U.S. patent application number 15/452973 was filed with the patent office on 2018-02-01 for down-like fiber.
The applicant listed for this patent is SHINKONG SYNTHETIC FIBERS CORPORATION. Invention is credited to SHING LANG CHENG, KUO CHUNG WU.
Application Number | 20180030619 15/452973 |
Document ID | / |
Family ID | 58347253 |
Filed Date | 2018-02-01 |
United States Patent
Application |
20180030619 |
Kind Code |
A1 |
CHENG; SHING LANG ; et
al. |
February 1, 2018 |
DOWN-LIKE FIBER
Abstract
The invention provides a down-like fiber which comprises a
hollow stem and a plurality of shaped lobes arranged radially
around the stem wherein each shaped lobe has a bottom end and a
head end opposite the bottom end. The bottom end attaches to the
surface of the hollow stem and two adjacent head ends do not
connect to one another to form an opening. The present invention
also provides a spinneret and a method for manufacturing the above
fiber.
Inventors: |
CHENG; SHING LANG; (TAIPEI,
TW) ; WU; KUO CHUNG; (TAOYUAN CITY, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHINKONG SYNTHETIC FIBERS CORPORATION |
TAIPEI |
|
TW |
|
|
Family ID: |
58347253 |
Appl. No.: |
15/452973 |
Filed: |
March 8, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01D 5/253 20130101;
D01D 5/24 20130101; D01F 6/62 20130101 |
International
Class: |
D01F 6/62 20060101
D01F006/62; D01D 5/253 20060101 D01D005/253 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 27, 2016 |
TW |
105123671 |
Claims
1. A down-like fiber, comprising: a hollow stem; and a plurality of
shaped lobes, arranged radially from the hollow stem as a center,
wherein each of the shaped lobes comprises a bottom end and a head
end opposite the bottom end, and the bottom end connects to a
surface of the hollow stem, and the head ends of two adjacent
shaped lobes do not connect with one another to form an
opening.
2. The fiber of claim 1, wherein the shaped lobes are T-shaped,
cross-shaped, Y-shaped, .uparw.-shaped, -shaped, W-shaped,
H-shaped, V-shaped or rectangular-shaped.
3. The fiber of claim 1, wherein the number of the shaped lobes is
from 2 to 6.
4. The fiber of claim 1, wherein the fiber is a filament or a
staple.
5. A spinneret for use in manufacturing the down-like fiber of
claim 1, comprising a plurality of slits of spinning nozzles, each
of the slits of spinning nozzles comprising: an inner ring portion;
and an outer lobe portion, comprising a bottom end and a head end
opposite the bottom end, wherein the bottom end connects to the
inner ring portion; wherein the inner ring portions of the
plurality of slits of spinning nozzles are arranged in a circle at
a regular interval, and the head ends of two adjacent outer lobe
portions do not connect with one another to form an opening.
6. The spinneret of claim 5, wherein the outer lobe portion are
T-shaped, cross-shaped, Y-shaped, .uparw.-shaped, -shaped,
W-shaped, H-shaped, V-shaped or rectangular-shaped.
7. The spinneret of claim 5, wherein the number of the slit of
spinning nozzle is from 2 to 6.
8. A method for manufacturing the down-like fiber as claimed in
claim 1, comprising extruding a polyester polymer in melting form
through a spinneret, wherein the spinneret comprises a plurality of
slits of spinning nozzles, and each of the slits of spinning
nozzles comprises: an inner ring portion; and an outer lobe
portion, comprising a bottom end and a head end opposite the bottom
end, wherein the bottom end connects to the inner ring portion;
wherein the inner ring portions of the plurality of slits of
spinning nozzles are arranged in a circle at a regular interval,
and the head ends of two adjacent outer lobe portions do not
connect with one another to form an opening.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a down-like fiber,
particularly, to a down-like fiber with a hollow stem and a
plurality of shaped lobes.
BACKGROUND OF THE INVENTION
[0002] Natural feathers consist of vaned feathers and down
feathers; the former has hollow stems, and the latter does not. The
arrangement of both vaned feathers and down feathers forms
irregular spaces, thereby trapping air to reduce heat dissipation
and thus can provide warm effect. However, the warm effect of
natural feathers is extremely decreased due to absorption of
water.
