U.S. patent number 3,774,387 [Application Number 05/259,175] was granted by the patent office on 1973-11-27 for hydrophilic textile products.
This patent grant is currently assigned to E. I. du Pont de Nemours and Company. Invention is credited to Rudolph Woodell.
United States Patent |
3,774,387 |
Woodell |
* November 27, 1973 |
HYDROPHILIC TEXTILE PRODUCTS
Abstract
Textile products comprising an assembly of fibrils. The assembly
can be in the form of a yarn, plexifilament, fabric, or the like,
and is of at least staple fiber length. The fibrils are of
irregular cross-section and are composed of a non-cellulosic,
synthetic organic polymer, and most are interconnected to form a
plexus. The products are stable to repeated water exposure, and
have a limiting surface tension greater than 72 dynes per
centimeter, a specific surface of at least about 0.8 square meter
per gram, a fibril concentration of at least about 5 .times.
10.sup.3 per quare centimeter, and a wicking parameter greater than
6. The products can be prepared by extruding an aqueous dispersion
of the polymer at selected elevated temperature and pressure
conditions. Preferred products are plexifilamentary strands of an
acrylonitrile polymer. The products are useful in textile
applications, particularly in such applications where good
water-absorption characteristics are desirable.
Inventors: |
Woodell; Rudolph (Richmond,
VA) |
Assignee: |
E. I. du Pont de Nemours and
Company (Wilmington, DE)
|
[*] Notice: |
The portion of the term of this patent
subsequent to April 11, 1989 has been disclaimed. |
Family
ID: |
26752397 |
Appl.
No.: |
05/259,175 |
Filed: |
June 2, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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86438 |
Nov 3, 1970 |
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71582 |
Sep 11, 1970 |
3655498 |
Apr 11, 1972 |
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677949 |
Oct 25, 1967 |
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Current U.S.
Class: |
428/397; 57/248;
57/907; 428/359; 428/400 |
Current CPC
Class: |
D01D
5/11 (20130101); Y10T 428/2904 (20150115); Y10T
428/2973 (20150115); Y10T 428/2978 (20150115); Y10S
57/907 (20130101) |
Current International
Class: |
D01D
5/00 (20060101); D01D 5/11 (20060101); D02g
003/02 (); D02g 003/22 () |
Field of
Search: |
;161/172,178,169,177,165
;264/176 ;57/14R,14J |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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891,943 |
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Mar 1962 |
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GB |
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891,945 |
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Mar 1962 |
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GB |
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1,090,478 |
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Nov 1967 |
|
GB |
|
1,114,151 |
|
May 1968 |
|
GB |
|
1,129,831 |
|
Oct 1968 |
|
GB |
|
Primary Examiner: Lesmes; George F.
Assistant Examiner: Kendell; Lorraine T.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No.
86,438, filed Nov. 3, 1970 and now abandoned, which application is
a continuation-in-part of application Ser. No. 71,582, filed Sept.
11, 1970, which issued as U.S. Pat. No. 3,655,498 on Apr. 11, 1972,
which application is a continuation-in-part of application Ser. No.
677,949, filed Oct. 25, 1967, and now abandoned.
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A textile product having water-absorbing characteristics
comprising an assembly of fibrils, said assembly being of at least
staple fiber length; said fibrils being of irregular cross-section
and being composed of a noncellulosic, synthetic, organic polymer,
with a majority of said fibrils being interconnected at various
points to form a plexus; said product being stable to repeated
exposure to water, and having a limiting surface tension
(.gamma..sub.o) greater than 72 dynes per centimeter, a specific
surface (S) of at least about 0.8 square meter per gram, and a
fibril concentration (F) of at least about 5 .times. 10.sup.3 per
square centimeter, said numerical values of .gamma..sub.o, S and F
also being such that the parameter
(.gamma..sub.o -72)(F/10,000).sup.0.74 (S).sup.0.3
for said product is greater than 6.
2. The textile product of claim 1 wherein said product is a
yarn.
3. The textile product of claim 1 wherein said product is a
fabric.
4. The textile product of claim 1 wherein said product is a
continuous plexifilamentary strand.
5. The continuous plexifilamentary strand of claim 4 wherein said
non-cellulosic synthetic organic polymer is an acrylonitrile
polymer.
6. The continuous plexifilamentary strand of claim 5 wherein said
acrylonitrile polymer is a copolymer wherein the major portion of
the copolymer is composed of acrylonitrile units.
7. The continuous plexifilamentary strand of claim 6 wherein the
acrylonitrile polymer is a terpolymer containing a major amount of
acrylonitrile and minor amounts of methyl acrylate and sodium
styrene sulfonate.
8. The continuous plexifilamentary strand of claim 6 wherein the
acrylonitrile polymer is a copolymer containing a major amount of
acrylonitrile and a minor amount of sodium styrene sulfonate.
9. The continuous plexifilamentary strand of claim 4 wherein said
non-cellulosic synthetic organic polymer is a polyamide.
10. The continuous plexifilamentary strand of claim 9 wherein said
polyamide is polycaproamide.
11. The textile product of claim 1 wherein the ratio of wet-to-dry
scattering coefficient is less than 0.4.
12. The textile product of claim 11 wherein said product is a
continuous plexifilamentary strand and said non-cellulosic
synthetic organic polymer is an acrylonitrile polymer.
Description
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to textile products, and more particularly
to assemblies of fibrils of non-cellulosic synthetic organic
polymers. The products possess good water-absorption
characteristics.
BACKGROUND OF THE INVENTION
Heretofore, fabrics that have the ability to absorb large amounts
of water, such as towels, or that can provide comfort by rapidly
absorbing body perspiration, such as men's underwear, have
primarily been made of cotton. Synthetic organic fibers, despite
their greater strength and durability over cotton, have generally
not been used in such applications due to their poor
water-absorption characteristics. However, the products of this
invention, which are prepared from noncellulosic synthetic organic
polymers, possess water-absorption properties that enable them to
be employed in such end uses.
Several types of textile products containing fibrils of synthetic
organic polymers are found in the prior art. Some are produced by
mechanically working or "fibrillating" sheets, bands, films, foils,
ribbons or filaments of highly oriented organic polymers. Others
are produced by melt-extruding blends of two or more incompatible
polymers into filaments or sheets, followed by drawing the
extrudate and then either mechanically working to cause
fibrillation or extracting or dissolving one of the polymers to
leave a coarsely fibrillated product. Other such fibrillated
products are prepared by stretching or mechanically working foamed
polymeric sheets or filaments. Still other fibrillated products,
such as plexifilamentary strands, are produced by flash-extruding a
solution of a crystalline synthetic organic polymer in an
activating liquid under superatmospheric pressure and at a
temperature in excess of the boiling point of the activating liquid
into a region of lower pressure.
None of the prior art products described above possess all the
structural features that provide the good water-absorption
characteristics of the textile products of this invention.
SUMMARY OF THE INVENTION
The invention is directed to a textile product comprising an
assembly of fibrils, said assembly being of at least staple-fiber
length; said fibrils being of irregular cross-section and being
composed of a non-cellulosic, synthetic, organic polymer, with a
majority of said fibrils being interconnected at various points to
form a plexus; said product being stable to repeated exposure to
water, and having a limiting surface tension (.gamma..sub.o)
greater than 72 dynes per centimeter, and a specific surface (S) of
at least about 0.8 square meter per gram, and a fibril
concentration (F) of at least about 5 .times. 10.sup.3 per square
centimeter, said numerical values of .gamma..sub.o, S and F also
being such that the expression
(.gamma..sub.o -72)(F/10,000).sup.0.74 (S).sup.0.3
for said product is greater than 6.
