EP0029666A1 - Method of blending homofilament and heterofilament staple fibres, a blend produced thereby and a bonded web produced from such blend - Google Patents

Method of blending homofilament and heterofilament staple fibres, a blend produced thereby and a bonded web produced from such blend Download PDF

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Publication number
EP0029666A1
EP0029666A1 EP80303861A EP80303861A EP0029666A1 EP 0029666 A1 EP0029666 A1 EP 0029666A1 EP 80303861 A EP80303861 A EP 80303861A EP 80303861 A EP80303861 A EP 80303861A EP 0029666 A1 EP0029666 A1 EP 0029666A1
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EP
European Patent Office
Prior art keywords
tow
blend
fibres
produced
homofilament
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP80303861A
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German (de)
French (fr)
Inventor
Kenneth Porter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imperial Chemical Industries Ltd
Original Assignee
Imperial Chemical Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imperial Chemical Industries Ltd filed Critical Imperial Chemical Industries Ltd
Publication of EP0029666A1 publication Critical patent/EP0029666A1/en
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G1/00—Severing continuous filaments or long fibres, e.g. stapling
    • D01G1/06—Converting tows to slivers or yarns, e.g. in direct spinning
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends

Definitions

  • This invention relates to a method for producing a blend of homofilament and heterofilament fibres, such fibres usually being destined for use in the production of non-woven webs by a carding process.
  • the blending of such fibres, in a staple form is carried out as a first stage in a carding process.
  • the staple fibres themselves are produced by drawing a tow of either continuous heterofilaments or continuous homofilaments, subjecting the drawn tow to a crimping operation and chopping the tow into a convenient staple length.
  • a method of blending homofilament and heterofilament fibres together comprising forming a continuous composite tow from a plurality of the homofilaments and a plurality of the heterofilaments, drawing the tow and cutting the drawn tow to form a blend of staple fibres.
  • the filaments are produced by melt extrusion of the molten polymer through a multiorifice spinneret and groups of filaments from a number of spinnerets are combined into a tow.
  • the tow used in the method of the invention is formed in a similar manner with one or more of the spinnerets producing one or more groups of heterofilaments and one or more of the spinnerets producing one or more groups of homofilaments.
  • the method of the invention is particularly suited to the blending of homofilaments of polymers based on terephthalic acid, the best known representative being polyethylene terephthalate, and heterofilaments having a core of a polymer based on terephthalic acid, for example polyethylene terephthalate, and a sheath of a polymer such as polyethylene isophthalate/polyethylene terephthalate copolymer.
  • blends useful in the production of non-woven webs can be produced by the method of the invention using a composite tow containing from % to 95% of homofilaments of polyethylene terephthalate and containing from 95% to 5% of heterofilaments having a core of polyethylene terephthalate and a sheath of polyethylene isophthalate/polyethylene terephthalate copolymer.
  • Such blends in staple form can be readily converted into a non-woven web by a carding process, optionally followed by cross-lapping or by an air laying process.
  • the composite tow may be drawn by any suitable process which produces a drawn tow of high uniformity even though both homofilaments and heterofilaments are present in the tow.
  • the drawn tow is chopped into staple fibre it is subjected to a further treatment which serves to impart a crimp to the individual fibres in the tow. Conveniently this is achieved as a last stage in the drawing operation by use of a standard stuffer box crimper.
  • One advantage of the described method of blending is that it allows full utilisation of the draw frame.
  • Full utilisation of the draw frame requires an optimum tow size. Hitherto, in the production of staple fibre for blending by carding, such a size may not be achieved with an unblended tow.
  • the composite tow used in the method of the invention is of much greater size allowing full utilisation of the frame.
  • Another, and a probably more important advantage, is that, because more effective blending is achieved, webs of much superior strength can be produced.
  • Staple fibre was produced from 67/33 core/sheath heterofilament fibre having a polyethylene terephthalate core and a 20 mole % polyethylene isophthalate/polyethylene terephthalate copolyner sheath by forming a tow from a plurality of filaments, drawing the tow by the process described in UK Patent No 1 362 793 with a subsequent stuffer box crimping operation and cutting the drawn crimped tow by means of a Lummus cutter into staple of 38mm length and 1.7 decitcx.
  • staple fibre was produced from polyethylene terephthalate homofilament fibre. The staple had a length of 38 mm and a decitex of 1.7.
  • the tensile strength (wet) of each bonded web was measured in the machine direction and in the cross machine direction.
  • the overall fabric strength normalised to 25 gsm was calculated from these measurements.
  • a graph A of overall fabric strength against percentage of heterofilaments in the fabric was prepared from the results obtained.
  • a plurality of continuous heterofilaments were blended with a plurality of continuous polyethylene terephthalate homofilaments to form a composite tow of filaments.
  • the tows were drawn by the process described in UK Patent No 1 362 793, with a subsequent stuffer box crimping operation and cut into staple by a Lummus cutter.
  • the staple had a length of 38 mm.
  • the homofilaments were of 2.0 decjtex and the heterofilaments of 2.1 decitex.
  • the staple fibre blends were converted into ca 25 gsm webs by the same carding process as was used in the COMPARATIVE EXAMPLES.
  • the tensile strength (wet) of each bonded web was measured in the machine direction and in the cross machine direction.
  • the overall fabric strength normalised to 25 gsm was calculated from these measurements.
  • a graph B of overall fabric strength against percentage of heterofilaments in the fabric was prepared from the results obtained.