[0003] In the prior art, fibers with different shaped lobes such as
cross-shaped, Y-shaped and W-shaped lobes have been disclosed. For
example, U.S. Pat. No. 5,057,368 discloses a fiber comprising 3 or
4 T-shaped lobes. Although the above fibers have capability of
absorbing moisture and relieving sweat, the warm effect thereof is
not good enough. Contrarily, polyester fibers sold in the market
have a hollow structure and thus possess the warm effect, but the
effects of absorbing moisture, relieving sweat and a soft touch
feeling are poor.
[0004] Therefore, it is highly desired to have a fiber that not
only has good effect of keeping warm but also possesses excellent
effects of drainage and fast-drying, and a lightened weight and a
soft tough feeling can be achieved as well.
SUMMARY OF THE INVENTION
[0005] To solve the above problems, the present invention provides
a down-like fiber which possesses an effect of keeping warm just
like feathers, and presents an outstanding fast drying effect as
well.
[0006] The present invention provides a down-like fiber which
comprises a hollow stem and a plurality of shaped lobes arranged
radially from the hollow stem as a center, wherein each of the
shaped lobes comprises a bottom end and a head end opposite the
bottom end. The bottom end connects to a surface of the hollow
stem, and the head ends of two adjacent shaped lobes do not connect
with one another to form an opening.
[0007] According to one aspect of the present invention, the shaped
lobes can be T-shaped, cross-shaped, Y-shaped, .uparw.-shaped,
-shaped, W-shaped, H-shaped, V-shaped or rectangular-shaped and the
number of the shaped lobes can range from 2 to 6.
[0008] According to one aspect of the present invention, the
down-like fiber stated above can be a filament or a staple.
[0009] The present invention also provides a spinneret for
manufacturing the down-like fiber stated above. The spinneret
comprises a plurality of slits of spinning nozzles. Each of the
slits of spinning nozzles comprises an inner ring portion and an
outer lobe portion which has a bottom end and a head end opposite
the bottom end wherein the bottom end connects to the inner ring
portion. The inner ring portions of the plurality of slits of
spinning nozzles are arranged in a circle at a regular interval,
and the head ends of two adjacent outer lobe portions do not
connect with one another to form an opening.
[0010] According to one aspect of the present invention, the outer
lobe portion can be T-shaped, cross-shaped, Y-shaped,
.uparw.-shaped, -shaped, W-shaped, H-shaped, V-shaped or
rectangular-shaped. The number of the slits of spinning nozzles can
range from 2 to 6.
[0011] The present invention also provides a method for
manufacturing the above down-like fiber, which comprises extruding
a polyester polymer in melting form through the spinneret stated
above.
[0012] The down-like fiber provided by the present invention has a
hollow stem and shaped lobes which imitates the structure of
feathers, and thus can not only conserve heat dissipated from body
but also lighten the weight of fiber, thereby providing a soft
touch feeling. Moreover, since the head ends of adjacent shaped
lobes do not connect with each other, the ditches formed therefrom
can improve drainage functions. Accordingly, the effects of keeping
warm and fast-drying can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawings will be provided by the Office upon
request and payment of the necessary fee.
[0014] FIG. 1 schematically shows the cross section of the
down-like fiber having T-shaped lobes according to one embodiment
of the present invention;
[0015] FIGS. 2A to 2H schematically show the cross sections of the
down-like fibers having different shaped lobes according to
embodiments of the present invention;
[0016] FIG. 3 shows a photograph of the cross section of physical
samples of down-like fibers having T-shaped lobes;
[0017] FIG. 4 schematically shows the arrangement of several
down-like fibers having T-shaped lobes according to one embodiment
of the present invention;
[0018] FIG. 5A schematically shows a spinneret used for
manufacturing down-like fibers having T-shaped lobes according to
one embodiment of the present invention;
[0019] FIG. 5B schematically shows a spinneret used for
manufacturing down-like fibers having cross-shaped lobes according
to one embodiment of the present invention; and
[0020] FIG. 6 shows a bar graph of warm effect tests.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 schematically shows the cross section of the
down-like fiber having T-shaped lobes according to one embodiment
of the present invention. In FIG. 1, the fiber 10 comprises a
hollow stem 13 and four T-shaped lobes 11 which arrange radially
from the hollow stem 13 as a center. Each of T-shaped lobes 11
comprises a head end 112 and a bottom end 111 wherein the bottom
end 111 connects to the surface of the hollow stem 13, and the head
ends 112 of two adjacent T-shaped lobes 11 do not connect with one
another to form an opening 12. The opening 12 can be used as a
ditch to drain moisture.