The products defined above have high surface area, high covering
power and absorb water as well as, or even better, than cotton,
thus rendering them useful in textile applications from which
wholly synthetic organic fibers have generally been excluded
heretofore.
Because of the fewer process steps needed compared to alternative
processes, and because of better control of product quality, it is
preferred to obtain the product of this invention in the form of
continuous plexifilamentary strands.
DESCRIPTION OF THE DRAWINGS
The invention may be more easily understood by reference to the
figures where
FIG. 1 illustrates the relationship between the water-absorption
rate and the parameter
"(.gamma..sub.o -72)(F/10,000).sup.0.74 (S).sup.0.3 "
for several assemblies of fibrils within the scope of this
invention and some conventional yarns outside the scope of this
invention;
FIG. 2 is a top view of a sample holder employed with the apparatus
of FIG. 3;
FIG. 3 is a cross-section of an apparatus for determining
liquid-absorption rates of textile products;
FIG. 4 shows the relationship between the surface tension and the
absorption rate of liquid as measured on three textile products of
an acrylonitrile terpolymer, each product having a different fibril
concentration;
FIG. 5 is a drawing of a magnified longitudinal section of an
assembly of fibrils of a textile product within the scope of this
invention;
FIG. 6 is a photomicrograph of a greatly magnified longitudinal
section of an assembly of fibrils of a textile product within the
scope of this invention; and
FIG. 7 is a drawing of an enlarged cross-section of an assembly of
fibrils of a textile product within the scope of this
invention.
DESCRIPTION OF THE INVENTION
It has been found that when fibril assemblies of non-cellulosic
synthetic organic textile products have the specific surface,
fibril concentration and limiting surface tension recited above,
the products have an increased propensity for absorbing water.
The ability of a fibrillated textile product to absorb water can be
determined from the expression
H = (.gamma..sub.o -72)(F/10,000).sup.0.74 (S).sup.0.3
where
H is a parameter of the product and is referred to hereinafter as
the "water-wicking parameter" or "wicking parameter",
.gamma..sub.o is the limiting surface tension characteristic of the
polymer from which the product is made, measured in dynes/cm.,
F is the fibril concentration, i.e., the number of fibrils per
square centimeter in the product cross-section, measured as
hereinafter described, and
S is the specific surface of the product measured as hereinafter
described, in square meters per gram.
As is shown in FIG. 1, the above-described water-wicking parameter
H is directly proportional to water-absorption rates. Thus, as the
water-wicking parameter of a textile product increases, the
water-absorption rate of the product also increases at roughly the
same percentage increments. FIG. 1 also depicts the superiority of
the plexifilamentary products of this invention over corresponding
conventional textile filaments.
The wicking parameter used herein to combine the various critical
structural features of the products of this invention is derived
from a more generalized equation for the rate of liquid absorption
by a textile product comprising an assembly of fibrils of generally
irregular cross-section, namely,
I = 0.14 .times. 10.sup.-.sup.4 (.gamma..sub.o
-.gamma./.mu.)(F).sup.0.735 (S).sup.0.323
where I is the absorption rate in ml./sec., .gamma. is the liquid
surface tension in dynes/cm. of the liquid tested, .mu. is the
liquid viscosity in centipoise of the liquid tested (usually at
25.degree. C.), and .gamma..sub.o, F and S are as previously
defined. This generalized equation was developed from a large
series of tests on products both within the scope of, and outside
the scope of, this invention. To reduce the generalized equation to
one applicable to water only, values for the viscosity and surface
tension of water are substituted, constants rearranged, and
exponents rounded off, to give the equation
I.sub.w = 0.014(.gamma..sub.o -72)(F/10,000).sup.0.74
(S).sup.0.3
where I.sub.w is the water-absorption rate.
Tests with various samples of cotton by procedures described below
show that cotton absorbs water at rates equal to or above 0.086
ml./sec. Thus, in order to absorb water as well as cotton, a
textile product of this invention must have a water-wicking
parameter of at least
(.gamma..sub.o -72)(F/10,000).sup.0.74 (S).sup.0.3 = I.sub.w
cotton/0.014 = 0.086/0.014 = 6.
When the wicking parameter exceeds 6, the textile products of this
invention absorb water as fast as, or even faster than, the cotton
materials tested. The preferred plexifilamentary products of this
invention, however, frequently have wicking parameters well in
excess of 6, as for example, up to 75 or more.
Of course, to fall within the scope of this invention, the textile
product must also be stable to repeated exposure to water, have a
limiting surface tension value (.gamma..sub.o) of greater than 72
dynes/cm. (and, preferably, at least 74 dynes/cm.), a fibril
concentration (F) of at least 5 .times. 10.sup.3 /cm..sup.2, and a
specific surface (S) of at least 0.8 m..sup.2 /gm. These
characteristics and the tests used to measure them are described
below.
DETERMINATION OF LIMITING SURFACE TENSION
The term "limiting surface tension" (.gamma..sub.o) as defined
herein is a characteristic of a synthetic organic polymer and is
independent of the shape of the polymer. That is, fibers,
filaments, fibrillated materials or films of the same polymer all
have the same limiting surface tension characteristic. The limiting
surface tension is important in determining whether a liquid will
be absorbed by a textile product prepared from any given polymer;
liquids with surface tensions (.gamma.) greater than the limiting
surface tension (.gamma..sub.o) characteristic of the polymer will
not be absorbed by a textile product made from the polymer, whereas
liquids with .gamma. less than the .gamma..sub.o of the polymer
will be absorbed at a rate proportional to the difference
(.gamma..sub.o -.gamma.). The term "absorb" as used herein refers
to capillary wicking absorption and not to absorption by swelling
or by a chemical mechanism.
To measure the limiting surface tension characteristic of a textile
product, a series of absorption-rate tests are carried out with
liquids of different surface tension, and the viscosity-normalized
initial absorption rates, I.sub.n, so obtained are plotted on
linear coordinates against the surface tension of the liquid used
in the tests.
To measure the absorption rate, the procedure described generally
by E. M. Buras, Jr., et al., "Measurement and Theory of Absorbency
of Cotton Fabrics," Textile Research Journal, Vol. 20, April, 1950,
pp. 239-248, is followed.
The textile product to be tested is first washed or treated (e.g.,
with water, soap solution, dry-cleaning fluid, or aqueous
hydrofluoric acid) to remove any additives or contaminants, then
rinsed, wrapped on a soft gauze-covered batting, boiled in
distilled water for about 30 minutes, dried in a vacuum oven at
about 60.degree. C., and cooled. The treated product is then
wrapped around a Teflon polytetrafluoroethylene form constructed,
as shown in FIG. 2, by cutting a 5.7-cm.-diameter circle from a
0.16-cm.thick sheet of Teflon and cutting so that dimension 11 is
3.2 cm. and dimension 12 is 4.0 cm. The form is mounted on a yarn
winder to permit rotation about axis 13. The product is fed to the
form through a constant tension device which exerts a load
equivalent to 0.05 gram per denier. The winder transverse pitch is
adjusted so that with each turn of the winder, product is laid on
the form as closely adjacent its neighbor as possible. The textile
product should preferably be twistless when wound. The number of
turns (Y) (i.e., the number of parallel lines of material) per
layer and the number of complete layers (N) needed to wind a total
of about 0.5 gram of product are recorded. A minimum of at least
two layers of product is required, and in those cases where very
large denier yarns are used, the 0.5-gram limit may be exceeded in
order to obtain the required two-layer minimum.
