U.S. patent application number 14/276532 was filed with the patent office on 2015-07-23 for method for producing fibers having a low surface energy and fibers, yarns and textiles having a low surface energy.
This patent application is currently assigned to SHINKONG SYNTHETIC FIBERS CORPORATION. The applicant listed for this patent is SHINKONG SYNTHETIC FIBERS CORPORATION. Invention is credited to YI JEN TU, KUO CHUNG WU.
Application Number | 20150203993 14/276532 |
Document ID | / |
Family ID | 53544290 |
Filed Date | 2015-07-23 |
United States Patent
Application |
20150203993 |
Kind Code |
A1 |
TU; YI JEN ; et al. |
July 23, 2015 |
METHOD FOR PRODUCING FIBERS HAVING A LOW SURFACE ENERGY AND FIBERS,
YARNS AND TEXTILES HAVING A LOW SURFACE ENERGY
Abstract
The present invention relates to a method for producing a low
surface energy fiber having a long-term liquid repellency and
anti-stain effect. The present invention relates to an addition of
a specific ratio of low surface energy additives to a thermoplastic
polymer used as a spinning raw material, which is subjected to
spinning processing procedure, such as melting spinning, to produce
fibers with a surface tension of between 25.about.72 dyne/cm.
Inventors: |
TU; YI JEN; (TAIPEI, TW)
; WU; KUO CHUNG; (TAIPEI, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHINKONG SYNTHETIC FIBERS CORPORATION |
TAIPEI |
|
TW |
|
|
Assignee: |
SHINKONG SYNTHETIC FIBERS
CORPORATION
TAIPEI
TW
|
Family ID: |
53544290 |
Appl. No.: |
14/276532 |
Filed: |
May 13, 2014 |
Current U.S.
Class: |
428/221 ;
264/103; 524/604; 524/605 |
Current CPC
Class: |
Y10T 428/249921
20150401; D01D 5/16 20130101; D01F 6/62 20130101; D01F 1/10
20130101; D01F 6/60 20130101; D01F 6/04 20130101 |
International
Class: |
D01F 6/92 20060101
D01F006/92; D01D 5/098 20060101 D01D005/098; D01D 5/08 20060101
D01D005/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 20, 2014 |
TW |
103102027 |
Claims
1. A method for producing fibers having a low surface energy
comprising step (i): formulating a thermoplastic polymer containing
0.1 wt %.about.30 wt % of a low surface energy additive; and one of
the following steps: step (ii-a): subjecting the thermoplastic
polymer as a spinning raw material to conduct melt spinning,
followed by drawing and false twist processing to produce fibers
with a surface tension of between 25.about.72 dyne/cm; step (ii-b):
subjecting the thermoplastic polymer as a spinning raw material to
conduct melt spinning, drawing and setting to produce a fully drawn
yarn (FDY) with a surface tension of between 25.about.72 dyne/cm;
or step (ii-c): subjecting the thermoplastic polymer as a spinning
raw material to conduct melt spinning, multi-stage drawing and
setting to produce a high tenacity yarn (HTY) with a surface
tension of between 25.about.72 dyne/cm.
2. The method according to claim 1, wherein a thermoplastic polymer
containing 0.1 wt %.about.30 wt % of a low surface energy additive
is obtained by adding 0.1 wt %.about.30 wt %, based on the total
amount of monomers, of the low surface energy additive to the
monomers and carrying out polymerization using monomers.
3. The method according to claim 1, wherein a thermoplastic polymer
containing 0.1 wt %.about.30 wt % of a low surface energy additive
is obtained by blending thermoplastic polymer particles containing
1.about.60 wt % of a low surface energy additive with thermoplastic
polymer particles free of a low surface energy additive in such a
manner that the concentration of the low surface energy additive is
0.1.about.30 wt % after blending.
4. The method according to claim 1, wherein the low surface energy
additive is a fluorine-series additive.
5. The method according to claim 1, wherein the fibers formed by
melt spinning have a circle, a non-circle or composite cross
section.
6. The method according to claim 1, wherein the melt spinning is
selected from mono spinning or composite spinning.