[0022] FIGS. 2A to 2H schematically show the cross sections of the
down-like fibers having different shaped lobes according to other
embodiments of the present invention. As shown in FIGS. 2A to 2H,
the shaped lobes can be cross-shaped, Y-shaped, -shaped, -shaped,
W-shaped, H-shaped, V-shaped or rectangular-shaped. The number of
the shaped lobes is preferably from 2 to 6. That is because if the
number of the shaped lobes is above 6, the design of spinning
nozzles will become more complicate and thus lead to increasing the
cost; however, if the number of the shaped lobes is too few, the
drainage function and warm effect of fibers will be affected.
[0023] FIG. 3 shows a photograph of the cross section of physical
samples of down-like fibers having T-shaped lobes. According to
FIG. 3, due to the design of T-shaped lobes, those fibers can keep
certain spaces to prevent from being tightly packed. FIG. 4
schematically shows the arrangement of several down-like fibers
having T-shaped lobes according to one embodiment of the present
invention. In FIG. 4, since the head ends 112 of the adjacent
T-shaped lobes 11 do not connect to each other, the opening 12
formed therefrom can be used as a ditch. Since water can be drained
through the openings 12, the fabrics woven by the fiber 10
demonstrate an outstanding drying effect after absorbing moisture
or sweat. Also, many air rooms formed by the arrangement of the
head ends 112 of the T-shaped lobes 11, in combination with the
closed hollow stems 13, can further conserve heat emitted from a
human body, thereby enhancing the warm effect.
[0024] FIG. 5A schematically shows a spinneret for manufacturing a
down-like fiber having T-shaped lobes according to one embodiment
of the present invention. As shown in FIG. 5A, a spinneret 20
comprises four "" shaped slits of spinning nozzles 21. Each of
slits of spinning nozzles 21 comprises an inner ring portion 211
and an outer lobe portion 213, wherein the outer lobe portion 213
has a bottom end 215 and a head end 217 opposite the bottom end
215, and the bottom end 215 connects to the inner ring portion 211.
The inner ring portions 211 of the four slits of spinning nozzles
21 are arranged in a circle at a regular interval, and the head
ends 217 of two adjacent outer lobe portions 213 do not connect
with one another to form an opening 22. A polymer is extruded from
the slits of spinning nozzles 21 which will further swell and
connect at the inner ring portions 211 to form a hollow ring,
thereby producing the fiber 10 shown in FIG. 1.
[0025] Polymers suitable for manufacturing fibers of the present
invention include but not limited to polyester, nylon, polyolefin,
polyacrylonitrile or cellulose, wherein polyester can be
polyethylene terephthalate (PET), polybutylene terephthalate (PBT)
or polypropylene terephthalate (PPT); nylon can be nylon 6 (N6) or
nylon 66 (N66); and polyolefin can be polypropylene (PP) or
polyethylene (PE). Besides, additives can be further added in the
fibers of the present invention which include but not limited to
antibacterial and antifungal agents, anti-conductive agents,
deodorants, anti-ultraviolet agents or far-infrared agent.