The textile product on the form, prepared as described above and
referred to hereinafter as a "sample pad," is placed in the
absorption-rate testing apparatus shown in FIG. 3. This apparatus
comprises a Buchner funnel 20, containing a flat, horizontal,
fritted-glass plate 21 measuring 5.8 cm. in diameter by 0.55 cm. in
thickness and having a resistance to flow of water of about 0.083
ml./sec./cm. water pressure. The funnel is attached through a
flexible coupling tube 22 to a horizontal tube 23 having a 0.31-cm.
inside diameter. When the apparatus is filled with liquid, tube 23
acts as a reservoir for liquid 24. The top of porous plate 21 is
positioned 1.3 cm. above the top inside surface of the horizontal
reservoir.
To carry out an absorption-rate determination, porous plate 21,
lower portion of funnel 20, flexible coupling tube 22, and part of
horizontal tube 23 are filled by adding liquid 24 through the top
of plate 21, and applying suction to tube 23. All bubbles are
removed from the liquid system. Excess liquid, if any, is removed
from the top of plate 21. The system is thus filled with liquid
from the meniscus in tube 23 to the top of plate 21. The sample pad
25 is then placed on top of porous plate 21 and an evenly
distributed load 26 of 500 grams placed on the pad. The amount of
liquid absorbed by pad 25 is measured by the movement of the
meniscus in tube 23 with the aid of scale 27. Absorption data are
collected as a function of time, starting within about two seconds
after the sample pad and weight are placed on the porous plate and
finishing when less than about 0.01 ml. of liquid is absorbed
during a 60-second period. The cumulative volume of liquid absorbed
q, in ml., is plotted against time t, in seconds. The "initial
absorption rate," I, in ml./sec., is readily determined from the
slope of the straightline portion of the plot, and as reported
herein, the slope is measured for the portion of data in the range
of q/Q values from 0.1 to 0.5 (Q being the total amount in mls. of
liquid absorbed in the test).
To obtain an accurate value for the initial absorption rate of a
test product, the results of the first run on a sample pad are
always discarded. Additional runs are made until the results from
three consecutive runs are substantially constant. Generally, a
total of four runs is sufficient. Between runs, the pads are washed
and then dried at 60.degree. C. in a vacuum oven. At least three
sample pads of the same product should be tested in this manner and
the measured absorption rates from each sample averaged to obtain
an accurate value for the initial absorption rate for the product
under test.
To characterize the liquid-absorption characteristics of the
textile products, the absorption-rate tests described above are
carried out with liquids of different surface tensions. These
liquids are easily prepared from solutions of ethanol in water,
calcium chloride in water or sodium nitrate in water, depending
upon the surface tension desired. To isolate the effect of surface
tension on liquid absorption, a correction is made for liquid
viscosity by multiplying the absorption rates by the viscosity of
the liquids employed and dividing by the viscosity of water. This
procedure gives viscosity-normalized initial absorption rates,
I.sub.n. Surface tensions for aqueous solutions of ethanol, calcium
chloride, and sodium nitrate are given in "Lange's Handbook of
Chemistry," 10th Edition, N. A. Lange, Editor, McGraw Hill, N.Y.,
1967, pages 1664, 1666. Viscosities of ethanol-water solutions are
given on page 1679. Viscosities of aqueous solutions of sodium
nitrate are given in Ann. Physik Chem., 159, 1-35 (1876) and of
calcium chloride in J. Timmermans, "The Physico-Chemical Constants
of Binary Systems in Concentrated Solutions," Vol. III,
Interscience Publishing, Inc., N.Y., 1960, p. 763.
The viscosity-normalized initial absorption rate, I.sub.n, is
plotted on linear coordinates against the surface tension of the
liquid used in the test. Such a plot is illustrated in FIG. 4 where
curve a represents the absorption-rate characteristics of a sample
pad made from very fine denier filaments (not fibrillated) of an
acrylonitrile terpolymer; curve b, a sample pad made from somewhat
fibrillated material of the same terpolymer falling outside the
scope of this invention; and c, a sample pad of well-fibrillated
material of the same terpolymer falling within the scope of this
invention. All three curves intersect the surface-tension axis at
the same value of 80.3 dynes/cm. This value, where the curves
intersect the axis, is the "limiting surface tension"
(.gamma..sub.o) characteristic of the polymer being tested.
All liquid absorption rates of the textile products of this
invention provided herein are determined on pads made with
twistless yarns, even though the determination of limiting surface
tension does not require that the yarns of the sample pad be
twistless.
The textile products of this invention generally display
absorption-characteristic curve similar to that of curve c in FIG.
4. As can be seen from the figure, these curves generally have a
steep straightline portion of negative slope which levels off as
liquid surface tension is reduced. This straightline portion must
be defined by several points in order to obtain an accurate
measurement (or extrapolation) for .gamma..sub.o. To improve the
accuracy of the determination, absorption curves for several
samples of a given polymer are generated and the intercepts of
these curves with the surface-tension axis are averaged to define
.gamma..sub.o to within about .+-.1 dyne/cm. Preferably,
.gamma..sub.o is determined from samples that yield an absorption
rate curve that has a slope steeper than -0.005
ml./sec./dyne/cm.
The limiting surface characteristic of six polymers and cotton,
determined in the above-described manner, are listed in the
following Table I.
TABLE I
Limiting Surface Test Material Tension, .gamma..sub.o, dynes/cm.
Polyethylene 32.1 Polyethylene terephthalate 57.7 6-6 nylon
(polyhexamethylene adi- 64.7 pamide) 6 nylon (polycaproamide) 78.8
Acrylic terpolymer (acrylonitrile/ 80.3 methyl acrylate/sodium
styrene sulfonate, 94/6/0.12) Acrylic copolymer (acrylonitrile/
81.5 sodium styrene sulfonate, 94/6) Cotton 82.2
Of the materials listed in Table I, those made from the first three
polymers, no matter how well fibrillated, do not absorb water;
those of the next three polymers, when in the well-fibrillated form
of this invention, absorb water very rapidly; and, of course, the
last material, cotton, also absorbs water very well. The limiting
surface tension characteristic of all polymers that absorb water in
these tests is greater than 72 dynes/cm., the surface tension of
water. Polymers with limiting surface tension characteristics
greater than 74 dynes/cm. are preferred. The .gamma..sub.o can
range up to 85 or greater.
