having been
woven into fabrics, as, for example, disclosed by Beaumont, et al.,
in U.S. Pat. No. 3,032,441. Fleischer, et al., in U.S. Pat. No.
4,731,281, discloses the coating of monofilaments with polymeric
solutions or dispersions. Cordova, et al., in U.S. Pat. No.
4,767,646, discloses aqueous based overfinish compositions for
monofilaments, which include an oxidized polyethylene emulsified
with a non-nitrogen, nonionic emulsifier and neutralized with an
alkali hydroxide and a compound selected from the group consisting
of a siloxane of the comonomers dimethyl and
3-[(2-aminoethyl)aminopropyl], and an amide melamine wax. Leydon,
et al., in U.S. Pat. No. 5,580,609, discloses a method to produce a
monofilament coated with an amide melamine wax.
[0005] Polyester monofilaments having coatings with improved
adhesion to the monofilaments are desired. The processes and
monofilaments disclosed herein utilize certain copolymers as
adhesives or tie layers that provide enhanced adhesion between the
coating materials and the monofilament.
BRIEF SUMMARY OF THE INVENTION
[0006] One aspect of the present invention is a monofilament
composition comprising a polyester core coated with one or more
vinylidene chloride copolymers.
[0007] Another aspect of the present invention is a textile fabric
produced from a monofilament composition comprising a polyester
core coated with one or more vinylidene chloride copolymers.
[0008] A further aspect of the present invention is a process for
producing a polyester monofilament coated with one or more
vinylidene chloride copolymers. The process includes providing a
polyester filament and depositing onto the polyester filament a
vinylidene chloride copolymer to form a coating.
[0009] Another aspect of the present invention is a process for
producing a textile fabric comprising a polyester monofilament
coated with one or more vinylidene chloride copolymers. The process
includes providing a polyester monofilament textile fabric and
depositing onto the polyester monofilament textile fabric a
vinylidene chloride copolymer to form a coating.
[0010] A further aspect of the present invention is a process for
improving the adhesion between polyester monofilaments and coatings
by depositing onto the polyester monofilaments a vinylidene
chloride copolymer tie layer and then applying one or more
coatings.
[0011] A further aspect of the present invention is a monofilament
composition, or textile fabric produced there from, which includes
a polyester core, one or more coatings and one or more vinylidene
chloride copolymer tie layers.
[0012] A further aspect of the present invention is a process for
producing a polyester monofilament having a polyester core, one or
more coatings and one or more vinylidene chloride copolymer tie
layers. The process includes providing a polyester filament,
depositing onto the polyester filament a vinylidene copolymer to
form a first coating, and depositing onto the first coating a
second coating.
[0013] Another aspect of the present invention is a process for
producing a textile fabric comprising a polyester monofilament
having a polyester core, one or more coatings and one or more
vinylidene chloride copolymer tie layers. In some embodiments, the
process includes providing a polyester monofilament textile fabric
and depositing onto the polyester monofilament textile fabric a
vinylidene chloride copolymer, and depositing onto said tie layer
one or more coatings. In other embodiments, the process includes
providing a polyester filament, depositing onto the polyester
filament a vinylidene copolymer to form a first coating, depositing
onto said first coating a second coating to form a coated polyester
monofilament, and forming a textile fabric from the
monofilament.
[0014] These and other aspects of the invention will be apparent to
those skilled in the art in view of the following disclosure and
the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention provides monofilaments comprising a
polyester core coated with certain vinylidene chloride copolymers,
textile fabrics produced from monofilaments coated with vinylidene
chloride copolymers, and processes for producing the monofilaments
and textile fabrics. The polyester monofilaments contain 100 to 99
mole percent of a dicarboxylic acid component; 100 to 99 mole
percent of a diol; and 0 to 1 mole percent of a polyfunctional
branching agent. The dicarboxylic acid component can be selected
from dicarboxylic acids and lower esters of dicarboxylic acids.
[0016] The dicarboxylic acid component is selected from
unsubstituted and substituted aromatic, aliphatic, unsaturated, and
alicyclic dicarboxylic acids and the lower alkyl esters of
dicarboxylic acids preferably having from 2 carbons to 36 carbons.
Specific examples of suitable dicarboxylic acid components include
terephthalic acid, dimethyl terephthalate, isophthalic acid,
dimethyl isophthalate, 2,6-napthalene dicarboxylic acid,
dimethyl-2,6-naphthalate, 2,7-naphthalenedicarboxylic acid,
dimethyl-2,7-naphthalate, 3,4'-diphenyl ether dicarboxylic acid,
dimethyl-3,4'diphenyl ether dicarboxylate, 4,4'-diphenyl ether
dicarboxylic acid, dimethyl-4,4'-diphenyl ether dicarboxylate,
3,4'-diphenyl sulfide dicarboxylic acid, dimethyl-3,4'-diphenyl
sulfide dicarboxylate, 4,4'-diphenyl sulfide dicarboxylic acid,
dimethyl-4,4'-diphenyl sulfide dicarboxylate, 3,4'-diphenyl sulfone
dicarboxylic acid, dimethyl-3,4'-diphenyl sulfone dicarboxylate,
4,4'-diphenyl sulfone dicarboxylic acid, dimethyl-4,4'-diphenyl
sulfone dicarboxylate, 3,4'-benzophenonedicarboxylic acid,
dimethyl-3,4'-benzophenonedicarboxylate,
4,4'-benzophenonedicarboxylic acid,
dimethyl-4,4'-benzophenonedicarboxylate, 1,4-naphthalene
dicarboxylic acid, dimethyl-1,4-naphthalate, 4,4'-methylene
bis(benzoic acid), dimethyl-4,4'-methylenebis(benzoate), oxalic
acid, dimethyl oxalate, malonic acid, dimethyl malonate, succinic
acid, dimethyl succinate, methylsuccinc acid, glutaric acid,
dimethyl glutarate, 2-methylglutaric acid, 3-methylglutaric acid,
adipic acid, dimethyl adipate, 3-methyladipic acid, 2,2,5,5
tetramethylhexanedioic acid, pimelic acid, suberic acid, azelaic
acid, dimethyl azelate, sebacic acid, 1,11-undecanedicarboxylic
acid, 1,10-decanedicarboxylic acid, undecanedioic acid,
1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic
acid, tetracosanedioic acid, dimer acid,
1,4-cyclohexanedicarboxylic acid,
dimethyl-1,4-cyclohexanedicarboxylate, 1,3-cyclohexanedicarboxylic
acid, dimethyl-1,3-cyclohexanedicarboxylate,
1,1-cyclohexanediacetic acid, metal salts of
5-sulfo-dimethylisophalate, fumaric acid, maleic anhydride, maleic
acid, hexahydrophthalic acid phthalic acid and the like and
mixtures derived there from. Other dicarboxylic acids suitable for
use in forming the monofilaments will be apparent to those skilled
in the art. Preferred dicarboxylic acids include terephthalic acid,
dimethyl terephthalate, isophthalic acid, and dimethyl
isophthalate.
[0017] The diol component is selected from unsubstituted,
substituted, straight chain, branched, cyclic aliphatic,
aliphatic-aromatic or aromatic diols having from 2 carbon atoms to
36 carbon atoms and poly(alkylene ether) glycols with molecular
weights between about 250 to 4,000. Specific examples of the
desirable diol component include ethylene glycol, 1,3-propanediol,
1,4-butanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol,
1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, dimer
diol, 4,8-bis(hydroxymethyl)-tricyclo[5.2.1.0/2.6]decane,
1,4-cyclohexanedimethanol, di(ethylene glycol), tri(ethylene
glycol), poly(ethylene ether) glycols with molecular weights
between 250 and 4000, poly(1,2-propylene ether) glycols with
molecular weights between 250 and 4000, block
poly(ethylene-co-propylene-co-ethylene ether) glycols with
molecular weights between 250 and 4000, poly(1,3-propylene ether)
glycols with molecular weights between 250 and 4000, poly(butylene
ether) glycols with molecular weights between 250 and 4000 and the
like and mixtures derived there from. Other diols suitable for use
in forming the monofilaments will be apparent to those skilled in
the art.
[0018] The polyfunctional branching agent can be any material with
three or more carboxylic acid functional groups, hydroxy functional
groups or a mixture thereof. The term "carboxylic acid functional
groups" is meant to include carboxylic acids, lower alkyl esters of
carboxylic acids, glycolate esters of carboxylic acids, and the
like and mixtures thereof. Specific examples of desirable
polyfunctional branching agent components include
1,2,4-benzenetricarboxylic acid, (trimellitic acid),
trimethyl-1,2,4-benzenetricarboxylate,
tris(2-hyroxyethyl)-1,2,4-benzenetricarboxylate,
trimethyl-1,2,4-benzenetricarboxylate, 1,2,4-benzenetricarboxylic
anhydride, (trimellitic anhydride), 1,3,5-benzenetricarboxylic
acid, 1,2,4,5-benzenetetracarboxylic acid, (pyromellitic acid),
1,2,4,5-benzenetetracarboxylic dianhydride, (pyromellitic
anhydride), 3,3',4,4'-benzophenonetetracarboxylic dianhydride,
1,4,5,8-naphthalenetetracarboxylic dianhydride, citric acid,
tetrahydrofuran-2,3,4,5-tetracarboxylic acid,
1,3,5-cyclohexanetricarboxylic acid, pentaerythritol,
2-(hydroxymethyl)-1,3-propanediol, 2,2-bis(hydroxymethyl)propionic
acid, trimer acid, and the like and mixtures there from.
Essentially any polyfunctional material that includes three or more
carboxylic acid or hydroxyl functions can be used, and such
materials will be apparent to those skilled in the art.
[0019] The polyesters preferably have an inherent viscosity (IV) in
the range of about 0.50 to 1.5 dL/g. More desirably, the inherent
viscosity of the polyesters is in the range of about 0.60 to 1.3
dL/g, as measured on a 0.5 percent (weight/volume) solution of the
polyester in a 50:50 (weight) solution of trifluoroacetic
acid:dichloromethane solvent system at room temperature. The
polymerization conditions can be adjusted by one skilled in the art
to obtain the desired inherent viscosities.
[0020] The polyesters can be prepared by conventional
polycondensation techniques. The product compositions can vary
somewhat based on the method of preparation used, particularly with
respect to the amount of diol that is present within the polymer.
Although not preferred, the polyesters can be prepared using
techniques that utilize acid chlorides. Such procedures are
disclosed, for example, in R. Storbeck, et al., J. Appl. Polymer
Science, Vol. 59, pp. 1199-1202 (1996), the disclosure of which is
hereby incorporated herein by reference.
[0021] Preferably, the polyesters are produced by melt
polymerization. In melt polymerization, the dicarboxylic acid
component, (as acids, esters, or mixtures thereof, the diol
component and the polyfunctional branching agent are combined in
the presence of a catalyst to a high enough temperature that the
monomers combine to form esters and diesters, then oligomers, and
finally polymers. The polymeric product at the end of the
polymerization process is a molten product. Generally, the diol
component is volatile and distills from the reactor as the
polymerization proceeds. Such procedures are disclosed, for
example, in U.S. Pat. No. 3,563,942, U.S. Pat. No. 3,948,859, U.S.
Pat. No. 4,094,721, U.S. Pat. No. 4,104,262, U.S. Pat. No.
4,166,895, U.S. Pat. No. 4,252,940, U.S. Pat. No. 4,390,687, U.S.
Pat. No. 4,419,507, U.S. Pat. No. 4,585,687, U.S. Pat. No.
5,053,482, U.S. Pat. No. 5,292,783, U.S. Pat. No. 5,446,079, U.S.
Pat. No. 5,480,962, and U.S. Pat. No. 6,063,464 and references
cited therein.
[0022] The melt process conditions, particularly the amounts of
monomers used, depend on the polymer composition desired. The
amount of the diol component, dicarboxylic acid component, and
branching agent are desirably chosen so that the final polymeric
product contains the desired amounts of the various monomer units,
desirably with equimolar amounts of monomer units derived from the
respective diol and diacid components. Because of the volatility of
some of the monomers, especially some of the diol components, and
depending on such variables as whether the reactor is sealed,
(i.e., is under pressure), the polymerization temperature ramp
rate, and the efficiency of the distillation columns used in
synthesizing the polymer, some of the monomers can be used in
excess at the beginning of the polymerization reaction and removed
by distillation as the reaction proceeds. This is particularly true
of the diol component.
[0023] The exact amount of monomers to be charged to a particular
reactor can be determined by a skilled practitioner, but often will
be in the ranges below. Excesses of the diacid and diol are often
desirably charged, and the excess diacid and diol is desirably
removed by distillation or other means of evaporation as the
polymerization reaction proceeds. The diol component is desirably
charged at a level 0 to 100 percent greater than the desired
incorporation level in the final product. For example, for diol
components that are volatile under the polymerization conditions,
such as ethylene glycol, 1,3-propanediol, or 1,4-butanediol, 30 to
100 percent excesses are desirably charged. For less volatile diol
components, such as the poly(alkylene ether) glycols or dimer diol,
excesses may not be required.
[0024] The amounts of monomers used can vary widely, because of the
wide variation in the monomer loss during polymerization, depending
on the efficiency of distillation columns and other kinds of
recovery and recycle systems and the like, and are only an
approximation. Exact amounts of monomers that are charged to a
specific reactor to achieve a specific composition can be
determined by a skilled practitioner.
[0025] In the melt polymerization process, the monomers are
combined, and are heated gradually with mixing with a catalyst or
catalyst mixture to a temperature in the range of 220.degree. C. to
about 300.degree. C., desirably 240.degree. C. to 295.degree. C.