[0026] FIG. 5B schematically shows a spinneret used for
manufacturing down-like fibers of FIG. 2A which have cross-shaped
lobes according to one embodiment of the present invention. As
shown in FIG. 5B, the spinneret 30 comprises four "" shaped slits
of spinning nozzles 31. The outer lobe portion 313 of the slit of
spinning nozzle 31 is "cross-shaped". In other embodiments of the
present invention, the outer lobe portion 313 can be Y-shaped,
.uparw.-shaped, -shaped, W-shaped, H-shaped, V-shaped or
rectangular-shaped to manufacture down-like fibers having different
shaped lobes shown in FIGS. 2B to 2H.
[0027] The following further describes manufacturing examples of
down-like fibers of the present invention and tests of effects.
EXAMPLE 1
Manufacture of Down-Like Staples Having T-Shaped Lobes
[0028] The polyester polymer in melting form is extruded through a
spinneret as shown in FIG. 5A at spinning temperature of
290.degree. C.; quenched by cooling air at a rate of 1.0 m/s; and
spun at a spinning rate of 700 m/min. The filaments are drawn at a
total elongation of 2.89 times followed by thermosetting at
160.degree. C., cooling, wrinkling, oiling, drying, cutting, and
packaging steps. The down-like staples of 3d*51 mm whose cross
section is a hollow stem with four T-shaped lobes are thus
obtained.
EXAMPLE 2
Manufacture of Down-Like Staples Having Cross-Shaped Lobes
[0029] The polyester polymer in melting form is extruded through a
spinneret as shown in FIG. 5B at spinning temperature of
290.degree. C.; quenched by cooling air at a rate of 1.0 m/s; and
spun at a spinning rate of 700 m/min. The filaments are drawn at a
total elongation of 2.89 times followed by being thermosetting at
160.degree. C. , cooling, wrinkling, oiling, drying, cutting, and
packaging steps. The down-like staples of 3d*51 mm whose cross
section is a hollow stem with four cross-shaped lobes are thus
obtained.
EXAMPLE 3
Manufacture of Down-Like Filament Textured Yarn Having T-Shaped
Lobes
[0030] The polyester polymer in melting form is extruded through a
spinneret as shown in FIG. 5A at spinning temperature of
290.degree. C.; quenched by cooling air at a rate of 0.6 m/s; and
winded at a spinning rate of 2500 m/min to produce 120/36 partially
oriented yarns (POY). The yarns are drawn at a total elongation of
1.6 times followed by thermosetting at 160.degree. C. and winding
steps. The 75/36 down-like filament textured yarns whose cross
section is a hollow stem with four T-shaped lobes are thus
obtained.
EXAMPLE 4
Manufacture of Down-Like Filament Oriented Yarn Having T-Shaped
Lobes
[0031] The polyester polymer in melting form is extruded through a
spinneret as shown in FIG. 5A at spinning temperature of
290.degree. C.; quenched by cooling air at a rate of 0.6 m/s; and
spun at a spinning rate of 4000 m/min. The yarns are drawn at a
total elongation of 2.0 times at the drawn temperature of
90.degree. C. followed by thermosetting at 130.degree. C. and
winding steps. The 75/36 down-like filament oriented yarns whose
cross section is a hollow stem with four T-shaped lobes are thus
obtained.
[0032] Test 1: Evaporation Rate Test
[0033] The evaporation rate tests of fabrics woven by the down-like
fibers having T-shaped lobes of the present invention, conventional
hollow round polyester fibers, solid round polyester fibers and
solid fibers having other shaped lobes are described below.
[0034] First, a sample of size 10.times.10 cm is placed in an
environment of constant temperature and humidity (23.degree. C.,
65% RH) for 24 hours and then moved onto a scale. A given amount of
water (W1, unit: gram) is dripped from 1 centimeter above the
fabric by using a volumetric pipet. After 5 minutes, the remaining
amount of water (W2, unit: gram) in the fabric is recorded and the
evaporation rate is calculated based on the following formula:
Evaporation Rate=(W1-W2)/W1.times.100%
The test results are shown in Table 1. Sample 1 to 5 are double
knit bird eye fabrics with a width of 36 inches*26 needles, which
are respectively woven by staples having T-shaped lobes of the
present invention, solid staples having 4T cross section, solid
staples having cross cross section, solid round polyester fibers
and hollow round polyester fibers (the above products are obtained
from Shinkong Synthetic Fibers Corporation, in which the solid
staples having 4T cross section have been issued Taiwan Patent no.