DETERMINATION OF FIBRIL CONCENTRATION AND SPECIFIC SURFACE
It has been found that the rate at which a textile product of this
invention absorbs liquid depends not only on the (.gamma..sub.o
-.gamma.) driving force and the viscosity (.mu.) of the liquid, but
also on fibril concentration (F) and specific surface (S). F may be
visualized as being related to the number of capillary paths
available to the liquid and S may be thought of as being related to
the surface available per path. These characteristics and tests
used to measure them are described as follows:
Fibril Concentration (F)
Fibril concentration (F) is defined as the number of "ends" per
cm..sup.2 of textile product cross-section and can be determined by
the following formula which applies to the sample pad used for the
absorption-rate test:
F = [(L) (Y) (n)]/[(t) (w)]
where L is the number of layers of product in the sample pad, Y is
the number of turns per layer on the pad (i.e., Y is defined as the
number of parallel lines of product). Thus, when yarn is employed,
Y is the number of turns per layer and when a sheet or ribbon is
used, Y is the number of sheets or ribbons that lie side by side in
each layer of the sample pad. Whether yarn, bundles, sheets,
strands, ribbons, filaments, etc., all will be referred to
hereinafter as yarn. The number of fibrils per cross-section of
yarn is n; the total thickness in cm. of the material while under
load in the Buchner funnel of the absorption-rate apparatus
(excluding the thickness of the Teflon form) is t; and the total
width in cm. of the sample wound on the pad is w. The number of
fibrils or ends per yarn n, is determined from photomicrographs of
the cross-section of the opened yarn (e.g., an opened
plexifilamentary strand). Four representative cross-sectional
samples, each 5 microns thick, are taken from the length of the
yarn and the photomicrographs of these cross-sections are prepared
by standard procedures, well known in the art. Three fibril counts
are made on each of the photomicrographs. The 12 counts are then
averaged to obtain n. Care must be taken not to alter the yarn
(e.g., by breaking tie points, breaking fibrils or joining fibrils)
during this determination. The photomicrograph should provide a
lineal magnification of about 500X. Each individual fibril appears
as an independent particle on the photomicrograph. A representation
of such a photomicrograph is shown in FIG. 6 where several types of
fibrils are identified, as discussed further below.
To fall within the scope of this invention, F must be at least 5
.times. 10.sup.3 /cm..sup.2. Below this value of F, the materials
are coarse and unsuited for general textile use. In general, F can
range up to 15 .times. 10.sup.4 /cm..sup.2, or more.
Specific Surface (S)
Specific surface (S) of a textile product is derived from optical
measurements of the light scattering coefficient (s). High specific
surface provides good covering power and promotes rapid absorption
of liquid. It is known that a light scattering coefficient is a
measure of the specific surface of a material (TAPPI, Vo. 42, No.
12, December 1959, pages 986-994). Light scattering measurements
are used to derive the specific surface of the textile products of
this invention by the procedure described below.
A sample suitable for light reflectance measurements is prepared by
winding a close-packed parallel warp of product, preferably in the
form of yarns, on a rectangular frame (e.g., measuring about 10 cm.
.times. 8 cm.). A yarn winder (e.g., "Suter" yarn evenness
controller) is used to hold the frame and rotate it. A light
tension (e.g., at about 2 grams) is maintained on the yarn to keep
it essentially straight. The guide traverse controlling the number
of threads per cm. is adjusted to provide a specimen with no gaps
between the elements of the parallel warp. When the sample is in
the form of a sheet or fabric, winding on a frame is not necessary;
the flat planar sample may be used directly.
A Bausch and Lomb Opacimenter is adjusted to read absolute
reflectance by calibration with a standard having an absolute
reflectance of about 75 percent. Absolute reflectance is measured
at ten points on the sample with the sample backed by a white body;
then ten more measurements are made with the sample backed with a
black body. The sample is placed over the opening of the instrument
so that the yarns run parallel to a line defined by the 5 and 11
o'clock positions (if it is assumed that the opening is a clock
facing the operator). The ten readings are averaged to give, in
each case,
R.sub.o = absolute reflectance with black backing
R = absolute reflectance with white backing
The rectangular area covered by the sample is measured. The sample
is then removed from the wire frame and weighed. The basis weight M
in g./m..sup.2 is calculated.
The formulas given by B. D. Judd "Color In Business, Science and
Industry," John Wiley and Sons, Inc., 1961, pp. 322, 323 (namely,
equations 48 and 55) are used to determine the scattering power K.
The scattering coefficient s is then determined from the
equation:
s = K/M
To convert this scattering coefficient into optical specific
surface area, the following equation is used:
S = s/C.sub.o N.sup.2
where C.sub.o is an instrument calibration constant and N.sup.2 is
the fiber surface reflectivity. The calibration constant can be
determined by measuring s for a variety of yarns of known specific
surface (e.g., smooth round fibers). This calibration constant
should not differ much from unity; in the measurements given here
it generally is about 0.9. Fiber surface reflectivity N.sup.2 is
calculated by the expression
N.sup.2 =[(n - 1)/(n + 1)].sup.2
where n is the mean index of refraction of the fiber. If the fiber
is birefringent and has two values for the index (n for parallel
and .sub..vertline. for perpendicular), then
n = (n + 2n.sub..vertline.)/3
It should be recognized from the above discussion that some textile
products could have large specific surface S principally due to
extraneous effects, e.g., the presence of numerous closed-cell
internal voids or pigments. Although such products might have the
same specific surface values as products without closed-cell
internal voids, they would not possess the same water-absorption
characteristics. For example, closed-cell voids would not generally
be available to a liquid and would not contribute to water
absorption even though they contribute to light scattering.
To distinguish these products having closed-cell internal voids
from the products without such voids, the scattering coefficient
may be measured on a wet specimen. Because water or any common
liquid has an index of refraction closer to that of the polymer
than does air, the surface reflectivity wet is less than when dry
and the scattering coefficient correspondingly lower. In the ideal
case where all of the available surface is wetted by liquid, the
wet and dry scattering would be proportional to the wet and dry
reflectivity. However, in the test procedure summarized below, the
sample is not immersed when it is tested. It is only wetted. The
sample is (1) soaked for 5 to 10 minutes in a water bath, (2)
removed from the bath, (3) has one edge brought briefly into
contact with a paper towel to eliminate excess liquid, and (4) then
has its scattering coefficient determined as above. Under these
test conditions, it is found that the products of this invention
generally have a ratio of wet-to-dry scattering coefficient of much
less than 0.4.
The textile products of this invention generally have a specific
surface (dry) of at least 0.8 m..sup.2 /gm. S can range up to 3 or
more, but below 0.8, the covering power of the material is less
than desired. An accepted measure of cover is Contrast Ratio which
is defined in ASTM Standards, Method D589-65, Part 15, April 1968,
p. 93 as 100 (R.sub.o /R), and as recorded herein is normalized to
a constant basis weight of 34 g./m.sup.2.
Stability to Water
The products of this invention are also stable to repeated exposure
to water. The term "stable to repeated exposure to water" means
that the products do not change their structural characteristics
(e.g., fibril concentration, specific surface or limiting surface
tension) upon such repeated exposure, and that the products remain
essentially unswollen, do not become slimy upon being wetted, and
upon drying do not become stiff or hardened but rather remain
essentially as pliable and soft as before wetting and drying. The
products are durable and derive their water-absorption
characteristics from their basic structure and not from an additive
that may be present only temporarily or that might be effected or
removed upon repeated use of solvents or detergents commonly
employed in laundering and drycleaning operations. Thus, the term
"repeated" is understood as not including any initial washings of
the product which may wash out or extract such additives. Such
additives which may be present in the products of this invention
include the usual textile additives, e.g., dyes, pigments,
antioxidants, delusterants, antistatic agents, adhesion promoters,
ultraviolet stabilizers, and the like.