Abstract

A method of blending homofilament and heterofilament fibres together by forming a continuous composite tow from a plurality of the homofilaments and a plurality of the heterofilaments, drawing the tow and cutting the drawn tow to form a blend of staple fibres; a mixed blend of staple fibres produced by the method and a bonded, non-woven web produced from such a mixed blend of staple fibres.

Description

  • This invention relates to a method for producing a blend of homofilament and heterofilament fibres, such fibres usually being destined for use in the production of non-woven webs by a carding process.
  • The efficiency of blending of homofilament and heterofilament fibres has an important bearing on the eventual properties of a non-woven web made from such fibres.
  • In general the blending of such fibres, in a staple form, is carried out as a first stage in a carding process. Usually the staple fibres themselves are produced by drawing a tow of either continuous heterofilaments or continuous homofilaments, subjecting the drawn tow to a crimping operation and chopping the tow into a convenient staple length.
  • We have now found that advantages can be achieved by blending the fibres by a novel process independent of the carding process.
  • According to the present invention we provide a method of blending homofilament and heterofilament fibres together comprising forming a continuous composite tow from a plurality of the homofilaments and a plurality of the heterofilaments, drawing the tow and cutting the drawn tow to form a blend of staple fibres.
  • We also provide a mixed blend of staple fibres containing both homofilament fibres and heterofilament fibres produced by the above method.
  • Methods for the production of tows from a large number, usually several hundred, filaments are well known in the art.
  • The filaments are produced by melt extrusion of the molten polymer through a multiorifice spinneret and groups of filaments from a number of spinnerets are combined into a tow. The tow used in the method of the invention is formed in a similar manner with one or more of the spinnerets producing one or more groups of heterofilaments and one or more of the spinnerets producing one or more groups of homofilaments.
  • The method of the invention is particularly suited to the blending of homofilaments of polymers based on terephthalic acid, the best known representative being polyethylene terephthalate, and heterofilaments having a core of a polymer based on terephthalic acid, for example polyethylene terephthalate, and a sheath of a polymer such as polyethylene isophthalate/polyethylene terephthalate copolymer.
  • We have found that blends useful in the production of non-woven webs can be produced by the method of the invention using a composite tow containing from % to 95% of homofilaments of polyethylene terephthalate and containing from 95% to 5% of heterofilaments having a core of polyethylene terephthalate and a sheath of polyethylene isophthalate/polyethylene terephthalate copolymer. Such blends in staple form, can be readily converted into a non-woven web by a carding process, optionally followed by cross-lapping or by an air laying process.
  • The composite tow may be drawn by any suitable process which produces a drawn tow of high uniformity even though both homofilaments and heterofilaments are present in the tow.
  • A suitable process is described in the Specification of UK Patent No 1 362 793.
  • In 1 362 793 is described a process in which the tow is passed around the peripheries of a plurality of feed rolls in series and a plurality of draw rolls in series, the latter rotating at a higher peripheral speed and treating the tow in contact with at least some of the feed rolls with water at a temperature above ambient temperature and substantially completing the drawing at the temperature of the water before the tow leaves the last feed roll.
  • In general before the drawn tow is chopped into staple fibre it is subjected to a further treatment which serves to impart a crimp to the individual fibres in the tow. Conveniently this is achieved as a last stage in the drawing operation by use of a standard stuffer box crimper.
  • One advantage of the described method of blending is that it allows full utilisation of the draw frame. Full utilisation of the draw frame requires an optimum tow size. Hitherto, in the production of staple fibre for blending by carding, such a size may not be achieved with an unblended tow. However the composite tow used in the method of the invention is of much greater size allowing full utilisation of the frame.
  • Another, and a probably more important advantage, is that, because more effective blending is achieved, webs of much superior strength can be produced.
  • The invention will now be described by way of the following examples:-
    • COMPARATIVE EXAMPIES
  • Staple fibre was produced from 67/33 core/sheath heterofilament fibre having a polyethylene terephthalate core and a 20 mole % polyethylene isophthalate/polyethylene terephthalate copolyner sheath by forming a tow from a plurality of filaments, drawing the tow by the process described in UK Patent No 1 362 793 with a subsequent stuffer box crimping operation and cutting the drawn crimped tow by means of a Lummus cutter into staple of 38mm length and 1.7 decitcx. In a similar manner staple fibre was produced from polyethylene terephthalate homofilament fibre. The staple had a length of 38 mm and a decitex of 1.7.
  • Various blends of the heterofilament fibres and homofilament fibres were formed at carding and in each case a ca 25 gsm non-woven web was produced. The webs were point bonded with a chequerboard pattern on a Ramisch calender at a temperature of 195°C and a pressure of 5 tonnes at a speed of 3 metres/min.
  • The tensile strength (wet) of each bonded web was measured in the machine direction and in the cross machine direction. The overall fabric strength normalised to 25 gsm was calculated from these measurements. A graph A of overall fabric strength against percentage of heterofilaments in the fabric was prepared from the results obtained.
    • EXAMPLES ACCORDING TO THE INVENTION
  • A plurality of continuous heterofilaments were blended with a plurality of continuous polyethylene terephthalate homofilaments to form a composite tow of filaments.
  • Various blends of heterofilament fibres and homofilament fibres were prepared so that a number of composite tows were produced.
  • The tows were drawn by the process described in UK Patent No 1 362 793, with a subsequent stuffer box crimping operation and cut into staple by a Lummus cutter. The staple had a length of 38 mm. The homofilaments were of 2.0 decjtex and the heterofilaments of 2.1 decitex.
  • The staple fibre blends were converted into ca 25 gsm webs by the same carding process as was used in the COMPARATIVE EXAMPLES.
  • The webs were subsequently point bonded with the same chequerboard pattern as was used in the COMPARATIVE EXAMPLES on a Ramisch calender at a temperature of 195°C and a pressure of 5 tonnes at a speed of 3 metres/min.
  • The tensile strength (wet) of each bonded web was measured in the machine direction and in the cross machine direction. The overall fabric strength normalised to 25 gsm was calculated from these measurements.
  • A graph B of overall fabric strength against percentage of heterofilaments in the fabric was prepared from the results obtained.
  • It is thought that the superior properties results from blending the fibres on a drawframe rather than in the carding process. This is contrary to what might have been expected purely from a comparison of the constituents of the web because all of the staple fibre used in the COMPARATIVE EXAMPLES was of smaller decitex than the staple fibre used in the invention Example and one would have expected, because of the larger number of fibres per unit weight of web in the COMPARATIVE EXAMPLES, that the webs in the COMPARATIVE EXAMPLES would have had superior strength to those in the INVENTION EXAMPLES.