The exact conditions and the catalysts depend on whether the
diacids are polymerized as true acids or as dimethyl esters. The
catalyst can be included initially with the reactants, and/or can
be added one or more times to the mixture as it is heated. The
catalyst used can be modified as the reaction proceeds. The heating
and stirring are continued for a sufficient time and to a
sufficient temperature, generally with removal by distillation of
excess reactants, to yield a molten polymer having a high enough
molecular weight to be suitable for the intended application.
[0026] Catalysts that can be used include salts of Li, Ca, Mg, Mn,
Zn, Pb, Sb, Sn, Ge, and Ti, such as acetate salts and oxides,
including glycol adducts, and Ti alkoxides. Suitable catalysts are
generally known, and the specific catalyst or combination or
sequence of catalysts used can be selected by a skilled
practitioner. The preferred catalyst and preferred conditions
differ depending on, for example, whether the diacid monomer is
polymerized as the free diacid or as a dimethyl ester, and the
exact chemical identity of the diol component.
[0027] Polymers having adequate inherent viscosity for many
applications can be made by the melt condensation process above.
Solid-state polymerization can be used to achieve even higher
inherent viscosities (molecular weights).
[0028] Polymers made by melt polymerization, after extruding,
cooling and pelletizing, can be essentially noncrystalline.
Noncrystalline material can be made semicrystalline by heating it
to a temperature above the glass transition temperature for an
extended period of time. This induces crystallization so that the
product can then be heated to a higher temperature to raise the
molecular weight. Semicrystallinity in the polymer may be preferred
for some end uses.
[0029] Crystallinity can be induced prior to solid-state
polymerization by treatment with a relatively poor solvent for
polyesters that induces crystallization. Such solvents reduce the
glass transition temperature (Tg) allowing for crystallization.
Solvent induced crystallization is known for polyesters and is
described in U.S. Pat. No. 5,164,478 and U.S. Pat. No.
3,684,766.
[0030] The semicrystalline polymer is subjected to solid-state
polymerization by placing the pelletized or pulverized polymer into
a stream of an inert gas, usually nitrogen, or under a vacuum of 1
Torr, at an elevated temperature, but below the melting temperature
of the polymer for an extended period of time.
[0031] The polyesters can contain additives, fillers, and/or other
materials. Useful additives include thermal stabilizers,
antioxidants, UV absorbers, UV stabilizers, processing aids, waxes,
lubricants, color stabilizers, and the like. Fillers include
calcium carbonate, glass, kaolin, talc, clay, carbon black, and the
like. Other materials that can be incorporated include nucleants,
pigments, dyes, delusterants such as titanium dioxide and zinc
sulfide, antiblocks such as silica, antistats, flame retardants,
brighteners, silicon nitride, metal ion sequestrants, anti-staining
agents, silicone oil, surfactants, soil repellants, modifiers,
viscosity modifiers, zirconium acid, reinforcing fibers, and the
like. The additives, fillers, and other materials can be
incorporated within the polyesters by a separate melt compounding
process utilizing any known intensive mixing process, such as
extrusion; by intimate mixing with solid granular polymer, such as
pellet blending, or by cofeeding within the monofilament
process.
[0032] The polyesters can be blended with other polymers. Such
other polymers include polyolefins, such as polyethylene,
polypropylene, polybutene, poly-4-methyl pentene, polystyrene, and
the like; cyclic olefin polymers, modified polyolefins, such as
copolymers of various alpha-olefins, glycidyl esters of unsaturated
acids, ionomers, ethylene/vinyl copolymers such as ethylene/vinyl
chloride copolymers, ethylene/vinyl acetate copolymers,
ethylene/acrylic acid copolymers, ethylene/methacrylic acid
copolymers and the like, thermoplastic polyurethanes, polyvinyl
chloride, polyvinlidene chloride copolymers, liquid crystalline
polymers, fluorinated polymers such as polytetrafluoroethylene,
ethylene tetrafluoroethylene copolymers, tetrafluoroethylene
hexafluoropropylene copolymers, polyfluoroalkoxy copolymers,
polyvinylidene fluoride, polyvinylidene copolymers, ethylene
chlorotrifluoroethylene copolymers, and the like, polyamides, such
as Nylon-6, Nylon-66, Nylon 69, Nylon 610, Nylon 611, Nylon 612,
Nylon 11, Nylon 12, and copolymers and the like, polyimides,
polyphenylene sulfide, polyphenylene oxide, polysulfones,
polyethersulfones, rubbers, polycarbonate, polyacrylates, terpene
resins, polyacetal, styrene/acrylonitrile copolymers,
styrene/maleic anhydride copolymers, styrene/maleimide copolymers,
coumarone/indene copolymers, and the like and combinations thereof.
Polyester monofilaments that incorporate thermoplastic
polyurethanes are disclosed in U.S. Pat. No. 5,169,711 and U.S.
Pat. No. 5,652,057. Polyester monofilaments that incorporate
polyphenylene sulfide are disclosed in U.S. Pat. No. 5,218,043,
U.S. Pat. No. 5,424,125, and U.S. Pat. No. 5,456,973. Polyester
monofilaments that incorporate fluoropolymers are disclosed in U.S.
Pat. No. 5,283,110, U.S. Pat. No. 5,297,590, U.S. Pat. No.
5,378,537, U.S. Pat. No. 5,407,736, U.S. Pat. No. 5,460,869, U.S.
Pat. No. 5,472,780, U.S. Pat. No. 5,489,467, and U.S. Pat. No.
5,514,472. Polyester monofilaments that incorporate
nonfluorine-containing polymers are disclosed in U.S. Pat. No.
5,686,552. Polyester monofilaments that incorporate liquid
crystalline polymers are disclosed in U.S. Pat. No. 5,692,938.
[0033] The other polymers can be incorporated within the polyesters
by a separate melt compounding process utilizing any known
intensive mixing process, such as extrusion through a single or
twin screw extruder, through intimate mixing with the solid
granular material, such as mixing, stirring or pellet blending
operations, or through cofeeding within the monofilament
process.
[0034] The polyesters can be stabilized with an effective amount of
any hydrolysis stabilization additive. The hydrolysis stabilization
additive can be any known material that enhances the stability of
the polyester monofilament to hydrolytic degradation. Examples of
the hydrolysis stabilization additive can include: diazomethane,
carbodiimides, epoxides, cyclic carbonates, oxazolines, aziridines,
keteneimines, isocyanates, alkoxy end-capped polyalkylene glycols,
and the like. Any material that increases the hydrolytic stability
of the monofilaments formed from the polyesters is suitable.
[0035] Preferred hydrolysis stabilization additives are
carbodiimides. Specific examples of carbodiimides include
N,N'-di-o-tolylcarbodiimide, N,N'-diphenylcarbodiimide,
N,N'dioctyldecylcarbodiimide,
N,N'-di-2,6-dimethylphenylcarbodiimide,
N-tolyl-N'cyclohexylcarbodiimide,
N,N'-di-2,6-diisopropylphenylcarbodiimide,
N,N'di-2,6-di-tert.-butylphenylcarbodiimide,
N-tolyl-N'-phenylcarbodiimide, N,N'-di-p-nitrophenylcarbodiimide,
N,N'di-p-aminophenylcarbodiimide,
N,N'-di-p-hydroxyphenylcarbodiimide,
N,N'-di-cyclohexylcarbodiimide, N,N'-di-p-tolylcarbodiimide,
p-phenylene-bis-di-o-tolylcarbodiimide,
p-phenylene-bisdicyclohexylcarbodiimide,
hexamethylene-bisdicyclohexylcarbodiimide,
ethylene-bisdiphenylcarbodiimide,
benzene-2,4-diisocyanato-1,3,5-tris(1-methylethyl) homopolymer, a
copolymer of 2,4-diisocyanato-1,3,5-tris(10methylethyl) with
2,6-diisoproyl diisocyanate, and the like. Such materials are
commercially sold under the tradenames: STABAXOL 1, STABAXOL P,
STABAXOL P-100, STABAXOL KE7646, (Rhein-Chemie, of Rheinau GmbH,
Germany and Bayer). The use of carbodiimides as polyester
hydrolysis stabilization additives is disclosed in U.S. Pat. No.
3,193,522, U.S. Pat. No. 3,193,523, U.S. Pat. No. 3,975,329, U.S.
Pat. No. 5,169,499, U.S. Pat. No. 5,169,711, U.S. Pat. No.
5,246,992, U.S. Pat. No. 5,378,537, U.S. Pat. No. 5,464,890, U.S.
Pat. No. 5,686,552, U.S. Pat. No. 5,763,538, U.S. Pat. No.
5,885,709 and U.S. Pat. No. 5,886,088.
[0036] Specific examples of epoxides suitable as hydrolysis
stabilization additives include iso-nonyl-glycidyl ether, stearyl
glycidyl ether, tricyclo- decylmethylene glycidyl ether, phenyl
glycidyl ether, p-tert.-butylphenyl glycidyl ether, o-decylphenyl
glycidyl ether, allyl glycidyl ether, butyl glycidyl ether, lauryl
glycidyl ether, benzyl glycidyl ether, cyclohexyl glycidyl ether,
alpha-cresyl glycidyl ether, decyl glycidyl ether, dodecyl glycidyl
ether, N-(epoxyethyl)succinimide, N-(2,3-epoxypropyl)phthalimide,
and the like. Catalysts can be included to increase the rate of
reaction, for example; alkali metal salts. Epoxides are disclosed
as polyester hydrolysis stabilization additives in U.S. Pat. No.
3,627,867, U.S. Pat. No. 3,657,191, U.S. Pat. No. 3,869,427, U.S.
Pat. No. 4,016,142, U.S. Pat. No. 4,071,504, U.S. Pat. No.
4,139,521, U.S. Pat. No. 4,144,285, U.S. Pat. No. 4,374,960, U.S.
Pat. No. 4,520,174, U.S. Pat. No. 4,520,175, U.S. Pat. No.
5,763,538, and U.S. Pat. No. 5,886,088.
[0037] Specific examples of cyclic carbonates suitable as
hydrolysis stabilization additives include ethylene carbonate,
methyl ethylene carbonate, 1,1,2,2-tetramethyl ethylene carbonate,
1,2-diphenyl ethylene carbonate, and the like. Cyclic carbonates,
such as ethylene carbonate, are disclosed as hydrolysis
stabilization additives in U.S. Pat. No. 3,657,191, U.S. Pat. No.
4,374,960, and U.S. Pat. No. 4,374,961.
[0038] The amount of hydrolysis stabilization additive required to
lower the carboxyl concentration of the polyester during its
conversion to monofilaments is dependent on the carboxyl content of
the polyester prior to extrusion into monofilaments. In general,
the amount of hydrolysis stabilization additive used is from 0.1 to
10.0 weight percent based on the polyester. Preferably the amount
of the hydrolysis stabilization additive used is in the range of
0.2 to 4.0 weight percent.
[0039] The hydrolysis stabilization additive can be incorporated
within the branched polyesters by a separate melt compounding
process as disclosed hereinabove for incorporation of other
polymers into the polyesters. However, it is preferred that the
hydrolysis additive is incorporated through cofeeding within the
monofilament process.
[0040] The polyesters can be formed into monofilaments by known
methods such as, for example, methods disclosed in U.S. Pat. No.
3,051,212, U.S. Pat. No. 3,999,910, U.S. Pat. No. 4,024,698, U.S.
Pat. No. 4,030,651, U.S. Pat. No. 4,072,457, and U.S. Pat. No.
4,072,663. As one skilled in the art will appreciate, the process
can be tailored to take into account the exact material to be
formed into monofilaments, the physical and chemical properties
desired in the monofilament and the like. The exact determination
of the spinning parameters for achieving a certain combination of
monofilament properties can be routinely carried out by determining
the dependence of the contemplated monofilament property on the
composition for the polyester and on the spinning parameters.
[0041] The polyesters are preferably dried prior to their formation
into monofilaments. To form monofilaments, the polyesters are
melted at a temperature in the range of about 150.degree. C. to
about 300.degree. C. Preferably, the polyesters are melted at a
temperature within the range of about 170.degree. C. to about
290.degree. C. The spinning can generally be carried out by use of
a spinning grid or an extruder. The extruder melts the dried
granular polyester and conveys the melt to the spinning aggregate
by a screw. It is well known that polyesters will tend to thermally
degrade based on time and temperature in the melt. It is preferred
that the time that the polyester is in the melt is minimized by the
use of the shortest practical length of pipes between the melting
of the polyester and the spinneret. The molten polyester can be
filtered through, for example, screen filters, to remove any
particulate foreign matter. The molten polyester can then be
conveyed, optionally through a metering pump, through a die to form
a monofilament. After exiting the die, the monofilaments can be
quenched in an air or a water bath to form solid monofilaments. The
monofilament can optionally be spin finished. The monofilaments can
be drawn at elevated temperatures up to 100.degree. C. between a
set of draw rolls. If the temperature is too high, sticking may
occur and/or control over the drawing of the monofilaments may be
lost. The monofilaments are preferably drawn to a draw ratio of
from 3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. Draw ratio is defined as the ratio of
the drawn monofilament length to the undrawn monofilament length.
The finished cooled monofilaments can then be wound up onto spools.
Any known process for producing monofilaments can be used to form
monofilaments from the polyesters.
[0042] In order to provide the desired tenacity, the filaments can
be drawn to a ratio of at least about 2:1. Preferably the filaments
are drawn to a ratio of at least about 4:1. The overall draw ratio
can be varied to allow for the production of a range of denier of
the monofilaments.
[0043] Monofiliments can range in size over a broad range depending
on intended use, preferably from a diameter of about 0.05
millimeters (mm) to about 5.0 mm. Typical ranges of sizes of
monofilaments used in press fabrics and dryer fabrics are 0.20 mm
to 1.27 mm in diameter. Depending upon the cross-sectional shape of
the monofilaments, monofilaments having masses within the mass of a
typical monofilament having a diameter within the stated range can
be produced, and may have diameters outside the above-stated range.