THE PRODUCTS AND THEIR PREPARATION
The term textile products as used herein is defined as including
strands, yarns, tapes, fabrics, ribbons, and the like. All these
textile products are made of assemblies of fibrils. The
"non-cellulosic, synthetic organic polymers" from which the textile
products are prepared are defined herein as polymeric products of
at least film-forming molecular weight which are man-made by
polymerization or copolymerization of various organic monomer
units. Polymers made by chemical modification of naturally
occurring products are not included in this definition.
Preferably, the textile products of this invention are made from
acrylonitrile or polyamide polymers. The term "polymer" as used
herein includes both homopolymers and copolymers, including binary
and terpolymers, and the like. Preferred polymers are the
polyacrylonitriles, especially the acrylonitrile copolymers which
contain major amounts of acrylonitrile units, and most preferably
at least about 80 percent by weight acrylonitrile units. Comonomers
with acrylonitrile include styrene, methyl acrylate, itaconic acid,
sodium styrene sulfonate, vinyl acetate, vinyl pyridine, and the
like. Useful polyamides include polycaproamide and its homologue
polyhexamethylene urea, poly-1,4-benzamide and methylphenylene
diamine isophthalic acid/terephthalic acid (70/30). Other polymers
which may be used to make textile products capable of absorbing
water are those containing large amounts of ionic groups (e.g.,
sulfonic or carboxylic acids) or hydrogen bonding sites (e.g.,
amide or hydroxyl groups).
Common polymers which do not permit absorption of water are
polypropylene, polyvinyl chloride, polyethylene terephthalate,
polystyrene and the polyacetals.
The "fibrils" of the fibril assemblies are fine elements which tend
to lie roughly parallel to the major axis of the assembly. An
assembly or portion of an assembly of fibrils is shown in FIG. 5
and in the photomicrograph of FIG. 6. A majority of the fibrils 30
are joined or interconnected to other fibrils to form a continuous
structure. Each fibril penetrates the array of adjacent fibrils in
a random fashion before terminating at a junction as indicated by
points 31. The fibrils may be interconnected in a three-dimensional
array. Thus, the fibrils may be thought of as an intermingled
non-planar matrix of very thin film or ribbon-like elements that
are interconnected (joined) at various points to form a web-like
three-dimensional network or plexus.
The "fibrils" come in many irregular shapes and sizes as shown in
FIG. 7 which is a drawing of an enlarged cross-section of an
assembly of fibrils called a plexifilamentary strand. The rather
irregular, convoluted, rolled up, or folded shape of most of the
fibrils provides bulk to the strand and prevents excessively close
packing of fibrils, which could block passages between fibrils
thereby deleteriously affecting the wicking and the absorption of
water.
"Film-fibrils" are the basic units from which the fibrils are
built. Individual film-fibrils may have thicknesses averaging less
than one or two microns, as measured with an interference
microscope. The individual film-fibrils may occasionally appear as
ribbons, such as the one labeled a in FIG. 7. More often, the
film-fibrils are folded or rolled or convoluted about their axis,
frequently appearing as multilayer laminates or aggregates (labeled
b). Sometimes film-fibrils contain voids (labeled c). Any of these
configurations, or combinations thereof, may constitute the
"fibrils" defined above. It will be seen that the cross-section of
the fibrils is irregular, thus lacking in symmetry and providing a
rough fibril surface. It is believed that such an irregular surface
promotes water absorption. Thus, the fibril may correspond to a
single film-fibril but more usually corresponds to an aggregation
of film-fibrils and may be one to several times as thick as the
film-fibrils of which it is constituted. Thickness measurements can
be made with an interference microscope by the methods discussed in
"Interference Microscopy," King, Rienitz and Schulz, translated by
J. H. Dickson, published by Hilger and Watts, Ltd., 1964.
A preferred type of fibril assembly is a plexifilamentary strand.
Plexifilamentary strands are a unitary or integral assembly of
fibrils which because of their high degree of interconnection among
fibrils form a continuous web or strand from one piece of polymer.
The term "continuous" is used herein in the sense that the
plexifilament is an integral structure (due to the joining) over
lengths many times greater than the length of its individual fibril
components (i.e., often many meters or longer). These continuous
plexifilaments may, of course, be cut into staple fiber lengths
(i.e., lengths suitable for conversion into yarn by established
methods, usually 0.6 cm. or greater). They may also be combined
intermingled or twisted together, and the like, to obtain higher
denier.
The textile products of this invention and especially the
plexifilamentary strands, are prepared by flash-extruding a uniform
dispersion of the non-cellulosic synthetic organic polymer in water
amounting to 25-40 percent by weight of the polymer through an
orifice of about 0.02 to 0.75 mm. diameter. To maintain uniformity
of the aqueous dispersion, particulate water-insoluble stabilizers,
comprising up to 15 percent (preferably 2 to 12 percent) based on
weight of the polymer employed, may be used. Such stabilizers
include: inorganic oxides, such as aluminum oxide; silicon
compounds, such as colloidal silica, aluminum silicate, ethyl
orthosilicate; cellulose; and cross-linked vinyl polymers, for
example, having sulfonic acid groups. The dispersion may also be
mechanically stirred to aid in maintaining uniformity. The
dispersion is heated and then extruded at temperatures between
about 260.degree. C. and about 280.degree. C. and pressures of
between about 50 atmospheres and about 110 atmospheres. The pH of
the aqueous dispersion is maintained on the acidic side, usually by
addition of sulfuric acid, and pH's of between 1.0 and 6.0,
depending on the stabilizer present, are most useful. It is
generally also useful to hold the dispersion at its extrusion
temperature for a short time before extruding, e.g., for about 1 to
5, 10, 15 or even 20 minutes; and it is sometimes convenient to
raise the temperature in two discrete and separate levels during
the heating. Moreover, it is sometimes advantageous to employ a
pressure let-down region immediately adjacent the extrusion
orifice. If desired, when the polymer used is an acrylonitrile
polymer, a mixture of water and acetonitrile may be employed as the
dispersant medium and lower extrusion temperatures (e.g.,
220.degree. C.) may be used. The procedure, described in greater
detail in the examples below, is preferred, particularly for use
with the acrylonitrile polymers.
The textile products of this invention may also be prepared by
flash spinning a solution of the non-cellulosic synthetic organic
polymer. In this procedure, the solvent employed is one that should
have a boiling point below the flow temperature of the polymer and
should be able to form a single-phase solution of the polymer at
the extrusion temperature but form a two-liquid phase system at the
same temperature when the pressure on the solution is reduced in a
let-down chamber. The extrusion temperature employed should be
within 40.degree. C. of the critical temperature of the solvent;
and a pressure of roughly 200-300 p.s.i. above the phase boundary
at the extrusion temperature should be employed. Preferably, a
let-down chamber is used and in this chamber the pressure is
dropped to a value about 200 p.s.i. below the phase boundary. The
polymer concentration in the solution to be flash spun can range
from about 10-40 percent by weight of the solution.
EXAMPLES
In all examples, the yarns obtained are characterized in accordance
with the procedures described above after all additives, finishes
or contaminants have been removed. For example, siliceous materials
are removed from the textile products by washing in dilute aqueous
hydrofluoric acid. Measured characteristics and some process
conditions for all samples prepared in Examples I through III are
given in Table II those of Examples IV and V, in Tables III and IV,
respectively. Also, in the succeeding examples, L is the length and
D is the diameter of a circular orifice or length of tubing or
pipe.