7. The method according to claim 1, wherein dyed fibers are
produced by dope dyeing or piece-dyeing.
8. The method according to claim 1, wherein the thermoplastic
polymer is selected from polyesters, polyamides or polyolefins.
9. The method according to claim 8, wherein the polyesters are
selected from the group consisting of polybutylene succinate (PBS),
polyethylene terephthalate (PET), polybutylene terephthalate (PBT),
polytrimethylene terephthalate (PTT), cationic dyeable polyester,
recycled PET, BioPET and polylactic acid (PLA).
10. The method according to claim 8, wherein the polyamides are
selected from the group consisting of nylon 6, nylon 66 and nylon
46.
11. The method according to claim 8, wherein the polyolefins are
selected from the group consisting of PE and PP.
12. The method according to claim 1, wherein the fibers produced by
drawing are partially oriented yarns (POY) or high oriented yarns
(HOY).
13. The method according to claim 1, wherein the false twist
processing is false twist (DTY) processing or air false twist (ATY)
processing.
14. A fiber having a low surface energy, which is produced by the
method according to claim 1.
15. A yarn having a low surface energy, which is solely composed of
the fibers having a low surface energy according to claim 14 or is
formed by compositing the fibers having a low surface energy
according to claim 14 with other fibers.
16. A textile, which comprises a fiber having a low surface energy
according to claim 14.
17. A textile, which essentially consists of yarns having a low
surface energy according to claim 15.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present application is directed to a production method
of fibers, and specifically to a production method of fibers having
a low surface energy.
[0003] 2. Description of the Related Art
[0004] The existing textiles having a low surface energy (low
surface tension) are usually produced by a processing procedure of
applying a low surface energy aid to a fabric, such as by means of
coating, dipping, padding, etc., to allow the low surface energy
aid to adsorb onto the fabric, and then fixing the aid onto the
fabric at a heating temperature of about 100.about.210.degree.
C.
[0005] TW Patent Application No. 098110619 (hereinafter, D1)
discloses a production method of yarns having water repellency,
wherein the yarns to be treated are allowed to pass through a
reagent vessel containing a water repellent agent, and then pass
through a heat treatment unit to fixing the water repellent agent
on the yarns to be treated to form yarns having water repellency.
However, said method requires movement through a reagent vessel
unit and a heat treatment unit in a series. In addition to a long
processing time and increasing costs, the water repellent agent is
scorched on the heat treatment unit due to the heat. Further, since
the water repellent agent only adsorbs onto the surface of the
yarns, it may transfer to other yarns which are not desired to
become water repellent during subsequent treatments (such as yarn
binding treatment).
[0006] In addition, Chinese Patent Publication No. CN101984154
(hereinafter, D2) discloses a production method of a water
repellent polyester fiber, wherein the water repellent agent is
directly added into the spinning finishing oil, and thereby the
water repellent agent directly adsorbs onto the fiber surface
during a melting spinning procedure in order to prepare fibers
having water repellency. However, during the latter processing
procedure of this method, since the water repellent agent adsorbing
onto the fiber surface is prone to adhering on the hot plate after
heating, scorched fouling (which cannot be easily cleaned and
scratched) is produced. This not only leads to hot plate equipment
damage, but the textile properties are also affected owing to a
non-uniform heating of fiber.
[0007] Moreover, after water washing the water repellent
fibers/yarns produced by the aforementioned prior arts for several
times, the water repellent agent adsorbing on the fibers/yarns is
prone to being washed out. Specifically, after subjected to water
washing according to AATCC (Association of Textile Chemists and
Colorists)-135 Standard, the water repellent effect of fibers will
become significantly worsen.
BRIEF SUMMARY OF THE INVENTION
[0008] In order to solve the above-mentioned problems, the
inventors of the present application studied and conducted
experiments to provide fibers having a low surface energy and a
production method thereof, thereby improving the disadvantages
existing in the known spinning production techniques and producing
fibers having excellent liquid repellency and anti-fouling effect
at low production costs.