For forming fabrics, finer monofilaments are generally used, for
example, as small as 0.05 mm to about 0.9 mm in diameter. Most
often, the monofilaments used in forming fabrics have a diameter
between about 0.12 mm to about 0.4 mm. On the other hand, for
special industrial applications, monofilaments of 3.8 mm in
diameter or greater can be desired.
[0044] The monofilaments can take any cross-sectional shape, for
example; as circle, flattened figure, square, triangle, pentagon,
polygon, multifoil, dumbbell, cocoon. The term "flattened figure"
as used herein refers to an ellipse or a rectangle. The term not
only embraces a geometrically defined exact ellipse and rectangle
but also shapes similar to an ellipse or a rectangle, e.g., an
imperfect ellipse or an irregular polygon, and includes a shape
obtained by rounding the four corners of a rectangle. When a
monofilament is intended as a warp in a papermaking drier canvas, a
monofilament having the cross-sectional shape of a flattened figure
is preferably used to improve the resistance against staining and
ensure a flatness of the produced drier canvas. The monofilaments
can further be woven into textile fabrics, using known
processes.
[0045] Vinylidene copolymers suitable for use in making the
polyester filaments comprise from about 35 to about 96 weight
percent vinylidene chloride and from about 65 to about 4 weight
percent of at least one other polymerizable olefin monomer.
[0046] The vinylidene chloride copolymer can also include one or
more copolymerizable olefin monomers selected from the group
consisting of vinyl acetate, vinyl propionate, vinyl chloroacetate,
vinyl chloride, vinyl bromide, methyl acrylate, ethyl acrylate,
propyl acrylate, butyl acrylate, octyl acrylate, n-dodecyl
acrylate, n-octadecyl acrylate, methoxyethyl acrylate, chloroethyl
acrylate, methyl methacrylate, ethyl methacrylate, propyl
methacrylate, butyl methacrylate, octyl methacrylate, n-dodecyl
methacrylate, n-octadecyl methacrylate, methoxyethyl methacrylate,
chloroethyl methacrylate, 2-nitro-2-methyl-propyl methacrylate,
methyl alpha-chloroacrylate, octyl alpha-chloroacrylate, acrylic
acid, methacrylic acid, methyl vinyl ketone, methyl isopropenyl
ketone, itaconic acid, acrylonitrile, methacrylonitrile, styrene,
isobutylene, vinyl naphthalene, ethyl vinyl ether, butyl vinyl
ether, N-vinyl phthalimide, N-vinyl succinimide, N-vinyl carbazole,
N-vinyl pyrollidone, methylene diethyl malonate, and the like. Any
other polymerizable olefin monomer known can be used in making the
polyesters.
[0047] Suitable vinylidene copolymers can be produced by any known
method. Suitable methods are disclosed in U.S. Pat. No. 2,160,903,
U.S. Pat. No. 2,160,931, U.S. Pat. No. 2,160,932, U.S. Pat. No.
2,160,933, U.S. Pat. No. 2,160,934, U.S. Pat. No. 2,160,935, U.S.
Pat. No. 2,160,936, U.S. Pat. No. 2,160,937, U.S. Pat. No.
2,160,938, U.S. Pat. No. 2,160,939, U.S. Pat. No. 2,160,940, U.S.
Pat. No. 2,160,941, U.S. Pat. No. 2,160,942, U.S. Pat. No.
2,160,943, U.S. Pat. No. 2,160,945, U.S. Pat. No. 2,160,946, and
U.S. Pat. No. 2,160,947. Preferably, the vinylidene monomers are
produced through emulsion polymerization to directly produce
dispersions, using known methods. Suitable methods are disclosed in
U.S. Pat. No. 2,491,023.
[0048] Preferably, the vinylidene copolymers comprise from about 35
to about 96 weight percent vinylidene chloride, 3.5 to 64.5 weight
percent of an acrylic ester, and 0.5 to 25 weight percent of
itaconic acid. More preferably, the vinylidene copolymers comprise
from about 75 to about 95 weight percent vinylidene chloride, 4 to
20 weight percent of an acrylic ester, and 1 to 5 weight percent of
itaconic acid. The acrylic ester can be, for example, an alkyl
ester of acrylic acid or methacrylic acid with 1 to 18 carbon atoms
in the alkyl group, such as methyl acrylate, ethyl acrylate, propyl
acrylate, butyl acrylate, octyl acrylate, n-dodecyl acrylate,
n-octadecyl acrylate, methyl methacrylate, ethyl methacrylate,
propyl methacrylate, butyl methacrylate, octyl methacrylate,
n-dodecyl methacrylate, n-octadecyl methacrylate, and the like and
mixture thereof.
[0049] The vinylidene chloride copolymers can be produced using any
known methods. Preferably they are produced through emulsion
polymerization to directly produce dispersions according to known
methods. Suitable methods are disclosed in U.S. Pat. No. 2,627,088,
U.S. Pat. No. 2,698,235, and U.S. Pat. No. 2,698,240. For example,
the copolymerization can be conducted in an aqueous emulsion
containing a mixture of the monomers, a catalyst, and an activator,
e.g., ammonium persulfate and meta sodium bisulfite, and an
emulsifying and/or dispersing agent. Alternatively, the vinylidene
chloride copolymers can be prepared by polymerization of the
monomeric components in bulk without added diluent, or the monomers
can be reacted in an appropriate organic solvent reaction media.
The total catalyst-activator concentration should be generally kept
within a range of about 0.01 to about 2 weight percent based on the
total monomer charge. Preferably, the total catalyst-activator
concentration should be generally kept within a range of about 0.1
to 1.0 weight percent. Improved solubility and viscosity values for
the vinylidene copolymer are obtained by conducting the
polymerization in the presence of mercaptans, such as ethyl
mercaptan, lauryl mercaptan, tertiary dodecyl mercaptan, and the
like. The mercaptans are effective in reducing crosslinking in the
vinylidene chloride copolymer. Typically, the mercaptans are used
in the concentrations of 0.1 to 5 weight percent based on the total
monomer charge.
[0050] Preferably, the vinylidene chloride copolymer is blended
with an additional polymer selected from polyacrylate esters, such
as alkyl acrylate and/or alkyl methacrylate homopolymers or
copolymers that incorporate at least 75 weight percent of an alkyl
acrylate and/or alkyl methacrylate monomer. The alkyl acrylate and
alkyl methacrylate monomers can be chosen from a group of alkyl
esters of acrylic acid or methacrylic acid with 1 to 18 carbon
atoms in the alkyl group, for example; methyl acrylate, ethyl
acrylate, propyl acrylate, butyl acrylate, octyl acrylate,
n-dodecyl acrylate, n-octadecyl acrylate, methyl methacrylate,
ethyl methacrylate, propyl methacrylate, butyl methacrylate, octyl
methacrylate, n-dodecyl methacrylate, n-octadecyl methacrylate, and
the like, and mixture thereof. These polymers can be produced
through emulsion polymerization, for example, as disclosed in U.S.
Pat. No. 3,325,286 and U.S. Pat. No. 3,460,944. These blends can
contain from 90 to 60 weight percent of the vinylidene copolymer,
based on the total blend weight. Suitable blends are disclosed in
U.S. Pat. No. 3,460,944. A convenient method of preparing such
blends is to start with two dispersions containing the same
percentage of solids and mix these in the desired proportions by
volume.
[0051] A more convenient, preferred method for preparing the
vinylidene chloride copolymer-polyacrylate ester blends is through
the sequential emulsion polymerization process disclosed in U.S.
Pat. No. 3,443,950. For example, in making the blend compositions,
90 to 60 parts, by weight, of an aqueous dispersion of the
vinylidene chloride copolymer is mixed with from 10 to 40 parts, by
weight, of a monomer of the alkyl acrylate and/or the alkyl
methacrylate, 0.01 20 5.0 percent or more, by weight, of an
addition polymerization initiator and, if desired, additional water
and a dispersing agent, and then the monomer is polymerized at a
temperature from 30.degree. C. to 55.degree. C. for 30 to 120
minutes.
[0052] The vinylidene chloride copolymers can be coated onto the
polyester monofilament or textile fabrics produced from the
polyester monofilament by any known process including, for example,
spray down, solution coating, emulsion coating and the like. The
coating process can be integrated into the polyester monofilament
production process, be performed in line just after the
monofilament process, be performed on preformed polyester
monofilament as a separate operation, be integrated into the fabric
weaving process, be performed in line just after the monofilament
weaving process or be performed on preformed textile fabrics woven
from polyester monofilaments.
[0053] Preferably, the vinylidene chloride-coated polyester
monofilaments are drawn at elevated temperatures up to 100.degree.
C. between a set of draw rolls to a draw ratio of from 3.0:1 to
4.5:1. The vinylidene chloride-coated polyester monofilaments can
optionally be further drawn at a higher temperature of up to
250.degree. C. Preferably, if the coated polyester monofilaments
are further drawn, they are drawn to a draw ratio of no more than
6.5:1 and then allowed to relax by up to about 30 percent of their
drawn length while heated. Drawing at elevated temperatures
provides enhanced adhesion between the polyester filament and the
vinylidene chloride coating. Drawing at elevated temperatures can
be done on the polyester monofilaments before and/or after the
vinylidene chloride is applied to the monofilaments. Moreover, the
drawing process can be carried out on the vinylidene
chloride-coated polyester monofilaments when the vinylidene
chloride coating, also referred to as a first coating, is to
function as a tie layer prior to the application of a second
coating.
[0054] Preferably, the vinylidene chloride-coated polyester
monofilaments or vinylidene chloride-coated textile fabrics
produced from the polyester monofilaments are heat set at a
temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. Heat
setting stabilizes the dimensional stability of the vinylidene
chloride-coated polyester monofilament or polyester monofilament
textile fabric and further provides enhanced adhesion between the
polyester monofilament and the vinylidene chloride coating. Heat
setting can be carried prior to and/or after the application of the
vinylidene chloride coating to the polyester monofilaments, and/or
after the application of a second coating. In preferred
embodiments, drawing at elevated temperatures and heat setting is
carried out after the application of the vinylidene chloride onto
the polyester monofilaments.
[0055] For example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a bath
containing an aqueous emulsion of the vinylidene chloride copolymer
and the coated solid filaments are then conveyed to a dryer whereby
the water is removed. These vinylidene chloride copolymer-coated
polyester monofilaments can be drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage.
[0056] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a second bath containing
either a solution or an aqueous emulsion of the vinylidene chloride
copolymer and the coated solid filaments are then conveyed to a
dryer whereby the solvent and/or water is removed. The vinylidene
chloride copolymer-coated polyester monofilaments are preferably
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. Also preferably, the vinylidene chloride-coated polyester
monofilaments are preferably heat set at a temperature in the range
of 100.degree. C. to 220.degree. C., preferably in the range of
160.degree. C. to 180.degree. C.
[0057] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a dryer whereby the water
is removed. The solid filaments are then conveyed to a bath
containing either a solution or an aqueous emulsion of the
vinylidene chloride copolymer and the coated solid filaments are
then conveyed to a dryer whereby the solvent and/or water is
removed. The vinylidene chloride copolymer-coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C.
[0058] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath. A
solution or an aqueous emulsion of the vinylidene chloride
copolymer is then pumped by a metering pump through nozzles and
sprayed onto the polyester filament. The coated solid filaments are
then conveyed to a dryer whereby the solvent and/or water is
removed. The vinylidene chloride copolymer-coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C.
[0059] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 29.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
then conveyed to a dryer whereby the water is removed. A solution
or an aqueous emulsion of the vinylidene chloride copolymer is then
pumped by a metering pump through nozzles and sprayed onto the
polyester filament. The coated solid filaments are then conveyed to
a dryer whereby the solvent and/or water is removed. The vinylidene
chloride copolymer-coated polyester monofilaments are preferably
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C.
[0060] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a dryer whereby the water
is removed. The polyester monofilaments can be drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. The solid filaments are then
conveyed to a bath containing either a solution or an aqueous
emulsion of the vinylidene chloride copolymer and the coated solid
filaments are then conveyed to a dryer whereby the solvent and/or
water is removed. The polyester monofilaments are preferably drawn
at elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage. The vinylidene
chloride-coated polyester monofilaments are preferably heat set at
a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C.
[0061] As a further example, the dried polyesters are melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath.
The solid filaments are then conveyed to a dryer whereby the water
is removed. The polyester monofilaments can be drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. A solution or an aqueous emulsion
of the vinylidene chloride copolymer is then pumped by a metering
pump through nozzles and sprayed onto the polyester filament. The
coated solid filaments are then conveyed to a dryer whereby the
solvent and/or water is removed. The polyester monofilaments are
preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C.
[0062] Preformed polyester monofilament can also be coated. For
example, preformed polyester filament can be removed from spools
and conveyed into a bath containing either a solution or an aqueous
emulsion of the vinylidene chloride copolymer. The coated polyester
monofilament is then conveyed through a dryer and the solvent
and/or water is removed. The polyester monofilaments are preferably
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. Alternatively, preformed polyester filament can be removed
from spools and a solution or an aqueous emulsion of the vinylidene
chloride copolymer is pumped through nozzles by a metering pump and
sprayed onto the polyester monofilament. The coated polyester
monofilament is then conveyed through a dryer and the solvent
and/or water is removed. The coated polyester monofilaments are
preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. These vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C.
[0063] Woven fabrics produced from polyester monofilaments by
conventional processes can also be coated. For example, a woven
textile fabric is conveyed through a bath containing either a
solution or an aqueous emulsion of the vinylidene chloride
copolymer. Preferably, the excess solution or emulsion contained
within the interstices of the fabric is removed. This can be
performed by passing the treated fabric over a vacuum box or by
blowing it out with pressurized air or inert gases, such as
nitrogen and the like. The coated woven textile fabric is then
conveyed through a dryer and any solvent and/or water is removed.