EXAMPLE I
In this example, 15 samples of textile products in the form of
continuous plexifilamentary strands having interconnected fibrils
of irregular shape are prepared in accordance with the details
given below from an acrylic terpolymer comprising 94 parts
acrylonitrile (AN), 6 parts methyl acrylate (MA) and 0.12 parts
sodium styrene sulfonate (SSS).
Sample 1. A slurry comprising 35 grams of the acrylic terpolymer, 2
grams of "Cab-O-Sil" colloidal silica and 79 ml. of water is
prepared and adjusted to a pH of 4.8. A portion of this slurry is
loaded into a cylindrical pressure vessel of about 15-cm. length
and 2-cm. inside diameter which is fitted with a closed spinneret
at one end and a piston at the other. Nitrogen pressure of 54.4
atm. is applied to the rear of the piston. The contents of the
vessel are heated to 230.degree. C., held at temperature for 5
minutes, and heated further to about 245.degree. C. Total time of
heating is about 20 minutes. The orifice, which measures 0.64 mm. D
.times. 1.27 mm. L, is then opened and the sample is extruded.
Sample 2. A slurry is prepared as for Sample 1 except that 65 ml.
of water is used. A 100-gram portion is concentrated at 60.degree.
C. to a weight of 68 grams. A portion of this is extruded as per
Sample 1, except that the temperatures are 250.degree. and
270.degree. C. and the orifice measures 0.51 mm. D .times. 0.64 mm.
L.
Sample 3. A slurry is prepared as for Sample 1 except that 50 ml.
of water is used and a portion processed in the same manner except
that a 4-minute hold at 250.degree. C. and extrusion at 250.degree.
C. are used.
Sample 4. An aqueous slurry containing 29.5 percent of the acrylic
terpolymer and 3.7 percent finely divided aluminum silicate is
mixed continuously in a 208-liter tank and pumped with a metering
pump through 6.1 m. of steam-jacketed tubing of 6.35 mm. I.D.
(inside diameter) in which it is heated to about 150.degree. to
170.degree. C. The slurry is then raised to 280.degree. C. and 83.3
atm. in an additional 6.1 m. of electrically heated, 7.72-mm. I.D.
tubing.
The slurry is passed through a 0.46 mm. D .times. 0.46 mm. L
orifice into a pressure let-down chamber of 3.2-cm..sup.3 volume,
and finally through a 0.38 mm. D .times. 0.38 mm. L orifice to the
atmosphere. In the let-down chamber, the temperature is 280.degree.
C. and the pressure is 63.9 atm. Total residence time in the heated
zones is approximately 1 minute.
Sample 5. A slurry comprising 35 g. of the acrylic terpolymer, 0.14
g. of "Cab-O-Sil" silica, 6.0 g. of finely divided aluminum
silicate, 11 ml. of water and 60 ml. of acetonitrile is prepared. A
portion of this slurry is processed in the same manner as for
Sample 1 except that extrusion is at 255.degree. C. through a 0.76
mm. D .times. 1.52 mm. L orifice.
Sample 6. An aqueous slurry containing 31 percent of the acrylic
terpolymer and 4 percent finely divided aluminum silicate is
processed continuously in the same equipment as used for Sample 4
except that (1) the slurry in the final heating stage reaches
279.degree. C. and 85.7 atm., (2) the orifice at the entrance to
the let-down chamber is 0.51 mm. D .times. 0.81 mm. L, and (3) the
extrusion orifice, which measures 0.46 mm. D .times. 0.46 mm. L, is
connected to a "shroud" comprising a 70.degree. cone opening into a
cylindrical tube of 3.05 mm. D .times. 1.78 mm. L.
Sample 7. The same materials and apparatus as for Sample 6 are used
except that: the slurry contains 31.5 percent acrylic terpolymer,
is adjusted to a pH of 4.7, and finally heated to 272.degree. C.
and 91.8 atm.; the first orifice measures 0.51 mm. D .times. 0.51
mm. L, and steel wool is packed in the let-down chamber.
Sample 8. The same materials and apparatus as for Sample 6 are used
except that: the slurry contains 31.5 percent acrylic terpolymer,
is adjusted to a pH of 5.2, and is finally heated to 270.degree. C.
and 105.4 atm. in final heating-stage tubing of 18.3-meter length;
and the "shroud" has a 40.degree. entrance cone.
Sample 9. The same materials and apparatus as for Sample 7 are used
except that: the slurry contains 31.5 percent acrylic terpolymer
and 3 percent aluminum silicate, is adjusted to a pH of 4.8, and is
finally heated to 280.degree. C. and 90.1 atm. The extruded
plexifilament is drawn 1.5X at 190.degree. C.
Sample 10. The same materials and apparatus as for Sample 6 are
used except that: the slurry contains 29.5 percent acrylic
terpolymer and 3.7 percent aluminum silicate; and is finally heated
to 273.degree. C. and 100.3 atm.
Sample 11. The same components, process and apparatus as for Sample
9 are used except that the extruded plexifilament is not drawn.
Sample 12. The same materials and apparatus as for Sample 6 are
used except that: the slurry contains 31.5 percent acrylic
terpolymer and is finally heated to 270.degree. C. and 90.1 atm.;
the entrance orifice to the let-down chamber is 0.38 mm. D .times.
0.38 mm. L; the extrusion orifice is 0.30 mm. D .times. 0.30 mm. L;
and the tubular section of the "shroud" is 2.03 mm. D .times. 1.27
mm. L.
Sample 13. An aqueous slurry containing 31.4 percent of the acrylic
terpolymer and 4.6 percent "Cab-O-Sil" colloidal silica is prepared
and then processed in the same way as Sample 1, except that the
temperature after the final heating is 260.degree. C. and the
extrusion orifice measures 0.064 mm. D .times. 0.127 mm. L.
Sample 14. The same materials and apparatus as for Sample 6 are
used except that: the slurry contains 32.5 percent acrylic
terpolymer and 4.1 percent finely divided aluminum silicate, is
adjusted to a pH of 4.0, is finally heated to 275.degree. C. and
97.8 atm., and in the let-down chamber conditions are 273.degree.
C. and 91.1 atm.; the orifice at the inlet to the let-down chamber
measures 0.76 mm. D .times. 0.89 mm. L; the extrusion orifice
measures 0.33 mm. D .times. 0.33 mm. L; and the volume of the
let-down chamber is 12.1 cm..sup.3.
The extruded plexifilamentary yarn is passed through a 46-cm. long
bath containing 95/5 water/ethylene carbonate at 34.3 cm./sec. at
room temperature, then wrapped on a bobbin, and finally dried in an
oven under vacuum at 80.degree. C.
Sample 15. This sample is prepared the same way as Sample 14 except
that the post-extrusion treatment bath contains 97.5/2.5
water/ethylene carbonate, the yarn speed in the bath is 10.7
cm./sec. and the yarn is dried by passage through a 60-cm.-long
hot-tube oven held at 240.degree. C.
As shown in Table II, Samples 1 through 13 are arranged in order of
increasing fibril concentration. With the exception of Samples 1, 2
and 3, all samples of Example I absorbed water as rapidly as, if
not more rapidly than, cotton (see Example V). Samples 1, 2 and 3
each are outside the scope of this invention because of their low
fibril concentration (i.e., less than 5 .times. 10.sup.3
/cm..sup.2).