[0009] According to an embodiment of the present invention, a
production method of fibers having a low surface energy comprises
the following steps:
[0010] formulating a thermoplastic polymer containing 0.1.about.30
wt % of a lower surface energy additive; and
[0011] subjecting said thermoplastic polymer as a spinning raw
material to melt spinning, followed by drawing and false twist
processing to produce fibers with a surface tension of between
25.about.72 dyne/cm.
[0012] According to another embodiment of the present application,
a production method of fibers having a low surface energy comprises
the following steps:
[0013] formulating a thermoplastic polymer containing 0.1.about.30
wt % of a lower surface energy additive; and
[0014] subjecting said thermoplastic polymer as a spinning raw
material to melt spinning, drawing and setting to produce a fully
drawn yarn (FDY) with a surface tension of between 25.about.72
dyne/cm.
[0015] According to a further embodiment of the present
application, a production method of fibers having a low surface
energy comprises the following steps:
[0016] formulating a thermoplastic polymer containing 0.1.about.30
wt % of a lower surface energy additive; and
[0017] subjecting said thermoplastic polymer as a spinning raw
material to melt spinning, multi-stage drawing and setting to
produce a high tenacity yarn (HTY) with a surface tension of
between 25.about.72 dyne/cm.
[0018] The production method of fibers having a low surface energy
of the present invention can shorten processing time and reduce
equipment volume and costs, since the low surface energy additive
is added into the spinning raw materials at the spinning raw
material stage and it is unnecessary to pass through a reagent
vessel of water repellent agent and a heat treatment unit in series
as required by D1. In addition, different from D1, the low surface
energy additive is incorporated into the spinning raw materials at
the spinning raw material stage in the present invention, and thus
the application of the water repellent agent onto the yarn surface
during a subsequent processing as required by D1 can be omitted,
thereby avoiding a poor situation caused by heating a water
repellent to scorch when yarns pass through a heat treatment unit.
The scorching resulting from heating the water repellent agent to
adhere onto a hot plate during a latter spinning processing as
required by D2 can be also omitted. Further, since the prepared
fibers have a surface tension of 25.about.72 dyne/cm, they have
excellent liquid repellency and anti-fouling effect.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0019] FIG. 1 is an illustrative FIGURE showing a measurement of a
water droplet contact angle of a textile.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the present invention, the spinning raw materials can be
thermoplastic polymers such as polyesters, polyamides or
polyolefins, etc. Specifically, examples of polyester polymers can
be polybutylene succinate (PBS), polyethylene terephthalate (PET),
polybutylene terephthalate (PBT), polytrimethylene terephthalate
(PTT), cationic dyeable polyester, recycled PET, BioPET and
polylactic acid (PLA), etc. Examples of polyamides can be nylon 6,
nylon 66 and nylon 46, etc. In addition, examples of polyolefin
polymers can be polyethylene (PE), polypropylene (PP), etc.
[0021] In order to produce the fibers having a low surface energy
described below, the present invention adds a specific low surface
energy additive to the aforementioned thermoplastic polymer before
melting spinning said thermoplastic polymer. Considering that the
low surface energy additive added into the thermoplastic polymer
should be free from deterioration at a high temperature during
melting spinning procedure, the present invention selects
fluorine-series additives with a high thermal resistance, such as
the fluorine-series low surface energy aid of model FC-L624
produced by GOULSTON company.
[0022] In the present invention, a low surface energy additive is
added into a thermoplastic polymer in an amount of 0.1 wt
%.about.30 wt %. When the amount of a low surface energy additive
is lower than 0.1 wt %, the effect for reducing the surface energy
of fibers is insufficient. On the other hand, when the amount of a
low surface energy additive is higher than 30 wt %, the costs
relatively increase and the production becomes difficult, even
though the effect for reducing the surface energy of fibers is
good.
[0023] In the present invention, a thermoplastic polymer containing
0.1 wt %.about.30 wt % of a low surface energy additive as a
spinning raw material can be obtained by: adding 0.1 wt %.about.30
wt %, based on the total amounts of the monomers, of a low surface
energy additive to the monomers, followed by polymerization in the
process of using monomers; or alternatively, blending thermoplastic
polymer particles containing a specific amount (such as 1.about.60
wt %) of a low surface energy additive with thermoplastic polymer
particles free of a low surface energy additive such that the
concentration of the low surface energy additive is 0.1.about.30 wt
% after blending.