As a further example, preformed woven textile fabric is sprayed
with a solution or an aqueous emulsion of the vinylidene chloride
copolymer, pumped through nozzles by a metering pump. Preferably,
the excess solution or emulsion contained within the interstices of
the fabric is removed according to methods described hereinabove.
The coated woven textile fabric is then conveyed through a dryer
and the solvent and/or water is removed.
[0064] Preferably, the vinylidene chloride-coated textile fabrics
produced from the polyester monofilaments are heat set at a
temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. The
heat set process stabilizes the dimensional stability of the
vinylidene chloride-coated polyester monofilament textile fabric
and further provides enhanced adhesion between the polyester
monofilament and the vinylidene chloride coating.
[0065] The vinylidene chloride copolymer-coated polyester
monofilaments or fabrics can include from 0.01 to 50 weight percent
of the vinylidene chloride copolymer based on the final weight of
the vinylidene chloride copolymer-coated polyester monofilament.
Preferably, the vinylidene chloride copolymer-coated polyester
monofilaments or fabrics can include from 0.01 to 10 weight percent
of the vinylidene chloride copolymer based on the final weight of
the vinylidene chloride copolymer-coated polyester monofilament.
More preferably, the vinylidene chloride copolymer-coated polyester
monofilaments or fabrics can include from 0.1 to 5 weight percent
of the vinylidene chloride copolymer based on the final weight of
the vinylidene chloride copolymer-coated polyester
monofilament.
[0066] The monofilaments are useful, for example, as reinforcements
for rubbers, fishing lines, toothbrush bristles, paintbrush
bristles and the like. When woven into fabrics, the monofilaments
can be utilized in making industrial belts and paper machine
clothing.
[0067] In some embodiments, the present invention provides
monofilaments having a polyester core, a vinylidene chloride
coating, and one or more additional coatings. In such embodiments,
the vinylidene chloride coating functions as a "tie layer", and may
be referred to as a tie layer herein.
[0068] Materials used to coat the polymers can be monomeric or
polymeric. Suitable monomeric coating materials include, for
example, fluorinated surfactants. Suitable polymeric coating
materials include, for example, polyolefins, such as polyethylene,
polypropylene, polybutene, poly-4-methyl pentene, polystyrene, and
the like, cyclic olefin polymers, modified polyolefins, such as
oxidized polyethylene, polyolefin copolymers, such as copolymers of
various alpha-olefins, glycidyl esters of unsaturated acids,
ionomers, ethylene/vinyl copolymers such as ethylene/vinyl chloride
copolymers, ethylene/vinyl acetate copolymers, ethylene/acrylic
acid copolymers, ethylene/methacrylic acid copolymers and the like,
ethylene/vinyl alcohol copolymers, poly(vinyl alcohol), poly(vinyl
alcohol-cobutyral), polyurethanes, thermoplastic polyurethanes,
polyvinyl chloride, polyvinylidene chloride copolymers, liquid
crystalline polymers, fluorinated polymers, such as
polytetrafluoroethylene, ethylene tetrafluoroethylene copolymers,
tetrafluoroethylene hexafluoropropylene copolymers,
polyfluoroalkoxy copolymers, polyvinylidene fluoride,
polyvinylidene copolymers, ethylene chlorotrifluoroethylene
copolymers, and the like, polyamides, such as Nylon-6, Nylon-66,
Nylon 69, Nylon 610, Nylon 611, Nylon 612, Nylon 11, Nylon 12, and
copolymers and the like, polyimides, polyphenylene sulfide,
polyphenylene oxide, polysulfones, polyethersulfones, rubbers,
polycarbonate, polyacrylates, terpene resins, polyacetal,
styrene/acrylonitrile copolymers, styrene/maleic anhydride
copolymers, styrene/maleimide copolymers, coumarone/indene
copolymers, and combinations thereof.
[0069] The coating materials can contain known additives. Such
additives can include thermal stabilizers such as, for example,
phenolic antioxidants; secondary thermal stabilizers such as, for
example, thioethers and phosphates; UV absorbers such as, for
example benzophenone- and benzotriazole-derivatives; UV
stabilizers; and hindered amine light stabilizers (HALS). Other
suitable additives include plasticizers, processing aids, flow
enhancing additives, lubricants, pigments, conductive materials,
such as carbon black or metal fibers, flame retardants, impact
modifiers, nucleating agents to increase crystallinity,
antiblocking agents such as silica, and base buffers, such as
sodium acetate, potassium acetate, and tetramethyl ammonium
hydroxide. In addition, the polyester compositions can include
inorganic, organic and clay fillers, for example, wood flour,
gypsum, wollastonite, montmorillonite minerals, chalk, kaolin,
clay, silicon oxide, calcium terephthalate, aluminum oxide,
titanium oxide, calcium phosphate, lithium fluoride, cellulose,
starch, chemically modified starch, thermoplastic starch, calcium
carbonate, calcium hydroxide, reinforcing agents, such as glass,
and the like. Other suitable additives will be known to those
skilled in the art and can be selected depending upon the intended
end use of the polyesters.
[0070] The coatings can be applied through solution coating
processes, emulsion coating processes or melt coating processes.
The coating process is typically performed in line with the
addition of the vinylidene chloride copolymer to the monofilament
or to a woven textile fabric produced from the monofilament. The
coating process can be integrated into the polyester monofilament
production process, be performed in line just after the
monofilament process, be performed on preformed polyester
monofilament as a separate operation, integrated as part of the
weaving process, be performed in line with the weaving process or
be performed on preformed woven textile fabrics as a separate
operation. The solution and emulsion coating processes can be
performed, for example, through successive baths containing the
vinylidene chloride copolymer and the coating material and/or
through spray down processes whereby the solutions or emulsions are
sprayed onto the fiber or fabric. Suitable solution and emulsion
coating processes are disclosed, for example, in U.S. Pat. No.
2,698,235 and U.S. Pat. No. 2,779,684. Melt coating can be carried
out using any known melt coating process. Suitable melt coating
processes are disclosed in, for example, U.S. Pat. No. 4,297,413,
U.S. Pat. No. 4,839,132, U.S. Pat. No. 4,894,195, U.S. Pat. No.
5,573,850, and U.S. Pat. No. 5,601,775 and references cited
therein, and in the Handbook of Plastic Materials and Technology, p
1208, John Wiley & Sons, Inc., New York (1990). The melt
coating processes can include contacting the vinylidene chloride
copolymer coated polyester monofilament with the molten coating
material. For example, the vinylidene chloride copolymer coated
polyester monofilament can be continuously fed through a melt of
the coating material in a crosshead pressure extrusion die where
the coating is applied. From the die, the coated polyester
monofilament is conveyed through a cooling zone and then taken up
on a spool. Such crosshead pressure extrusion dies and processes
are well known as wire-coating pressure dies. In such a process,
the melt temperature of the coating material can be below, at, or
above the melting temperature of the polyester monofilament.
[0071] Preferably, the vinylidene chloride-coated polyester
monofilaments are drawn at elevated temperatures up to 100.degree.
C. between a set of draw rolls to a draw ratio of from 3.0:1 to
4.5:1, and optionally be further drawn at a higher temperature of
up to 250.degree. C. to a maximum draw ratio of 6.5:1 and allowed
to relax up to about 30 percent maximum while heated in a relaxing
stage before the application of the second coating. The preferable
drawing process provides enhanced adhesion between the polyester
filament and the vinylidene chloride coating.
[0072] Preferably, the vinylidene chloride-coated polyester
monofilaments or vinylidene chloride-coated textile fabrics
produced from the polyester monofilaments are heat set at a
temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. before
the application of the second coating. Heat setting stabilizes the
dimensional stability of the vinylidene chloride-coated polyester
monofilament or polyester monofilament textile fabric and further
provides enhanced adhesion between the polyester monofilament and
the vinylidene chloride coating.
[0073] For example, the dried polyesters can be melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted at a
temperature within the range of about 170.degree. C. to about
290.degree. C. The spinning can generally be carried out by a
spinning grid or an extruder. The extruder melts the dried granular
polyester and conveys the melt to the spinning aggregate by a
screw. It is well known that polyesters will tend to thermally
degrade due to time and temperature in the melt. It is preferred
that the time that the polyester is in the melt is minimized, which
can be accomplished by using the shortest practical length of pipes
between the melting of the polyester and the spinneret. The molten
polyester can be filtered through, for example, screen filters, to
remove any particulate foreign matter. The molten polyester can
then be conveyed, optionally through a metering pump, through a die
to form the monofilament. After exiting the die, the monofilaments
are quenched in a bath containing an aqueous emulsion of the
vinylidene chloride copolymer, thus coating the monofilaments, and
the coated solid filaments are then conveyed to a dryer for removal
of water. The vinylidene chloride-coated polyester monofilaments
are preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C. The vinylidene chloride copolymer-coated polyester
monofilaments are then conveyed to a second bath containing an
aqueous emulsion or a solution of the coating material. The coated
monofilaments are then conveyed through a dryer and can be drawn at
elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage.
[0074] Alternatively, for example, the dried polyesters can be
melted at a temperature in the range of about 150.degree. C. to
about 300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a second bath containing
either absolution or an aqueous emulsion of the vinylidene chloride
copolymer and the coated solid filaments are then conveyed to a
dryer whereby the solvent and/or water is removed. The vinylidene
chloride-coated polyester monofilaments are preferably drawn at
elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage. The vinylidene
chloride-coated polyester monofilaments are preferably heat set at
a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. The
vinylidene chloride copolymer-coated polyester monofilaments are
then conveyed through a third bath containing a solution or an
aqueous emulsion of the coating material. The coated monofilaments
are then dried and can be drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage.
[0075] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
practical length of pipes between the melting of the polyester and
the spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a second bath containing
either a solution or an aqueous emulsion of the vinylidene chloride
copolymer. The wet vinylidene chloride copolymer coated polyester
monofilaments are then conveyed through a third bath containing a
solution or an aqueous emulsion of the coating material. The coated
solid filaments are then conveyed to a dryer whereby the solvent
and/or water is removed. The coated monofilaments then can be drawn
at elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage. The coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., more preferably in
the range of 160.degree. C. to 180.degree. C.
[0076] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a dryer whereby the water
is removed. The solid filaments are then conveyed to a bath
containing either a solution or an aqueous emulsion of the
vinylidene chloride copolymer and the coated solid filaments are
then conveyed to a dryer whereby the solvent and/or water is
removed. The vinylidene chloride copolymer-coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C. The vinylidene chloride
copolymer coated polyester monofilaments are then conveyed through
a bath containing a solution or an aqueous emulsion of the coating
material and then dried to remove solvent and/or water.
[0077] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath. A
solution or an aqueous emulsion of the vinylidene chloride
copolymer is then pumped by a metering pump through nozzles and
sprayed onto the polyester filament. A solution or an aqueous
emulsion of the coating material is then pumped by a metering pump
through nozzles and sprayed onto the vinylidene chloride copolymer
coated polyester monofilaments. The solid filaments are then
conveyed to a dryer whereby the solvent and/or water is removed.
The coated polyester monofilaments can be drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. The coated polyester
monofilaments are preferably heat set at a temperature in the range
of 100.degree. C. to 220.degree. C., preferably in the range of
160.degree. C. to 180.degree. C.
[0078] As a further example, the dried polyesters can be melted at
a temperature in the range of about 1500 to about 300.degree. C.
Preferably, the polyesters are melted in the temperature range of
about 1700 to about 290.degree. C. The spinning can generally be
carried out by a spinning grid or an extruder. The extruder melts
the dried granular polyester and conveys the melt to the spinning
aggregate by a screw. It is well known that polyesters will tend to
thermally degrade based on time and temperature in the melt. It is
preferred that the time that the polyester is in the melt is
minimized through use of the shortest length of pipes between the
melting of the polyester and the spinneret. The molten polyester
can be filtered through, for example, screen filters, to remove any
particulate foreign matter. The molten polyester can then be
conveyed, optionally through a metering pump, through a die to form
the monofilament. After exiting the die, the monofilaments are
quenched in a water bath and then conveyed to a dryer whereby the
water is removed. A solution or an aqueous emulsion of the
vinylidene chloride copolymer is then pumped by a metering pump
through nozzles and sprayed onto the polyester filament. The
vinylidene chloride copolymer coated solid filaments are then
conveyed to a dryer whereby the solvent and/or water is removed.
The vinylidene chloride-coated polyester monofilaments are
preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C. The monofilaments are then conveyed into a bath
containing a solution or an aqueous emulsion of the coating
material. These coated polyester monofilaments are then conveyed
through a dryer and the water and/or solvent is removed and then
they can be drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage.
[0079] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a dryer whereby the water
is removed. The polyester monofilaments can be drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. The solid filaments are then
conveyed to a bath containing either a solution or an aqueous
emulsion of the vinylidene chloride copolymer and the coated solid
filaments are then conveyed to a dryer whereby the solvent and/or
water is removed. The vinylidene chloride-coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C. The vinylidene chloride
copolymer coated polyester monofilaments are then conveyed to a
bath containing a solution or an aqueous emulsion of the coating
material and the coated solid filaments are then conveyed to a
dryer whereby the solvent and/or water is removed.
[0080] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath.
The solid filaments are then conveyed to a dryer whereby the water
is removed. The polyester monofilaments can be drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. A solution or an aqueous emulsion
of the vinylidene chloride copolymer is then pumped by a metering
pump through nozzles and sprayed onto the polyester filament. A
solution or an aqueous emulsion of the coating material is then
pumped by a metering pump through nozzles and sprayed onto the
polyester monofilament. The coated solid filaments are then
conveyed to a dryer whereby the solvent and/or water is removed.
The coated polyester monofilaments are preferably drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. The coated polyester
monofilaments are preferably heat set at a temperature in the range
of 100.degree. C. to 220.degree. C., preferably in the range of
160.degree. C. to 180.degree. C.