Samples 14 and 15 show the general effect of how reducing specific
surface, reduces the absorption rate. These two samples, which were
given a special post-extrusion ethylene-carbonate treatment to
reduce their specific surface to the values listed in Table II
still absorb water as well as cotton, but Sample 14, which because
of its very low specific surface, is outside the scope of this
invention, and has poorer cover power than is desired for textile
applications.
Samples 4 through 13 and 15 are examples of this invention. If such
continuous plexifilamentary yarns are to be dyed to a dark hue, one
would choose a sample with a small value of specific surface (e.g.,
Sample 15). If whiteness is desired, a plexifilamentary yarn of
high specific surface with large light-scattering ability would be
preferred.
EXAMPLE II
In this example, four samples of textile products in the form of
continuous plexifilament yarns falling within the scope of this
invention are prepared from an acrylic copolymer comprising about
96 parts acrylonitrile (AN) and 4 parts sodium styrene sulfonate
(SSS).
Sample 1. A slurry comprising 35 grams of the acrylic copolymer, 65
ml. of water, and 9 grams of ethyl orthosilicate is prepared, and
its pH adjusted to 1.4. A portion of this slurry is loaded into the
same pressure vessel as used for Example I, Sample 1. Nitrogen
pressure of 54.4 atm. is applied to the piston. The vessel is then
heated to 170.degree. C., held at 170.degree. C. for 5 minutes, and
finally heated to 260.degree. C. he contents are then passed
through a 0.51 mm. D .times. 0.64 mm. L orifice into a 1.8
cm..sup.3 pressure let-down chamber, then through a 0.46 mm. D
.times. 0.46 mm. L extrusion orifice which is attached to the same
"shroud" as that described in Example I, Sample 6.
Sample 2. A slurry comprising 35 grams of the acrylic copolymer, 3
grams of "Cab-O-Sil" silica, and 65 ml. of water is prepared and
the pH adjusted to 1.5. A portion of this slurry is processed as in
Example I, Sample 1, except that a 2-minute hold at 230.degree. C.
is used, and the extrusion orifice measures 0.46 mm. D .times. 0.46
mm. L.
Sample 3. A mixture of 4,620 grams of acrylic copolymer, 770 grams
of "Triton X-100" isooctyl phenoxy polyoxyethanol surfactant, 6,160
grams of acetonitrile, and 3,850 grams of water is heated in a
stirred 18.9-liter autoclave to 222.degree.-223.degree. C. and 118
atm. Total heat-up time is 1 hour. The charge completely fills the
vessel at the extrusion temperature and the pressure is internally
generated by the confided liquid. The mixture is passed through a
100-mesh filter screen, then through a 0.61 mm. D .times. 0.64 mm.
L orifice into a 1.27 cm. D .times. 8.4 cm. L pressure let-down
chamber and finally through a 0.41 mm. D .times. 0.38 mm. L orifice
to the atmosphere. Within the let-down chamber, the temperature is
222.degree. C. and the pressure is 105 atm. The resultant
plexifilamentary yarn is drawn 2.8X at about 200.degree. C. The
"Triton X-100" is removed by washing with water.
Sample 4. The same materials and apparatus as for Sample 3 are used
except that: the temperature and pressure in the autoclave are
221.degree. C. and 120 atm.; the total heating time is 40 min.; the
let-down chamber inlet orifice measures 0.86 mm. D .times. 0.64 mm.
L and the extrusion orifice measures 0.58 mm. D .times. 0.51 mm. L;
within the let-down chamber the temperature is 219.degree. C. and
the pressure is 102 to 103 atm.; and the extruded plexifilamentary
yarn is drawn 2.4X.
EXAMPLE III
In this example, two samples of textile products of this invention
in the form of plexifilamentary strands are made of 6 nylon
(polycaproamide). Measured characteristics of these samples are
also listed in Table II.
Sample 1. A slurry comprising 35 grams of polycaproamide, 5.0 grams
of "Cab-O-Sil" silica, and 65 ml. of water is mixed and a portion
is loaded into the same pressure vessel as used for Example I,
Sample 1. The pH of the mixture is 6.0. Nitrogen pressure of 54.4
atm. is applied to the piston and the vessel is heated to
230.degree. C., held at 230.degree. C. for 5 minutes, and then
heated further to about 260.degree. C. Total heat-up time,
including the hold, is about 20 minutes. The material is then
extruded through an orifice measuring 0.64 mm. D .times. 1.27 mm.
L.
Sample 2. A mixture comprising 35 grams of polycaproamide and 65
grams of 95 percent ethanol is heated to 200.degree. C. in a
cylindrical autoclave of about 1-liter capacity, which is fitted
with a piston which applies a pressure of 170 atm. to the mixture.
Total heat-up time is about 35 minutes. The autoclave is connected
to a twin autoclave by two square channels, each being about 6.25
mm. .times. 6.25 mm. .times. 13 cm. long, each having four
90.degree. bends and the interior of each being connected to the
other three times between their common entrances and exits. The
heated charge is forced back and forth through this tortuous path
to ensure good mixing. The charge is finally passed from one of the
cylinders through a 0.64 mm. D .times. 0.64 mm. L orifice into a
1.7-cm..sup.3 pressure let-down chamber, and then through a 0.46
mm. D .times. 0.51 mm. L extrusion orifice to atmospheric
conditions. ##SPC1##
EXAMPLE IV
In this example, several other copolymers of acrylonitrile are used
to make six samples of textile products of this invention. The
products are in the form of plexifilamentary yarns comprising
continuous assemblies of fibrils, the fibrils being generally of
irregular cross-section. The yarns are stable to repeated exposure
to water, have a limiting surface tension (.gamma..sub.o) of
greater than 72 dynes/cm., a specific surface (S) of greater than
0.8 m..sup.2 /g., a fibril concentration (F) of greater than 5
.times. 10.sup.3 /cm..sup.2, and an H parameter, (.gamma..sub.o
-72)(F/10.sup.4).sup.0.74 (S).sup.0.3, of greater than 6.
Sample 1. A slurry is prepared containing 13.3 grams of a copolymer
comprising 94 parts by weight of acrylonitrile (AN), about 0.1 part
sodium styrenesulfonate and 6 parts vinyl acetate (VA), 26 ml. of
water, and 1.4 grams of "Cab-O-Sil" colloidal silica. The pH is
adjusted to 4.0. The slurry is loaded into the same pressure vessel
as used for Example I, Sample 1. A pressure of 54.4 atm. is
applied. The slurry is heated rapidly to 260.degree. C., then
passed through a filter comprising a 1.5-cm. thickness of stainless
steel wool and a 100-mesh screen, and finally extruded through a
0.63-mm. D .times. 0.63-mm. L orifice which is connected to a
"shroud" having a 60.degree. cone of about 2-mm. length.
Sample 2. The same materials, apparatus, and process as used for
Sample 1 are employed for this sample, except that the slurry
contains 1.4 g. of finely divided aluminum silicate in place of the
"Cab-O-Sil" and the pH is adjusted to 4.5.