1374952).
TABLE-US-00001 TABLE 1 sample 1 (the present 5 invention) 2 3 4
(comparative down-like (comparative (comparative (comparative
example) staples example) example) example) hollow having solid
staples solid staples solid round round T-shaped having 4T having
cross polyester polyester lobes cross section cross section fiber
fiber evaporation 76.8 73.5 69.2 50.1 49.6 rate (%)
[0035] According to Table 1, the evaporation rate of the down-like
fiber having T-shaped lobes provided by the present invention is
around 76.8%, which is much better than 50.1% achieved by the solid
round polyester fiber and 49.6% achieved by the hollow round
polyester fiber. The test result demonstrates that since fibers of
the present invention possess lobe structures as ditches, the
fabric woven by fibers of the present invention can keep larger
spaces between fibers, and thus facilitate drainage. The fibers of
the present invention exhibit a fast drying effect compared with
conventional hollow or solid round polyester fibers. Furthermore,
the evaporation rate of fibers of the present invention is also
higher than solid fibers having other cross sections (i.e. samples
2 and 3). This shows that compared with conventional solid fibers
having 4T cross section or cross cross section, fibers of the
present invention possess excellent drainage effect, and thus
fabrics woven thereby can achieve fast drying effect without a
muggy feeling.
[0036] Test 2: Warm-Keeping Test
[0037] The warm-keeping test of fabrics woven by down-like fibers
having T-shaped lobes of the present invention is described below.
The test is performed by AGEMA Thermal vision 900 thermal
conductivity meter. A 500W halogen lamp is used as a heat source to
irradiate a sample for 10 minutes at a distance of 100 centimeters.
The temperature of the sample is measured before and after exposure
to the light. Samples 1 to 4 represent double knit bird eye fabrics
with a width of 36 inches*26 needles which are respectively woven
by four different fibers, including down-like fibers having
T-shaped lobes of the present invention, conventional solid fibers
having 4T cross section, solid round polyester fibers and hollow
round polyester fibers
TABLE-US-00002 TABLE 2 Before After Irradiation Irradiation
Differences of Sample (.degree. C.) (.degree. C.) Temperatures 1
down-like fiber having 23.1 29.5 +6.4 T-shaped lobes (the present
invention) 2 solid fibers having 4T 23.2 27.8 +4.6 cross section
(comparative example) 3 solid round polyester 23.1 25.6 +2.5 fiber
(comparative example) 4 hollow round 23.2 26.3 +3.1 polyester fiber
(comparative example)
[0038] FIG. 6 shows a bar graph based on the results of
warm-keeping test. According to Table 2 and FIG. 6, the temperature
of the fabric woven by fibers of the present invention is obviously
raised after irradiation with a light source. The increase of
temperature is much greater than those of round polyester fibers
(i.e. sample 3 and sample 4), and a better warm effect is also
presented compared with conventional solid fibers having 4T cross
section (i.e. sample 2).
[0039] According to the above, the hollow stem of the down-like
fiber provided by the present invention, which is like a feather
stem, not only reduces the weight of fiber but also provides effect
of keeping warm. Moreover, the shaped lobes around the main stem
provide several air rooms due to disconnection of adjacent head
ends. The ditch structures formed therefrom can further enhance the
effects of heat conservation, and improve the effects of drainage
and fast-drying. Accordingly, the down-like fibers provided by the
present invention can overcome disadvantages of bird feathers, i.e.
decrease in the effect of keeping warm as a result of moisture
absorption, and of conventional fibers having shaped lobes which
has a drainage function but a poor effect of keeping warm.
Meanwhile, since the weight of fiber of the present invention has
been reduced, a down-like touch feeling is reserved.
[0040] Exemplary embodiments have been described herein, but do not
intend to limit the scope of the present invention. It will be
understood by those skilled in the art that various changes and
modifications may be made therein without departing from the spirit
and the scope encompassed by the appended claims. Therefore, the
scope of the present invention is determined by the claims that
follow.
* * * * *