[0081] For example, the dried polyesters can be melted at a
temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a bath
containing an aqueous emulsion of the vinylidene chloride copolymer
and the coated solid filaments are then conveyed to a dryer whereby
the water is removed. The vinylidene chloride copolymer coated
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The coated polyester monofilaments are
preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The coated polyester monofilaments are preferably heat set
at a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. The
vinylidene chloride copolymer-coated polyester monofilaments are
then conveyed through a crosshead die in a direction perpendicular
to the axis of the extruder that contains the molten coating
material. After contacting the molten coating material at the exit
of the crosshead die and passing through an air gap, the coated
polyester monofilament is cooled. The coated monofilaments can be
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage.
[0082] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath and
the solid filaments are then conveyed to a second bath containing
either a solution or an aqueous emulsion of the vinylidene chloride
copolymer and the coated solid filaments are then conveyed to a
dryer whereby the solvent and/or water is removed. The vinylidene
chloride copolymer coated monofilaments are preferably drawn at
elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage. The vinylidene
chloride-coated polyester monofilaments are preferably heat set at
a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. The
vinylidene chloride copolymer-coated polyester monofilaments are
then conveyed through a crosshead die in a direction perpendicular
to the axis of the extruder that contains the molten coating
material. After contacting the molten coating material at the exit
of the crosshead die and passing through an air gap, the coated
polyester monofilament is cooled. The coated monofilaments can be
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage.
[0083] As a further example, the dried polyesters can be melted at
a temperature in the range of about 150.degree. C. to about
300.degree. C. Preferably, the polyesters are melted in the
temperature range of about 170.degree. C. to about 290.degree. C.
The spinning can generally be carried out by a spinning grid or an
extruder. The extruder melts the dried granular polyester and
conveys the melt to the spinning aggregate by a screw. It is well
known that polyesters will tend to thermally degrade based on time
and temperature in the melt. It is preferred that the time that the
polyester is in the melt is minimized through use of the shortest
length of pipes between the melting of the polyester and the
spinneret. The molten polyester can be filtered through, for
example, screen filters, to remove any particulate foreign matter.
The molten polyester can then be conveyed, optionally through a
metering pump, through a die to form the monofilament. After
exiting the die, the monofilaments are quenched in a water bath. A
solution or an aqueous emulsion of the vinylidene chloride
copolymer is then pumped by a metering pump through nozzles and
sprayed onto the polyester filament. The vinylidene chloride
copolymer coated solid filaments are then conveyed to a dryer
whereby the solvent and/or water is removed. The coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C. The vinylidene chloride
copolymer-coated polyester monofilaments are then conveyed through
a crosshead die in a direction perpendicular to the axis of the
extruder that contains the molten coating material. After
contacting the molten coating material at the exit of the crosshead
die and passing through an air gap, the coated polyester
monofilament is cooled. The coated monofilaments can be drawn at
elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage.
[0084] Preformed polyester monofilament can also be coated. For
example, preformed polyester filament is removed from spools and
conveyed into a bath containing either a solution or an aqueous
emulsion of the vinylidene chloride copolymer. The coated polyester
monofilament is then conveyed through a dryer and the solvent
and/or water is removed. The vinylidene chloride-coated polyester
monofilaments are preferably drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C. The vinylidene chloride
copolymer coated polyester monofilament is then conveyed through a
bath containing a solution or an aqueous emulsion of the coating
material. The coated polyester monofilament is then conveyed
through a dryer and the solvent and/or water is removed. These
polyester monofilaments can be drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage. As a further example, preformed
polyester filament is removed from spools and a solution or an
aqueous emulsion of the vinylidene chloride copolymer is pumped
through nozzles by a metering pump and sprayed onto the polyester
monofilament. A solution or an aqueous emulsion of the coating
material is then pumped by a metering pump through nozzles and
sprayed onto the polyester monofilament. The coated polyester
monofilament is then conveyed through a dryer and the solvent
and/or water is removed. The polyester monofilaments can be drawn
at elevated temperatures up to 100.degree. C. between a set of draw
rolls to a draw ratio of from 3.0:1 to 4.5:1, and optionally be
further drawn at a higher temperature of up to 250.degree. C. to a
maximum draw ratio of 6.5:1 and allowed to relax up to about 30
percent maximum while heated in a relaxing stage. The coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C.
[0085] For example, preformed polyester filament is removed from
spools and conveyed into a bath containing either a solution or an
aqueous emulsion of the vinylidene chloride copolymer. The coated
polyester monofilament is then conveyed through a dryer to remove
solvent and/or water. The vinylidene chloride copolymer coated
polyester monofilaments are preferably drawn at elevated
temperatures up to 100.degree. C. between a set of draw rolls to a
draw ratio of from 3.0:1 to 4.5:1, and optionally be further drawn
at a higher temperature of up to 250.degree. C. to a maximum draw
ratio of 6.5:1 and allowed to relax up to about 30 percent maximum
while heated in a relaxing stage. The vinylidene chloride-coated
polyester monofilaments are preferably heat set at a temperature in
the range of 100.degree. C. to 220.degree. C., preferably in the
range of 160.degree. C. to 180.degree. C. The vinylidene chloride
copolymer-coated polyester monofilaments are then conveyed through
a crosshead die in a direction perpendicular to the axis of the
extruder that contains the molten coating material. After
contacting the molten coating material at the exit of the crosshead
die and passing through an air gap, the coated polyester
monofilament is cooled. The coated monofilaments are preferably
drawn at elevated temperatures up to 100.degree. C. between a set
of draw rolls to a draw ratio of from 3.0:1 to 4.5:1, and
optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. As a further example, preformed polyester filament is
removed from spools and a solution or an aqueous emulsion of the
vinylidene chloride copolymer is pumped through nozzles by a
metering pump and sprayed onto the polyester monofilament. The
coated polyester monofilament is then conveyed through a dryer and
the solvent and/or water is removed. The polyester monofilaments
are preferably drawn at elevated temperatures up to 100.degree. C.
between a set of draw rolls to a draw ratio of from 3.0:1 to 4.5:1,
and optionally be further drawn at a higher temperature of up to
250.degree. C. to a maximum draw ratio of 6.5:1 and allowed to
relax up to about 30 percent maximum while heated in a relaxing
stage. The vinylidene chloride-coated polyester monofilaments are
preferably heat set at a temperature in the range of 100.degree. C.
to 220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C. The vinylidene chloride copolymer-coated polyester
monofilaments are then conveyed through a crosshead die in a
direction perpendicular to the axis of the extruder that contains
the molten coating material. After contacting the molten coating
material at the exit of the crosshead die and passing through an
air gap, the coated polyester monofilament is cooled. The coated
monofilaments can be drawn at elevated temperatures up to
100.degree. C. between a set of draw rolls to a draw ratio of from
3.0:1 to 4.5:1, and optionally be further drawn at a higher
temperature of up to 250.degree. C. to a maximum draw ratio of
6.5:1 and allowed to relax up to about 30 percent maximum while
heated in a relaxing stage.
[0086] Woven fabrics produced from polyester monofilaments by any
conventional art processes can also be coated. For example, a woven
textile fabric is conveyed through a bath containing either a
solution or an aqueous emulsion of the vinylidene chloride
copolymer. Preferably, the excess solution or emulsion contained
within the interstices of the fabric is removed. This can be
performed by passing the treated fabric over a vacuum box or by
blowing it out with pressurized air or inert gases, such as
nitrogen and the like. The coated woven textile fabric is then
conveyed through a dryer and the solvent and/or water is removed.
The vinylidene chloride-coated polyester monofilament woven textile
fabric is preferably heat set at a temperature in the range of
100.degree. C. to 220.degree. C., preferably in the range of
160.degree. C. to 180.degree. C. The vinylidene chloride copolymer
coated textile fabric is then conveyed through a bath containing a
solution or an aqueous emulsion or dispersion of the coating
material. Preferably, the excess solution, emulsion or dispersion
contained within the interstices of the fabric is removed as
described above. The coated textile fabric is then conveyed through
a dryer and the solvent and/or water is removed. The processes can
be simplified by conveying the woven textile fabric successively
through baths containing the vinylidene chloride copolymer and the
coating material. Preferably, the excess solutions, emulsions
and/or dispersions are removed from the interstices of the fabric.
The coated fabric can then be dried. The vinylidene chloride-coated
polyester monofilament woven textile fabric is preferably heat set
at a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C.
[0087] As a further example, preformed woven textile fabric is
sprayed with a solution or an aqueous emulsion of the vinylidene
chloride copolymer, pumped through nozzles by a metering pump.
Preferably, the excess solution or emulsion contained within the
interstices of the fabric is removed as suggested above. The coated
woven textile fabric is then conveyed through a dryer and the
solvent and/or water is removed. The vinylidene chloride-coated
polyester monofilament woven textile fabric is preferably heat set
at a temperature in the range of 100.degree. C. to 220.degree. C.,
preferably in the range of 160.degree. C. to 180.degree. C. The
coated fabric is then sprayed with a solution, emulsion or
dispersion containing the coating material, pumped through nozzles
by a metering pump. Preferably the excess solution, emulsion or
dispersion of the coating materials is removed from the interstices
of the fabric as suggested above. The coated fabric is then
conveyed through a dryer and the solvent and/or water is removed.
The processes can be simplified by spraying the woven textile
fabric successively with solutions or emulsions containing the
vinylidene chloride copolymer and solutions, emulsions or
dispersions containing the coating material. Preferably, the excess
solutions, emulsions and/or dispersions are removed from the
interstices of the fabric. The coated fabric can then be dried. The
coated polyester monofilament woven textile fabric is preferably
heat set at a temperature in the range of 100.degree. C. to
220.degree. C., preferably in the range of 160.degree. C. to
180.degree. C.
[0088] The coated polyester monofilaments or fabrics can include
from 0.01 to 10 weight percent of the vinylidene chloride copolymer
and from 0.01 to 80 weight percent of the coating material based on
the final weight of the coated polyester monofilament. Preferably,
the coated polyester monofilaments or fabrics can include from 0.01
to 5 weight percent of the vinylidene chloride copolymer and 0.1 to
65 weight percent of the coating material based on the final weight
of the coated polyester monofilament. More preferably, the coated
polyester monofilaments or fabrics can include from 0.1 to 2.5
weight percent of the vinylidene chloride copolymer and 0.1 to 50
weight percent of the coating material based on the final weight of
the coated polyester monofilament.
[0089] The monofilaments are useful as reinforcements for rubbers,
fishing lines, toothbrush bristles, paintbrush bristles and the
like. When woven into fabrics, the monofilaments are useful in
industrial belts and paper machine clothing.
EXAMPLES AND COMPARATIVE EXAMPLES
Test Methods
[0090] Inherent Viscosity, (IV), is defined in "Preparative Methods
of Polymer Chemistry", W. R. Sorenson and T. W. Campbell, 1961, p.
35. It is determined at a concentration of 0.5 g./100 mL of a 50:50
weight percent trifluoroacetic acid:dichloromethane acid solvent
system at room temperature by a Goodyear R-103B method.
[0091] Adhesion of the coating material to the core polyester
monofilament can be tested in accordance with Federal Motor Vehicle
Safety Standard 209, as modified as follows. The coated
monofilament is clamped at one end and subjected to a reciprocating
motion in a horizontal direction over a distance of 32 cm at a
frequency of 0.5 Hz. To the other end of the coated monofilament is
suspended a 1 oz. weight. At a point between the two ends of the
coated monofilament, it passes through and bears against a fishing
rod guide, ("Hardloy" silicon carbide guide by Fuji), of 8 mm
diameter. As the coated monofilament passes through the guide, the
direction of the line is changed from horizontal to vertical. The
number of cycles of reciprocating motion are noted until there is
visual observation of detachment of the coating material layer from
the polyester core.
Preparative Example PE 1
[0092] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), ethylene glycol, (78.0 pounds), manganese(II)
acetate tetrahydrate, (37.65 grams), and antimony(III) trioxide,
(13.6 grams). The autoclave is purged three times with nitrogen and
heated to 245.degree. C. over 4.5 hours with stirring. Over this
heating cycle, distillate is recovered. With continued heating and
stirring, vacuum is staged onto the autoclave over 1.5 hours. The
resulting reaction mixture is stirred at 275.degree. C. under full
vacuum, (pressure equal to or less than 2 mm Hg), for 4 hours. The
vacuum is then released and the resulting reaction mixture is
extruded out of the autoclave as a ribbon, the polymer ribbon is
cooled and chopped.
[0093] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.67 dL/g.
Preparative Example PE 2
[0094] A portion of the material produced in Preparative Example PE
1 is subjected to solid phase polymerization at a temperature of
230.degree. C. until the polymer is tested for inherent viscosity,
as described above and is found to have an IV of 0.72 dL/g.
Preparative Example PE 3
[0095] A portion of the material produced in Preparative Example PE
1 is subjected to solid phase polymerization at a temperature of
230.degree. C. until the polymer is tested for inherent viscosity,
as described above and is found to have an IV of 0.83 dL/g.
Preparative Example PE 4
[0096] A portion of the material produced in Preparative Example PE
1 is subjected to solid phase polymerization at a temperature of
230.degree. C. until the polymer is tested for inherent viscosity,
as described above and is found to have an IV of 0.95 dL/g.
Preparative Example PE 5
[0097] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), trimellitic anhydride, (1,2,4-benzenetricarboxylic
anhydride), (0.0936 pounds), ethylene glycol, (73.4 pounds),
manganese(II) acetate tetrahydrate, (37.65 grams), and
antimony(III) trioxide, (13.6 grams). The autoclave is purged three
times with nitrogen and heated to 245.degree. C. over 4.5 hours
with stirring. Over this heating cycle, distillate is recovered.