Sample 3. A slurry is prepared containing 13.3 grams of a copolymer
comprising 90 parts acrylonitrile (AN), about 0.1 part sodium
styrenesulfonate and 10 parts vinyl acetate (VA), 26 ml. of water,
and 2.0 g. of "Cab-O-Sil." The pH is adjusted to 4.9. The slurry is
loaded into the same pressure vessel as is used for Sample 1. A
pressure of 54.4 atm. is applied. The slurry is heated rapidly to
230.degree. C., held at temperature for 5 minutes and then heated
further to about 260.degree. C. Total heating time is about 14
minutes. The contents of the vessel are then extruded to the
atmosphere through a 0.64 mm. D .times. 0.64 mm L orifice.
Sample 4. A slurry is prepared containing 10.0 grams of a copolymer
comprising 95.5 parts acrylonitrile (AN) and 4.5 parts ethylene
(E), 22 ml. of water and 1.5 grams of "Cab-O-Sil." The pH is
adjusted to 4.8. The same process and apparatus as used for Sample
3 is used to prepare this sample except that the final temperature
before extrusion is 265.degree. C. and the orifice measures 0.51
mm. D .times. 0.51 mm. L.
Sample 5. A slurry is prepared containing 13.3 grams of a copolymer
comprising 93.3 parts acrylonitrile (AN) and 6.7 part
2-methyl-5-vinylpyridine (MVP), 26 ml. of water and 2.0 grams of
"Cab-O-Sil." The same process and apparatus as used for Sample 3 is
used for this sample, except that the total time of heating is
about 15 minutes.
Sample 6. A slurry is prepared containing 6.7 grams of a terpolymer
comprising 88.8 parts acrylonitrile (AN), 5.8 parts methyl acrylate
(MA) and 5.4 parts 2-methyl-5-vinyl-pyridine (MVP), 10 ml. of water
and 0.7 gram of "Cab-O-Sil." The same process and apparatus as used
for Sample 3 is used to prepare this sample.
TABLE III
PLEXIFILAMENTARY YARNS OF EXAMPLE IV
Product Characteristics Sample Polymer Total Den- No. Components
Denier sity.sup.2 I.sub.w.sup.3 1 AN/VA -- 94/6 460 0.091 0.44 2
AN/VA -- 94/6 530 0.104 0.32 3 AN/VA -- 90/10 634 0.094 0.58 4 AN/E
-- 95.5/4.5 322 0.089 0.37 5 AN/MVP -- 93.3/6.7 546 0.120 0.54 6
AN/MA/MVP -- 88.8/5.8/5.4 840 0.091 0.39 Notes .sup.1 The numbers
represent the respective parts by weight of each polymeric
component, and AN = acrylonitrile VA = vinyl acetate E = ethylene
MVP = 2-methyl-5-vinylpyridine MA = methyl acrylate .sup.2 Density
of the textile product (in the water-absorption sample pad) in
gram/cm.sup.3 .sup.3 I.sub.w is the water-absorption rate in
ml/sec.
EXAMPLE V
In this example, several yarns made from conventional fibers or
filaments are tested in accordance with the procedures of this
application for the purpose of comparing their water-absorption
characteristics, bulk and cover power with those of the textile
products of this invention. These yarns include two of
acrylonitrile terpolymer, one of 6-nylon and four of cotton. Their
characteristics are listed in Table IV.
Sample 1. A dimethyl formamide solution containing 26 percent of
the acrylic terpolymer used in Example I is dry spun through a
10-hole spinneret having 0.16 mm.-diameter holes. Solution
temperature is 80.degree. C. and spinning pressure is 6.1 atm.
Wind-up speed is 128 m./min. The yarn is drawn 4.5X at 150.degree.
C. Four yarns are put together without twisting to make a bundle of
forty 2-dpf. continuous filaments (dpf. = denier per filament).
Sample 2. A 23 percent solution of the same acrylic terpolymer used
for Sample 1 is dry spun through a 10-hole spinneret having
0.13-mm. diameter holes. Spinning pressure is 4.8 atm. and solution
temperature is 45.degree. C. The extrudate is collected at the rate
of 272 m./min. with a spin-stretch factor of 10. The yarn is plied
and steam drawn 13X. The final yarn has 2,000 filaments of 0.2
dpf.
Sample 3. This commercial continuous filament nylon yarn
manufactured and sold by Allied Chemical Company, Hopewell,
Virginia, as 200-16-1.5Z-BW, is a bright 6-nylon (polycaproamide)
yarn having 16 filaments totaling 200 denier. The yarn has a Z
twist of 11/2 turns per inch.
Samples 4, 5, 6, 7. These samples are conventional spun yarns of
cotton (4, 5). Sample 6 is a spun yarn removed from a man's cotton
T-shirt. Sample 7 is a spun yarn removed from a cotton towel. The
yarns are characterized after removal of all additives and
finishes. ##SPC2##
Even though Samples 1 and 2 of this example have very high apparent
"wicking parameters" and are made of polymer that in the textile
products of this invention absorb water very rapidly, these samples
of continuous filament yarns still exhibit very low water
absorption rates. This distinction between the yarns of this
example and the textile-product yarns of the invention is shown
further in the graph of FIG. 1 which indicates about a 100-fold
advantage in water absorption rate for the textile-product yarns of
this invention over the "conventional" acrylic yarns and an even
greater advantage over the 6-nylon yarn of Sample 3. Also, FIG. 1
shows the products of this invention absorb water at least as well
as and usually better than the conventional cotton yarns of this
example (Samples 4-7). Comparison of Tables II and III shows the
further advantage of the textile products of this invention over
conventional yarns in cover power (i.e., contrast ratio of usually
between 70 and 85 percent vs. 25-50 percent) as well as the
satisfactory bulk (i.e., reciprocal density) of these products.
The textile products of this invention are intended for a wide
range of textile uses. Because of the extraordinary ability to
absorb large quantities of water rapidly, many can serve in end
uses from which synthetic organic polymeric fibers have heretofore
been excluded. In many instances, spun cotton yarns may be inferior
to the preferred plexifilamentary strands of this invention,
because cotton requires high amounts of twist to form a continuous
load bearing structure while the preferred plexifilamentary strands
are a continuous network as formed and require little or nor twist.
High amounts of twist reduce the absorption rate of yarns. However,
the strands may be twisted or may be cut into staple lengths and
spun into yarns as is cotton or may be converted into paper or
processed into other nonwoven materials. The resultant products
still provide acceptable water absorption rates along with
satisfactory cover and bulk.
Fabrication of a terry-cloth towel completely from textile-product
yarns of this invention is illustrated as follows: plexifilaments
of acrylonitrile terpolymer are spun essentially in the same manner
as those of Example I, Sample 8. The plexifilaments are prepared
into yarns and then fabricated into a terry-cloth towel. The towel
contains a woven ground having 25.2 ends per cm. (in the warp
direction) and 20.5 picks per cm. (in the fill direction); has a
pile-to-ground-yarn weight ratio of 5.8/1, weighs 373
grams/m..sup.2 ; and measures 0.43 cm. in thickness. The ground
yarns are of 260 to 265 denier and have a twist of two turns per
cm. The yarn for the pile is passed at 15.2 m./sec. through an
interlacing jet operating with steam at 9.5 atm. and 275.degree. C.
The pile yarn is 223 denier. The towel is very soft and highly
effective in absorbing water.
The foregoing detailed description has been given for clearness of
understanding only and no unnecessary limitations are to be
understood therefrom. The invention is not limited to the exact
details shown and described for obvious modifications will occur to
those skilled in the art.
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