[0024] The production method of fibers having a low surface energy
of the present invention allows a thermoplastic polymer containing
0.1.about.30 wt % of a low surface energy additive to eject from a
spinneret of a spinning machine in a mono spinning or composite
spinning manner at a molten state; wind at a spinning rate of
2500.about.3500 m/min (in the case of producing partially oriented
yarn (POY)) or at a spinning rate of 3500.about.6000 m/min (in the
case of producing high oriented yarn (HOY)); and then false twist
at a winding rate of 100.about.1300 m/min and at a hot plate
temperature of 60.about.400.degree. C.
[0025] (DTY) or air false twist at a winding rate of 100.about.800
m/min and at a hot plate temperature of 60.about.400.degree. C.
(ATY) to produce fibers having a low surface energy.
[0026] In addition, the production method of fibers having a low
surface energy of the present invention also allows a thermoplastic
polymer containing 0.1.about.30 wt % of a low surface energy
additive to eject from a spinneret of a spinning machine in a mono
spinning or composite spinning manner at a molten state, and
melting spin, draw and set at a spinning rate of 1000.about.6000
m/min, drawing ratio of 1.0.about.10, drawing temperature of
25.about.200.degree. C. and setting temperature of
60.about.260.degree. C. to produce a fully drawn yarn (FDY) having
a surface tension of between 25.about.72 dyne/cm.
[0027] Further, the production method of fibers having a low
surface energy of the present invention also allows a thermoplastic
polymer containing 0.1.about.30 wt % of a low surface energy
additive to eject from a spinneret of a spinning machine in a mono
spinning or composite spinning manner at a molten state, and
multi-stage draw the thermoplastic polymer at a spinning rate of
1000.about.6000 m/min, drawing temperature of 25.about.200.degree.
C. and setting temperature of 60.about.260.degree. C., with a total
drawing ratio of 1.0.about.10, to produce a high tenacity yarn
(HTY) having a surface tension of between 25.about.72 dyne/cm.
[0028] During the production process of fibers having a low surface
energy according to the present invention, other functional
additives such as flame retardants, heat accumulating and
insulating agents, anti-ultraviolet agents, anti-statistic agents,
fluorescence brighteners, antibacterial agents, delustering agents
or color concentrates, etc. may further be added, depending on the
demands.
[0029] In addition, in the production method of fibers having a low
surface energy of the present invention, fibers with a circle, a
non-circle or composite cross section can be formed by melt
spinning depending on the demands.
[0030] Further, in the production method of fibers having a low
surface energy of the present invention, dyed fibers can be
produced by dope dyeing or piece-dyeing. The processing conditions
for dope dyeing and piece-dyeing can be those disclosed by commonly
known techniques.
[0031] In addition, in the production method of fibers having a low
surface energy of the present invention, filament products or
staple products having a low surface energy can be produced
depending on the demands.
[0032] The fibers having a low surface energy produced by the
production method of the present invention can be solely composed
of yarns having a low surface energy or further be composited with
other fibers to form yarns having a low surface energy.
[0033] According to the present invention, the fibers having a low
surface energy or the yarns having a low surface energy prepared as
stated above can be used for preparation of prepare related
textiles by textile techniques known in the industry.
[0034] The surface tensions of common liquid are as following:
water 72 dyne/cm, wine 45 dyne/cm, milk 43 dyne/cm, peanut oil 40
dyne/cm, olive oil 32 dyne/cm, gasoline 28 dyne/cm. The fibers
having a low surface energy, yarns having a low surface energy and
textiles of the present invention have good liquid repellency
toward these liquids for their surface tensions of between
25.about.72 dyne/cm.