With continued heating and stirring, vacuum is staged onto the
autoclave over 1.5 hours. The resulting reaction mixture is stirred
at 275.degree. C. under full vacuum, (pressure equal to or less
than 2 mm Hg), for 4 hours. The vacuum is then released and the
resulting reaction mixture is extruded out of the autoclave as a
ribbon, the polymer ribbon is cooled and chopped.
[0098] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.67 dL/g.
Preparative Example PE 6
[0099] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), pentaerythritol, (0.0624 pounds), ethylene glycol,
(73.4 pounds), manganese(II) acetate tetrahydrate, (37.65 grams),
and antimony(III) trioxide, (13.6 grams). The autoclave is purged
three times with nitrogen and heated to 245.degree. C. over 4.5
hours with stirring. Over this heating cycle, distillate is
recovered. With continued heating and stirring, vacuum is staged
onto the autoclave over 1.5 hours. The resulting reaction mixture
is stirred at 275.degree. C. under full vacuum, (pressure equal to
or less than 2 mm Hg), for 4 hours. The vacuum is then released and
the resulting reaction mixture is extruded out of the autoclave as
a ribbon, the polymer ribbon is cooled and chopped.
[0100] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.60 dL/g.
Preparative Example PE 7
[0101] To a 200 gallon autoclave is charged dimethyl terephthalate,
(122.38 pounds), dimethyl isophthalate, (3.78 pounds), ethylene
glycol, (78.0 pounds), manganese(II) acetate tetrahydrate, (37.65
grams), and antimony(III) trioxide, (13.6 grams). The autoclave is
purged three times with nitrogen and heated to 245.degree. C. over
4.5 hours with stirring. Over this heating cycle, distillate is
recovered. With continued heating and stirring, vacuum is staged
onto the autoclave over 1.5 hours. The resulting reaction mixture
is stirred at 275.degree. C. under full vacuum, (pressure equal to
or less than 2 mm Hg), for 4 hours. The vacuum is then released and
the resulting reaction mixture is extruded out of the autoclave as
a ribbon, the polymer ribbon is cooled and chopped.
[0102] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.60 dL/g.
Preparative Example PE 8
[0103] A portion of the material produced in Preparative Example PE
7 is subjected to solid phase polymerization at a temperature of
230.degree. C. until the polymer is tested for inherent viscosity,
as described above and is found to have an IV of 0.83 dL/g.
Preparative Example PE 9
[0104] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), ethylene glycol, (78.0 pounds),
1,4-cyclohexanedimethanol, (1.87 pounds), manganese(II) acetate
tetrahydrate, (37.65 grams), and antimony(III) trioxide, (13.6
grams). The autoclave is purged three times with nitrogen and
heated to 245.degree. C. over 4.5 hours with stirring. Over this
heating cycle, distillate is recovered. With continued heating and
stirring, vacuum is staged onto the autoclave over 1.5 hours. The
resulting reaction mixture is stirred at 275.degree. C. under full
vacuum, (pressure equal to or less than 2 mm Hg), for 4 hours. The
vacuum is then released and the resulting reaction mixture is
extruded out of the autoclave as a ribbon, the polymer ribbon is
cooled and chopped.
[0105] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.67 dL/g.
Preparative Example PE 10
[0106] A portion of the material produced in Preparative Example PE
9 is subjected to solid phase polymerization at a temperature of
230.degree. C. until the polymer is tested for inherent viscosity,
as described above and is found to have an IV of 0.85 dL/g.
Preparative Example PE 11
[0107] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), 1,3-propanediol, (64.27 pounds), and titanium(IV)
isopropoxide, (72.10 grams). The autoclave is purged three times
with nitrogen and heated to 225.degree. C. over 4.5 hours with
stirring. Over this heating cycle, distillate is recovered. With
continued heating and stirring, vacuum is staged onto the autoclave
over 1.5 hours. The resulting reaction mixture is stirred at
255.degree. C. under full vacuum, (pressure equal to or less than 2
mm Hg), for 4 hours. The vacuum is then released and the resulting
reaction mixture is extruded out of the autoclave as a ribbon, the
polymer ribbon is cooled and chopped.
[0108] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.90 dL/g.
Preparative Example PE 12
[0109] To a 200 gallon autoclave is charged dimethyl terephthalate,
(126.16 pounds), 1,4-butanediol, (76.11 pounds), and titanium(IV)
isopropoxide, (77.00 grams). The autoclave is purged three times
with nitrogen and heated to 225.degree. C. over 4.5 hours with
stirring. Over this heating cycle, distillate is recovered. With
continued heating and stirring, vacuum is staged onto the autoclave
over 1.5 hours. The resulting reaction mixture is stirred at
255.degree. C. under full vacuum, (pressure equal to or less than 2
mm Hg), for 4 hours. The vacuum is then released and the resulting
reaction mixture is extruded out of the autoclave as a ribbon, the
polymer ribbon is cooled and chopped.
[0110] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.75 dL/g.
Preparative Example PE 13
[0111] To a 200 gallon autoclave is charged dimethyl terephthalate,
(63.08 pounds), ethylene glycol, (39.0 pounds), poly(ethylene
glycol), (average molecular weight of 2000, 62.37 pounds),
manganese(II) acetate tetrahydrate, (37.65 grams), and
antimony(III) trioxide, (13.6 grams). The autoclave is purged three
times with nitrogen and heated to 245.degree. C. over 4.5 hours
with stirring. Over this heating cycle, distillate is recovered.
With continued heating and stirring, vacuum is staged onto the
autoclave over 1.5 hours. The resulting reaction mixture is stirred
at 275.degree. C. under full vacuum, (pressure equal to or less
than 2 mm Hg), for 4 hours. The vacuum is then released and the
resulting reaction mixture is extruded out of the autoclave as a
ribbon, the polymer ribbon is cooled and chopped.
[0112] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.80 dL/g.
Preparative Example PE 14
[0113] To a 200 gallon autoclave is charged dimethyl terephthalate,
(31.54 pounds), 1,3-propanediol, (16.07 pounds), poly(ethylene
glycol)-block-poly(propylene glycol)-block-poly(ethylene glycol),
(average molecular weight=2,800, 10 weight percent ethylene glycol,
100.37 pounds), and titanium(IV) isopropoxide, (72.10 grams). The
autoclave is purged three times with nitrogen and heated to
225.degree. C. over 4.5 hours with stirring. Over this heating
cycle, distillate is recovered. With continued heating and
stirring, vacuum is staged onto the autoclave over 1.5 hours. The
resulting reaction mixture is stirred at 255.degree. C. under full
vacuum, (pressure equal to or less than 2 mm Hg), for 4 hours. The
vacuum is then released and the resulting reaction mixture is
extruded out of the autoclave as a ribbon, the polymer ribbon is
cooled and chopped.
[0114] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 1.20 dL/g.
Preparative Example PE 15
[0115] To a 200 gallon autoclave is charged dimethyl terephthalate,
(107.24 pounds), 1,4-butanediol, (64.69 pounds),
poly(tetramethylene ether)glycol, (average molecular weight=2000,
21.44 pounds), and titanium(IV) isopropoxide, (77.00 grams). The
autoclave is purged three times with nitrogen and heated to
225.degree. C. over 4.5 hours with stirring. Over this heating
cycle, distillate is recovered. With continued heating and
stirring, vacuum is staged onto the autoclave over 1.5 hours. The
resulting reaction mixture is stirred at 255.degree. C. under full
vacuum, (pressure equal to or less than 2 mm Hg), for 4 hours. The
vacuum is then released and the resulting reaction mixture is
extruded out of the autoclave as a ribbon, the polymer ribbon is
cooled and chopped.
[0116] The polymer is tested for inherent viscosity, as described
above and is found to have an IV of 0.85 dL/g.
Preparative Example PE 16
[0117] The polyester produced in Preparative Example PE 3 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0118] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
Comparative Example CE 1
[0119] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 5 weight percent solids aqueous latex
of polyurethane. The nascent coated monofilament is then conveyed
through a dryer at about 100.degree. C. and taken up on spools for
testing.
[0120] The coated monofilament is tested for adhesion as described
above.
Example 1
[0121] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 0.1 weight percent solids aqueous
dispersion of a vinylidene chloride/methyl acrylate/itaconic acid
copolymer, (90:10:2 weight percent, produced as described in Alles
et al., in U.S. Pat. No. 2,627,088, Example 1, column 5, line 26,
as diluted with water to 0.1 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 80.degree. C. and stretched to a
draw ratio of 3:1, passed through a second dryer and heat set at a
temperature of 160.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C. and taken up on spools for testing.
[0122] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 2
[0123] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 0.5 weight percent solids aqueous
dispersion of a vinylidene chloride/methyl acrylate/itaconic acid
copolymer, (90:10:2 weight percent, produced as described in Alles
et al., in U.S. Pat. No. 2,627,088, Example 1, column 5, line 26,
as diluted with water to 0.5 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 90.degree. C. and stretched to a
draw ratio of 4:1, passed through a second dryer and heat set at a
temperature of 180.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C. and taken up on spools for testing.
[0124] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 3
[0125] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 1 weight percent solids aqueous
dispersion of a vinylidene chloride/methyl acrylate/itaconic acid
copolymer, (90:10:2 weight percent, produced as described in Alles
et al., in U.S. Pat. No. 2,627,088, Example 1, column 5, line 26,
as diluted with water to 0.1 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 80.degree. C. and stretched to a
draw ratio of 4:1, passed through a second dryer and heat set at a
temperature of 170.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C. and taken up on spools for testing.
[0126] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 4
[0127] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 1 weight percent solids aqueous
dispersion of a vinylidene chloride/methyl acrylate/itaconic acid
copolymer, (90:10:2 weight percent, produced as described in Alles
et al., in U.S. Pat. No. 2,627,088, Example 1, column 5, line 26,
as diluted with water to 1 weight percent total solids). The
nascent vinylidene chloride copolymer monofilament is conveyed
through a second bath containing a 5 weight percent solids aqueous
latex of polyurethane. The nascent coated monofilament is then
conveyed through a dryer at about 100.degree. C. and taken up on
spools for testing.
[0128] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 5
[0129] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 0.1 weight percent solids aqueous
emulsion containing a mixture comprised of 70 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 30 weight percent of a poly(ethyl
acrylate), (produced as described in Cohen in U.S. Pat. No.
3,460,944, Example 1, column 4, line 66, as diluted with water to
0.1 weight percent total solids). The nascent vinylidene chloride
copolymer coated polyester monofilament is conveyed through a dryer
at about 100.degree. C., passed through draw rolls at a temperature
of 80.degree. C. and stretched to a draw ratio of 4:1, passed
through a second dryer and heat set at a temperature of 170.degree.
C., and then through a second bath containing a 5 weight percent
solids aqueous latex of polyurethane. The nascent coated
monofilament is then conveyed through a dryer at about 100.degree.
C. and taken up on spools for testing.
[0130] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 6
[0131] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 1.0 weight percent solids aqueous
emulsion containing a mixture comprised of 70 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 30 weight percent of a poly(ethyl
acrylate), (produced as described in Cohen in U.S. Pat. No.
3,460,944, Example 1, column 4, line 66, as diluted with water to
1.0 weight percent total solids). The nascent vinylidene chloride
copolymer coated polyester monofilament is conveyed through a dryer
at about 100.degree. C., passed through draw rolls at a temperature
of 70.degree. C. and stretched to a draw ratio of 3.0:1, passed
through a second dryer and heat set at a temperature of 160.degree.
C., and then through a second bath containing a 5 weight percent
solids aqueous latex of polyurethane. The nascent coated
monofilament is then conveyed through a dryer at about 100.degree.
C. and taken up on spools for testing.
[0132] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 7
[0133] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 2.5 weight percent solids aqueous
emulsion containing a mixture comprised of 70 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 30 weight percent of a poly(ethyl
acrylate), (produced as described in Cohen in U.S. Pat. No.
3,460,944, Example 1, column 4, line 66, as diluted with water to
2.5 weight percent total solids). The nascent vinylidene chloride
copolymer coated polyester monofilament is conveyed through a dryer
at about 100.degree. C., passed through draw rolls at a temperature
of 80.degree. C. and stretched to a draw ratio of 3.5:1, passed
through a second dryer and heat set at a temperature of 170.degree.
C., and then through a second bath containing a 5 weight percent
solids aqueous latex of polyurethane. The nascent coated
monofilament is then conveyed through a dryer at about 100.degree.
C. and taken up on spools for testing.
[0134] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 8
[0135] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 5 weight percent solids aqueous
emulsion containing a mixture comprised of 70 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 30 weight percent of a poly(ethyl
acrylate), (produced as described in Cohen in U.S. Pat. No.
3,460,944, Example 1, column 4, line 66, as diluted with water to 5
weight percent total solids). The nascent vinylidene chloride
copolymer coated polyester monofilament is conveyed through a
second bath containing a 5 weight percent solids aqueous latex of
polyurethane. The nascent coated monofilament is then conveyed
through a dryer at about 100.degree. C., passed through draw rolls
at a temperature of 70.degree. C. and stretched to a draw ratio of
3:1, passed through a second dryer and heat set at a temperature of
160.degree. C., and taken up on spools for testing.
[0136] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 9
[0137] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 0.1 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 0.1 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 80.degree. C. and stretched to a
draw ratio of 3.5:1, passed through a second dryer and heat set at
a temperature of 170.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C., and taken up on spools for testing.
[0138] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 10
[0139] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 1.0 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 1.0 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 70.degree. C. and stretched to a
draw ratio of 3:1, passed through a second dryer and heat set at a
temperature of 170.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C. and taken up on spools for testing.
[0140] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 11
[0141] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 10.0 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 10.0 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 80.degree. C. and stretched to a
draw ratio of 3.5:1, passed through a second dryer and heat set at
a temperature of 170.degree. C., and then through a second bath
containing a 5 weight percent solids aqueous latex of polyurethane.
The nascent coated monofilament is then conveyed through a dryer at
about 100.degree. C. and taken up on spools for testing.
[0142] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 12
[0143] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 10.0 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 10.0 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a dryer at about 100.degree. C., passed through
draw rolls at a temperature of 70.degree. C. and stretched to a
draw ratio of 3:1, passed through a second dryer and heat set at a
temperature of 180.degree. C., and then through a second bath
containing a 10.0 weight percent solids aqueous latex of
polyurethane. The nascent coated monofilament is then conveyed
through a dryer at about 100.degree. C. and taken up on spools for
testing.
[0144] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 13
[0145] The polyester monofilament produced as described in
Preparative Example PE 16 is unwound from the spool and passed
through a bath containing a 25.0 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 25.0 weight percent total solids). The
nascent vinylidene chloride copolymer coated polyester monofilament
is conveyed through a second bath containing a 25.0 weight percent
solids aqueous latex of polyurethane. The nascent coated
monofilament is then conveyed through a dryer at about 100.degree.
C., passed through draw rolls at a temperature of 80.degree. C. and
stretched to a draw ratio of 3.5:1, passed through a second dryer
and heat set at a temperature of 170.degree. C., and taken up on
spools for testing.
[0146] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 1 until there is visual observation of detachment of the
coating material layer from the polyester core.
Comparative Example CE 2
[0147] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0148] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a dryer at
about 100.degree. C., passed through draw rolls at a temperature of
80.degree. C. and stretched to a draw ratio of 3.5:1, passed
through a second dryer and heat set at a temperature of 170.degree.
C., and a second bath containing a 10 weight percent solution of
ELVAMIDE.RTM. 8061 in a solvent mixture consisting of 85 weight
percent methanol and 15 weight percent of water. ELVAMIDE.RTM. 8061
is a commercial product of the DuPont Company and is a nylon
multipolymer. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
[0149] The coated monofilament is tested for adhesion as described
above.
Example 14
[0150] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0151] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
bath containing a 10.0 weight percent solids aqueous emulsion of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent, produced as described in Alles et al., in
U.S. Pat. No. 2,627,088, Example 1, column 5, line 26, as diluted
with water to 10.0 weight percent total solids), at a temperature
of 66.degree. C., positioned 2.0 cm under the die. The monofilament
is then conveyed through a dryer at about 100.degree. C., passed
through draw rolls at a temperature of 80.degree. C. and stretched
to a draw ratio of 3.5:1, passed through a second dryer and heat
set at a temperature of 170.degree. C., and a second bath
containing a 10 weight percent solution of ELVAMIDE.RTM. 8061 in a
solvent mixture consisting of 85 weight percent methanol and 15
weight percent of water. ELVAMIDE.RTM. 8061 is a commercial product
of the DuPont Company and is a nylon multipolymer. The quenched
monofilament is drawn in a hot air oven at a temperature of
74.degree. C. with a draw ratio of 3.36, drawn further in a hot air
oven at a temperature of 230.degree. C. to a total draw ratio of
5.0 and allowed to relax 25 percent at a temperature of 200.degree.
C. The finished monofilament is then taken up on spools for
testing.
[0152] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 15
[0153] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0154] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
bath containing a 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 70 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 30 weight percent of a poly(ethyl acrylate), (produced
as described in Cohen in U.S. Pat. No. 3,460,944, Example 1, column
4, line 66, as diluted with water to 10.0 weight percent total
solids), at a temperature of 66.degree. C., positioned 2.0 cm under
the die. The monofilament is then conveyed through a dryer at about
100.degree. C., passed through draw rolls at a temperature of
80.degree. C. and stretched to a draw ratio of 3.5:1, passed
through a second dryer and heat set at a temperature of 170.degree.
C., and a second bath containing a 10 weight percent solution of
ELVAMIDE.RTM. 8061 in a solvent mixture consisting of 85 weight
percent methanol and 15 weight percent of water. ELVAMIDE.RTM. 8061
is a commercial product of the DuPont Company and is a nylon
multipolymer. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
[0155] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 16
[0156] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0157] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
bath containing a 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids), at a temperature of
66.degree. C., positioned 2.0 cm under the die. The monofilament is
then conveyed through a dryer at about 100.degree. C., passed
through draw rolls at a temperature of 70.degree. C. and stretched
to a draw ratio of 3:1, passed through a second dryer and heat set
at a temperature of 160.degree. C., and a second bath containing a
10 weight percent solution of ELVAMIDE.RTM. 8061 in a solvent
mixture consisting of 85 weight percent methanol and 15 weight
percent of water. ELVAMIDE.RTM. 8061 is a commercial product of the
DuPont Company and is a nylon multipolymer. The quenched
monofilament is drawn in a hot air oven at a temperature of
74.degree. C. with a draw ratio of 3.36, drawn further in a hot air
oven at a temperature of 230.degree. C. to a total draw ratio of
5.0 and allowed to relax 25 percent at a temperature of 200.degree.
C. The finished monofilament is then taken up on spools for
testing.
[0158] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 17
[0159] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0160] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a dryer at about 100.degree. C., passed
through draw rolls at a temperature of 70.degree. C. and stretched
to a draw ratio of 3:1, passed through a second dryer and heat set
at a temperature of 180.degree. C., and a second bath containing a
10 weight percent solution of ELVAMIDE.RTM. 8061 in a solvent
mixture consisting of 85 weight percent methanol and 15 weight
percent of water. ELVAMIDE.RTM. 8061 is a commercial product of the
DuPont Company and is a nylon multipolymer. The quenched
monofilament is drawn in a hot air oven at a temperature of
74.degree. C. with a draw ratio of 3.36, drawn further in a hot air
oven at a temperature of 230.degree. C. to a total draw ratio of
5.0 and allowed to relax 25 percent at a temperature of 200.degree.
C. The finished monofilament is then taken up on spools for
testing.
[0161] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 18
[0162] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0163] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is passed through a drying oven at
100.degree. C. where the water is removed, passed through draw
rolls at a temperature of 90.degree. C. and stretched to a draw
ratio of 4:1, and passed through a second dryer and heat set at a
temperature of 160.degree. C. The monofilament is then conveyed
through a second bath containing a 10 weight percent solution of
ELVAMIDE.RTM. 8061 in a solvent mixture consisting of 85 weight
percent methanol and 15 weight percent of water. ELVAMIDE.RTM. 8061
is a commercial product of the DuPont Company and is a nylon
multipolymer. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
[0164] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 19
[0165] The polyester produced in Preparative Example PE 2 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0166] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The monofilament is then conveyed through a second bath containing
a 10 weight percent solution of ELVAMIDE.RTM. 8061 in a solvent
mixture consisting of 85 weight percent methanol and 15 weight
percent of water. ELVAMIDE.RTM. 8061 is a commercial product of the
DuPont Company and is a nylon multipolymer. The quenched
monofilament is drawn in a hot air oven at a temperature of
74.degree. C. with a draw ratio of 3.36, drawn further in a hot air
oven at a temperature of 230.degree. C. to a total draw ratio of
0.5.0 and allowed to relax 25 percent at a temperature of
200.degree. C. The finished monofilament is then taken up on spools
for testing.
[0167] The coated monofilament is tested for adhesion as described
above and is found to survive greater than 10 percent more cycles
than found for the coated monofilament prepared in Comparative
Example CE 2 until there is visual observation of detachment of the
coating material layer from the polyester core.
Example 20
[0168] The polyester produced in Preparative Example PE 5 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0169] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 10 weight percent
solution of ELVAMIDE.RTM. 8061 in a solvent mixture consisting of
85 weight percent methanol and 15 weight percent of water.
ELVAMIDE.RTM. 8061 is a commercial product of the DuPont Company
and is a nylon multipolymer. The quenched monofilament is drawn in
a hot air oven at a temperature of 74.degree. C. with a draw ratio
of 3.36, drawn further in a hot air oven at a temperature of
230.degree. C. to a total draw ratio of 5.0 and allowed to relax 25
percent at a temperature of 200.degree. C. The finished
monofilament is then taken up on spools for testing.
Example 21
[0170] The polyester produced in Preparative Example PE 8 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0171] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 10 weight percent
solution of ELVAMIDE.RTM. 8061 in a solvent mixture consisting of
85 weight percent methanol and 15 weight percent of water.
ELVAMIDE.RTM. 8061 is a commercial product of the DuPont Company
and is a nylon multipolymer. The quenched monofilament is drawn in
a hot air oven at a temperature of 74.degree. C. with a draw ratio
of 3.36, drawn further in a hot air oven at a temperature of
230.degree. C. to a total draw ratio of 5.0 and allowed to relax 25
percent at a temperature of 200.degree. C. The finished
monofilament is then taken up on spools for testing.
Example 22
[0172] The polyester produced in Preparative Example PE 10 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0173] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 15 weight percent
aqueous solution of poly(vinyl alcohol). The quenched monofilament
is drawn in a hot air oven at a temperature of 74.degree. C. with a
draw ratio of 3.36, drawn further in a hot air oven at a
temperature of 230.degree. C. to a total draw ratio of 5.0 and
allowed to relax 25 percent at a temperature of 200.degree. C. The
finished monofilament is then taken up on spools for testing.
Example 23
[0174] The polyester produced in Preparative Example PE 11 is dried
at 130.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 235.degree. C.
Second Heater Zone Temperature: 250.degree. C.
Third Heater Zone Temperature: 250.degree. C.
Extruder Die Temperature: 255.degree. C.
[0175] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 15 weight percent
aqueous solution of poly(vinyl pyrrolidone). The quenched
monofilament is drawn in a hot air oven at a temperature of
74.degree. C. with a draw ratio of 3.36, drawn further in a hot air
oven at a temperature of 200.degree. C. to a total draw ratio of
5.0 and allowed to relax 25 percent at a temperature of 170.degree.
C. The finished monofilament is then taken up on spools for
testing.
Example 24
[0176] The polyester produced in Preparative Example PE 12 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0177] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 15 weight percent
aqueous solution of poly(acrylic acid). The quenched monofilament
is drawn in a hot air oven at a temperature of 74.degree. C. with a
draw ratio of 3.36, drawn further in a hot air oven at a
temperature of 200.degree. C. to a total draw ratio of 5.0 and
allowed to relax 25 percent at a temperature of 170.degree. C. The
finished monofilament is then taken up on spools for testing.
Example 25
[0178] The polyester produced in Preparative Example PE 13 is dried
at 60.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 180.degree. C.
Second Heater Zone Temperature: 190.degree. C.
Third Heater Zone Temperature: 190.degree. C.
Extruder Die Temperature: 195.degree. C.
[0179] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at room temperature, positioned 2.0 cm under the die.
The monofilament is then conveyed through a bath containing a 10.0
weight percent solids aqueous emulsion containing a mixture
comprised of 75 weight percent of a vinylidene chloride/methyl
acrylate/itaconic acid copolymer, (90:10:2 weight percent) and 25
weight percent of a poly(ethyl acrylate), (produced by sequential
polymerization as described in Rawlins in U.S. Pat. No. 3,443,950,
Procedure A, column 3, line 59, as diluted with water to 10.0
weight percent total solids). The monofilament is then conveyed
through a second bath containing a 15 weight percent aqueous
emulsion of oxidized polyethylene. The quenched monofilament is
drawn in a hot air oven at a temperature of 50.degree. C. with a
draw ratio of 3.36, drawn further in a hot air oven at a
temperature of 100.degree. C. to a total draw ratio of 5.0 and
allowed to relax 25 percent at a temperature of 170.degree. C. The
finished monofilament is then taken up on spools for testing.
Example 26
[0180] The polyester produced in Preparative Example PE 14 is dried
at 60.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 180.degree. C.
Second Heater Zone Temperature: 190.degree. C.
Third Heater Zone Temperature: 190.degree. C.
Extruder Die Temperature: 195.degree. C.
[0181] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at room temperature, positioned 2.0 cm under the die.
The monofilament is then conveyed through a bath containing a 10.0
weight percent solids aqueous emulsion containing a mixture
comprised of 75 weight percent of a vinylidene chloride/methyl
acrylate/itaconic acid copolymer, (90:10:2 weight percent) and 25
weight percent of a poly(ethyl acrylate), (produced by sequential
polymerization as described in Rawlins in U.S. Pat. No. 3,443,950,
Procedure A, column 3, line 59, as diluted with water to 10.0
weight percent total solids). The monofilament is then conveyed
through a second bath containing a 15 weight percent methanolic
solution of poly(vinyl butyral-co-vinyl alcohol-co-vinyl acetate).
The quenched monofilament is drawn in a hot air oven at a
temperature of 50.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 100.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C. The finished monofilament is then
taken up on spools for testing.
Example 27
[0182] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0183] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The monofilament is
then conveyed through a second bath containing a 15 weight percent
aqueous emulsion of polyurethane. The quenched monofilament is
drawn in a hot air oven at a temperature of 74.degree. C. with a
draw ratio of 3.36, drawn further in a hot air oven at a
temperature of 200.degree. C. to a total draw ratio of 5.0 and
allowed to relax 25 percent at a temperature of 170.degree. C. The
finished monofilament is then taken up on spools for testing.
Example 28
[0184] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0185] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The quenched monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C.
[0186] Polyethylene, with a melting point of 135.degree. C., is fed
to a single screw extruder, (diameter of 2.54 cm and a 25:1 L/D),
fitted with a crosshead die of 0.107 cm exit diameter. The extruder
has a flat temperature profile of 155.degree. C., with a feed
section temperature of 130.degree. C. and a die temperature of
160.degree. C. The polymer is melted and conveyed by the extruder
screw to the crosshead vacuum die. The above described vinylidene
chloride copolymer coated polyester monofilament is fed transverse
through the crosshead die in a direction perpendicular to the axis
of the extruder. The design of the crosshead die is such that the
extruded polymer melt contacted the yarn and the vacuum aided in
pulling the melt into contact with the monofilament. After
contacting the polymer melt at the exit of the crosshead die, the
coated polyester monofilament passes through an air gap of 20 cm
and is quenched in a water bath. The coated monofilament is
conveyed through an oven at 100.degree. C., dried and wound up on
spools.