EXAMPLES
Example 1
[0035] Polyethylene terephthalate (A) particles and polyethylene
terephthalate particles containing 30 wt % of a fluorine-series low
surface energy additive (FC-L624, produced by GOULSTON company) (B)
were blended in an AB ratio of =90/10; melt spun at a spinning rate
of 2800 m/min at 288.degree. C.; followed by a false twist
processing procedure (DTY) at a winding rate of 600 m/min, a hot
plate temperature of 230.degree. C. and a drawing ratio of 1.75 to
produce fibers containing 3 wt % of a low surface energy additive.
The thus produced fibers are woven to form textiles, and the
surface tension value, water droplet contact angle and water
repellent test characteristic were measured. The results are shown
in Table 1.
Example 2
[0036] Polyethylene terephthalate (A) particles and polyethylene
terephthalate particles containing 30 wt % of a fluorine-series low
surface energy additive (FC-L624, produced by GOULSTON company) (B)
were blended in an A/B ratio of =90/10; melt spun at a spinning
rate of 2800 m/min at 288.degree. C.; followed by a fully drawn
yarn processing at a spinning rate of 4000 m/min, a drawing
temperature of 85.degree. C., a setting temperature of 130.degree.
C. and a drawing ratio of 2.1 to produce fibers containing 3 wt %
of a low surface energy additive. The thus produced fibers are
woven to form textiles, and the surface tension value, water
droplet contact angle and water repellent test characteristic were
measured. The results are shown in Table 1.
Example 3
[0037] Polyethylene terephthalate (A) particles and polyethylene
terephthalate particles containing 30 wt % of a fluorine-series low
surface energy additive (FC-L624, produced by GOULSTON company) (B)
were blended in an A/B ratio of =90/10, followed by HOY processing
at a spinning rate of 4500 m/min at a melting temperature of
288.degree. C. to produce fibers containing 3 wt % of a low surface
energy additive. The thus produced fibers are woven to form
textiles, and the surface tension value, water droplet contact
angle and water repellent test characteristic were measured. The
results are shown in Table 1.
Example 4
[0038] Polyethylene terephthalate (A) particles and polyethylene
terephthalate particles containing 30 wt % of a fluorine-series low
surface energy additive (FC-L624, produced by GOULSTON company) (B)
were blended in an A/B ratio of =90/10, and subjected to HOY
processing at a spinning rate of 4500 m/min at a melting
temperature of 288.degree. C., followed by an air false twist
processing (ATY) at a winding rate of 200 m/min to produce fibers
containing 3 wt % of a low surface energy additive. The thus
produced fibers are woven to form textiles, and the surface tension
value, water droplet contact angle and water repellent test
characteristic were measured. The results are shown in Table 1.
Example 5
[0039] Polyethylene terephthalate (A) particles and polyethylene
terephthalate particles containing 30 wt % of a fluorine-series low
surface energy additive (FC-L624, produced by GOULSTON company) (B)
were blended in an A/B ratio of =60/40, melt spun a spinning rate
of 2600 m/min at 285.degree. C., followed by a false twist
processing procedure (DTY) at a winding rate of 600 m/min, a hot
plate temperature of 230.degree. C. and a drawing ratio of 1.8 to
produce fibers containing 20 wt % of a low surface energy additive.
The thus produced fibers are woven to become textiles, and the
surface tension value, water droplet contact angle and water
repellent test characteristic were measured. The results are shown
in Table 1.
Example 6
[0040] 66 g of succinic acid, 72.6 g of butanediol and 3.05 g of a
fluorine-series low surface energy additive (FC-L624, produced by
GOULSTON company) were mixed and polymerized at a polymerization
temperature of 245.degree. C. to produce 102.5 g of polybutylene
succinate containing 3 wt % of a low surface energy additive, which
were wound up at a spinning rate of 2600 m/min at a melting
temperature of 200.degree. C., followed by a false twist processing
procedure (DTY) at a winding rate of 600 m/min, a hot plate
temperature of 190.degree. C. and a drawing ratio of 1.70 to
produce fibers containing 3 wt % of a low surface energy additive.
The thus produced fibers are woven to form textiles, and the
surface tension value, water droplet contact angle and water
repellent test characteristic were measured. The results are shown
in Table 1.