Example 29
[0187] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0188] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The quenched monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C.
[0189] Polyethylene, with a melting point of 100.degree. C., is fed
to a single screw extruder, (diameter of 2.54 cm and a 25:1 L/D),
fitted with a crosshead die of 0.107 cm exit diameter. The extruder
has a flat temperature profile of 125.degree. C., with a feed
section temperature of 100.degree. C. and a die temperature of
130.degree. C. The polymer is melted and conveyed by the extruder
screw to the crosshead vacuum die. The above described vinylidene
chloride copolymer coated polyester monofilament is fed transverse
through the crosshead die in a direction perpendicular to the axis
of the extruder. The design of the crosshead die is such that the
extruded polymer melt contacted the yarn and the vacuum aided in
pulling the melt into contact with the monofilament. After
contacting the polymer melt at the exit of the crosshead die, the
coated polyester monofilament passes through an air gap of 20 cm
and is quenched in a water bath. The coated monofilament is
conveyed through an oven at 80.degree. C., dried and wound up on
spools.
Example 30
[0190] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0191] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The quenched monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C.
[0192] The polyester produced in Preparative Example PE 11 is fed
to a single screw extruder, (diameter of 2.54 cm and a 25:1 L/D),
fitted with a crosshead die of 0.107 cm exit diameter. The extruder
has a flat temperature profile of 250.degree. C., with a feed
section temperature of 230.degree. C. and a die temperature of
255.degree. C. The polymer is melted and conveyed by the extruder
screw to the crosshead vacuum die. The above described vinylidene
chloride copolymer coated polyester monofilament is fed transverse
through the crosshead die in a direction perpendicular to the axis
of the extruder. The design of the crosshead die is such that the
extruded polymer melt contacted the yarn and the vacuum aided in
pulling the melt into contact with the monofilament. After
contacting the polymer melt at the exit of the crosshead die, the
coated polyester monofilament passes through an air gap of 20 cm
and is quenched in a water bath. The coated monofilament is
conveyed through an oven at 100.degree. C., dried and wound up on
spools.
Example 31
[0193] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0194] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The quenched monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C.
[0195] Poly(2,6-dimethylphenylene oxide) is fed to a single screw
extruder, (diameter of 2.54 cm and a 25:1 L/D), fitted with a
crosshead die of 0.107 cm exit diameter. The extruder has a flat
temperature profile of 210.degree. C., with a feed section
temperature of 190.degree. C. and a die temperature of 215.degree.
C. The polymer is melted and conveyed by the extruder screw to the
crosshead vacuum die. The above described vinylidene chloride
copolymer coated polyester monofilament is fed transverse through
the crosshead die in a direction perpendicular to the axis of the
extruder. The design of the crosshead die is such that the extruded
polymer melt contacted the yarn and the vacuum aided in pulling the
melt into contact with the monofilament. After contacting the
polymer melt at the exit of the crosshead die, the coated polyester
monofilament passes through an air gap of 20 cm and is quenched in
a water bath. The coated monofilament is conveyed through an oven
at 100.degree. C., dried and wound up on spools.
Example 32
[0196] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0197] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. A 10.0 weight percent solids aqueous emulsion
containing a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids) is pumped by a metering
pump, through spray nozzles and is sprayed onto the monofilament.
The quenched monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C.
[0198] Poly(phenylene sulfide) is fed to a single screw extruder,
(diameter of 2.54 cm and a 25:1 L/D), fitted with a crosshead die
of 0.107 cm exit diameter. The extruder has a flat temperature
profile of 310.degree. C., with a feed section temperature of
290.degree. C. and a die temperature of 315.degree. C. The polymer
is melted and conveyed by the extruder screw to the crosshead
vacuum die. The above described vinylidene chloride copolymer
coated polyester monofilament is fed transverse through the
crosshead die in a direction perpendicular to the axis of the
extruder. The design of the crosshead die is such that the extruded
polymer melt contacted the yarn and the vacuum aided in pulling the
melt into contact with the monofilament. After contacting the
polymer melt at the exit of the crosshead die, the coated polyester
monofilament passes through an air gap of 20 cm and is quenched in
a water bath. The coated monofilament is conveyed through an oven
at 100.degree. C., dried and wound up on spools.
Example 33
[0199] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0200] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 200.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C.
[0201] Polypropylene is fed to a single screw extruder, (diameter
of 2.54 cm and a 25:1 L/D), fitted with a crosshead die of 0.107 cm
exit diameter. The extruder has a flat temperature profile of
195.degree. C., with a feed section temperature of 155.degree. C.
and a die temperature of 200.degree. C. The polymer is melted and
conveyed by the extruder screw to the crosshead vacuum die. The
above described vinylidene chloride copolymer coated polyester
monofilament is fed transverse through the crosshead die in a
direction perpendicular to the axis of the extruder. The design of
the crosshead die is such that the extruded polymer melt contacted
the yarn and the vacuum aided in pulling the melt into contact with
the monofilament. After contacting the polymer melt at the exit of
the crosshead die, the coated polyester monofilament passes through
an air gap of 20 cm and is quenched in a water bath. The coated
monofilament is conveyed through an oven at 100.degree. C., dried
and wound up on spools.
Example 34
[0202] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0203] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 200.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C.
[0204] Thermoplastic polyurethane, with a melting point of
100.degree. C., is fed to a single screw extruder, (diameter of
2.54 cm and a 25:1 L/D), fitted with a crosshead die of 0.107 cm
exit diameter. The extruder has a flat temperature profile of
125.degree. C., with a feed section temperature of 105.degree. C.
and a die temperature of 130.degree. C. The polymer is melted and
conveyed by the extruder screw to the crosshead vacuum die. The
above described vinylidene chloride copolymer coated polyester
monofilament is fed transverse through the crosshead die in a
direction perpendicular to the axis of the extruder. The design of
the crosshead die is such that the extruded polymer melt contacted
the yarn and the vacuum aided in pulling the melt into contact with
the monofilament. After contacting the polymer melt at the exit of
the crosshead die, the coated polyester monofilament passes through
an air gap of 20 cm and is quenched in a water bath. The coated
monofilament is conveyed through an oven at 80.degree. C., dried
and wound up on spools.
Example 35
[0205] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0206] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 200.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C.
[0207] Polyvinylidene chloride is fed to a single screw extruder,
(diameter of 2.54 cm and a 25:1 L/D), fitted with a crosshead die
of 0.107 cm exit diameter. The extruder has a flat temperature
profile of 195.degree. C., with a feed section temperature of
155.degree. C. and a die temperature of 200.degree. C. The polymer
is melted and conveyed by the extruder screw to the crosshead
vacuum die. The above described vinylidene chloride copolymer
coated polyester monofilament is fed transverse through the
crosshead die in a direction perpendicular to the axis of the
extruder. The design of the crosshead die is such that the extruded
polymer melt contacted the yarn and the vacuum aided in pulling the
melt into contact with the monofilament. After contacting the
polymer melt at the exit of the crosshead die, the coated polyester
monofilament passes through an air gap of 20 cm and is quenched in
a water bath. The coated monofilament is conveyed through an oven
at 100.degree. C., dried and wound up on spools.
Example 36
[0208] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0209] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 200.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C.
[0210] Polyvinylidene fluoride is fed to a single screw extruder,
(diameter of 2.54 cm and a 25:1 L/D), fitted with a crosshead die
of 0.107 cm exit diameter. The extruder has a flat temperature
profile of 195.degree. C., with a feed section temperature of
155.degree. C. and a die temperature of 200.degree. C. The polymer
is melted and conveyed by the extruder screw to the crosshead
vacuum die. The above described vinylidene chloride copolymer
coated polyester monofilament is fed transverse through the
crosshead die in a direction perpendicular to the axis of the
extruder. The design of the crosshead die is such that the extruded
polymer melt contacted the yarn and the vacuum aided in pulling the
melt into contact with the monofilament. After contacting the
polymer melt at the exit of the crosshead die, the coated polyester
monofilament passes through an air gap of 20 cm and is quenched in
a water bath. The coated monofilament is conveyed through an oven
at 100.degree. C., dried and wound up on spools.
Example 37
[0211] The polyester produced in Preparative Example PE 15 is dried
at 120.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded. The extrusion
conditions, which are not considered limiting, are:
First Heater Zone Temperature: 230.degree. C.
Second Heater Zone Temperature: 245.degree. C.
Third Heater Zone Temperature: 245.degree. C.
Extruder Die Temperature: 250.degree. C.
[0212] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The monofilament is then conveyed through a bath
containing a 10.0 weight percent solids aqueous emulsion containing
a mixture comprised of 75 weight percent of a vinylidene
chloride/methyl acrylate/itaconic acid copolymer, (90:10:2 weight
percent) and 25 weight percent of a poly(ethyl acrylate), (produced
by sequential polymerization as described in Rawlins in U.S. Pat.
No. 3,443,950, Procedure A, column 3, line 59, as diluted with
water to 10.0 weight percent total solids). The vinylidene chloride
copolymer coated monofilament is drawn in a hot air oven at a
temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 200.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 170.degree. C.
[0213] Plasticized polyvinyl chloride is fed to a single screw
extruder, (diameter of 2.54 cm and a 25:1 L/D), fitted with a
crosshead die of 0.107 cm exit diameter. The extruder has a flat
temperature profile of 125.degree. C., with a feed section
temperature of 100.degree. C. and a die temperature of 130.degree.
C. The polymer is melted and conveyed by the extruder screw to the
crosshead vacuum die. The above described vinylidene chloride
copolymer coated polyester monofilament is fed transverse through
the crosshead die in a direction perpendicular to the axis of the
extruder. The design of the crosshead die is such that the extruded
polymer melt contacted the yarn and the vacuum aided in pulling the
melt into contact with the monofilament. After contacting the
polymer melt at the exit of the crosshead die, the coated polyester
monofilament passes through an air gap of 20 cm and is quenched in
a water bath. The coated monofilament is conveyed through an oven
at 80.degree. C., dried and wound up on spools.
Preparative Example PE 17
[0214] The polyester produced in Preparative Example PE 6 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded.
N.N'-di-2,6-diisopropylphenylcarbodiimide was melted at 80.degree.
C. and pumped into the extruder feed throat at a rate of 1.5 weight
percent based on the total blend (polyester and carbodiimide). The
extrusion conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0215] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
[0216] The polyester monofilament is woven into a paper machine
clothing textile fabric through conventional art processes.
Preparative Example PE 18
[0217] The polyester produced in Preparative Example PE 4 is dried
at 160.degree. C. for at least 6 hours. The dried polyester is then
placed in an extruder hopper and extruded.
N.N'-di-2,6-diisopropylphenylcarbodiimide was melted at 80.degree.
C. and pumped into the extruder feed throat at a rate of 1.5 weight
percent based on the total blend (polyester and carbodiimide). The
extrusion conditions, which are not considered limiting, are:
First Heater Zone Temperature: 260.degree. C.
Second Heater Zone Temperature: 275.degree. C.
Third Heater Zone Temperature: 275.degree. C.
Extruder Die Temperature: 285.degree. C.
[0218] The extruder die had eight 0.80 mm holes. The final
monofilament size was 0.30 mm. The monofilament was quenched in a
water bath at a temperature of 66.degree. C., positioned 2.0 cm
under the die. The quenched monofilament is drawn in a hot air oven
at a temperature of 74.degree. C. with a draw ratio of 3.36, drawn
further in a hot air oven at a temperature of 230.degree. C. to a
total draw ratio of 5.0 and allowed to relax 25 percent at a
temperature of 200.degree. C. The finished monofilament is then
taken up on spools for testing.
[0219] The polyester monofilament is woven into a paper machine
clothing textile fabric through conventional art processes.
Example 38
[0220] The textile fabric produced as described in Preparative
Example PE 17 is sprayed with a 10.0 weight percent solids aqueous
emulsion containing a mixture comprised of 75 weight percent of a
vinylidene chloride/methyl acrylate/itaconic acid copolymer,
(90:10:2 weight percent) and 25 weight percent of a poly(ethyl
acrylate), (produced by sequential polymerization as described in
Rawlins in U.S. Pat. No. 3,443,950, Procedure A, column 3, line 59,
as diluted with water to 10.0 weight percent total solids), by a
metering pump through spray nozzles. The vinylidene chloride
copolymer coated polyester monofilament textile fabric is then
sprayed with a 15 weight percent aqueous dispersion of a
fluorinated polyacrylate ester through spray nozzles and the
treated fabric is conveyed to an oven at 180.degree. C. and dried
and heat set.
Example 39
[0221] The textile fabric produced as described in Preparative
Example PE 18 is conveyed through a bath containing a 10.0 weight
percent solids aqueous emulsion containing a mixture comprised of
75 weight percent of a vinylidene chloride/methyl acrylate/itaconic
acid copolymer, (90:10:2 weight percent) and 25 weight percent of a
poly(ethyl acrylate), (produced by sequential polymerization as
described in Rawlins in U.S. Pat. No. 3,443,950, Procedure A,
column 3, line 59, as diluted with water to 10.0 weight percent
total solids), and then passed over a vacuum box to remove the
excess emulsion within the interstices of the fabric. The
vinylidene chloride copolymer coated polyester monofilament textile
fabric is conveyed to an oven at 100.degree. C. and dried. The
fabric is then conveyed through a bath containing a 15 weight
percent aqueous polyurethane latex and then passed over a vacuum
box to remove the excess latex within the interstices of the
fabric. The coated fabric is then conveyed through an oven at
160.degree. C. and dried and heat set.
* * * * *