Comparative Example 1
[0041] False twisted yarns prepared from 75D/72F of polyethylene
terephthalate pass through a reagent vessel containing a
fluorine-series low surface energy additive (FC-L624, produced by
GOULSTON company) in order that the low surface energy additive
adsorbs onto the surface thereof. A heat treatment was conducted by
a heat roller at 150.degree. C. to allow the low surface energy
additive to fix on the false twisted yarns and form false twisted
yarns having a low surface energy. The thus produced fibers are
woven to form textiles, and the surface tension value, water
droplet contact angle and water repellent test characteristic are
measured. The results were shown in Table 1.
Comparative Example 2
[0042] Polyethylene terephthalate as a spinning raw material was
melt spun at 288.degree. C. and a spinning rate of 3000 m/min, and
the thus obtained spun yarns were oiled with spinning finishing oil
containing a fluorine-series low surface energy additive (FC-L624,
produced by GOULSTON company) (oiling ratio: 0.6%), followed by a
false twist processing procedure (DTY) at a winding rate of 600
m/min, a hot plate temperature of 230.degree. C. and a drawing
ratio of 1.67 to produce fibers having water repellency. The thus
produced fibers are woven to form textiles, and the surface tension
value, water droplet contact angle and water repellent test
characteristic were measured. The results are shown in Table 1.
[0043] The physical properties of the textiles produced in the
examples and comparative examples of the present invention were
measured and assessed by the following methods.
[0044] 1. Water Droplet Contact Angle
[0045] A 0.5 cc of water droplet was dropped on the surface of the
textiles obtained from examples and comparative examples, and the
contact angle (.theta.) between the water droplet and textile was
measured, as shown in FIG. 1.
[0046] 2. Textile Surface Tension Test
[0047] Inks with different surface tensions (commercially available
dyne pens) were respectively used to brush ink traces of about 10
cm of length on the textiles obtained from examples and comparative
examples, and the ink traces were observed to confirm whether they
shrink and form ink droplet within 2 seconds. If it happens, an ink
of a lower surface tension was subsequently used to brush a trace
and the trace was then observed. The procedure was repeated until
an ink trace does not shrink and form an ink droplet, and this is
the corresponding surface tension the textile possesses.
[0048] 3. Water Repellency Test
[0049] The textiles obtained from examples and comparative examples
were cut into a size of 180 mm.times.180 mm and the specimens were
fixed at hoops located on a base in a manner that the surfaces for
water repellent test face upside at a declination angle of 45
degrees. 250 cc of water was flowed over the textile surface in 30
seconds. The specimens were unloaded from the base and slightly
patted. The assessment was conducted according to FTTS-FA-011.
[0050] 100: Surface is not wetted. [0051] 90: Surface is slight
wetted. [0052] 80: Surface is wetted in a form of scattering water
droplet. [0053] 70: Surface is mostly wetted. [0054] 50: Surface is
all wetted. [0055] 0: Thoroughly wetted.
[0056] 4. Scorched Fouling Accumulation on the Hot Plate.
[0057] After running one day, the heating units (hot plates or hot
rollers) used in the examples and comparative examples were
observed to evaluate the scorched fouling in accordance with the
following manner: [0058] Massive scorched fouling appears: X [0059]
Little or no scorched fouling: .largecircle.
TABLE-US-00001 [0059] TABLE 1 Water Scorched fouling droplet
Surface Water accumulation contact tension repellency state on the
angle .theta. (.degree.) (dyne/cm) assessment hot plate Example 1
123 35 100 .largecircle. Example 2 120 37 100 .largecircle. Example
3 120 37 100 .largecircle. Example 4 123 35 100 .largecircle.
Example 5 130 29 100 .largecircle. Example 6 122 36 100
.largecircle. Comparative 108 55 80 X Example 1 Comparative 100 53
80 X Example 2
[0060] Notwithstanding the present invention is disclosed by the
above-mentioned examples in detail, those examples are not used to
limit the present invention. A person in the art can make various
alterations or modifications to the invention without departing
from the spirit and scope of the present invention, and such
alterations and modifications are also included in the scope of the
present invention.
* * * * *