Claims (6)

1. A method of blending homofilament and heterofilament fibres together characterised by forming a continuous composite tow from a plurality of the homofilaments and a plurality of the heterofilaments, drawing the tow and cutting the drawn tow to form a blend of staple fibres.
2. A method as claimed in Claim 1 characterised by a composite tow of homofilaments of polyethylene terephthalate and heterofilaments having a core of polyethylene terephthalate and a sheath of a copolymer of polyethylene isophthalate and polyethylene terephthalate.
3. A method as claimed in Claim 2 characterised in that the composite tow contains from 5% to 95% of the homofilaments and from 95% to 5% of the heterofilaments.
4. A method as claimed in any one of the preceding Claims characterised in that the drawn tow is subjected to a treatment which imparts a crimp to the individual fibres in the tow.
5. A mixed blend of staple fibres containing both homofilament and heterofilasent fibres produced by a method as claimed in any one of Claims 1 to 4.
6. A bonded, non-woven web produced from a mixed blend of staple fibres as claimed in Claim 5.
EP80303861A 1979-11-26 1980-10-30 Method of blending homofilament and heterofilament staple fibres, a blend produced thereby and a bonded web produced from such blend Withdrawn EP0029666A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB7940728 1979-11-26
GB7940728 1979-11-26
GB8005387 1980-02-18
GB8005387 1980-02-18

Publications (1)

Publication Number Publication Date
EP0029666A1 true EP0029666A1 (en) 1981-06-03

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EP80303861A Withdrawn EP0029666A1 (en) 1979-11-26 1980-10-30 Method of blending homofilament and heterofilament staple fibres, a blend produced thereby and a bonded web produced from such blend

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EP (1) EP0029666A1 (en)
AU (1) AU6434880A (en)
DK (1) DK502580A (en)
NO (1) NO803349L (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0447110A2 (en) * 1990-03-07 1991-09-18 Hoechst Celanese Corporation Producing a copolyester from a lower dialkyl ester of terephthalic acid, a glycol and a dicarboxylic acid
US5336552A (en) 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith
CN105155008A (en) * 2015-09-14 2015-12-16 江苏乘鹰新材料股份有限公司 Preparation method and special spinneret plate of stereo color elastic fiber

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1035908A (en) * 1962-07-31 1966-07-13 British Nylon Spinners Ltd Improvements in or relating to methods and apparatus for the production of heterofilaments and heteroyarns
FR1581284A (en) * 1967-09-05 1969-09-12
DE1510195A1 (en) * 1963-05-31 1969-12-18 Ernst Bienz Process for the production of a draftable spinnable staple fiber sliver and system for carrying out the process, as well as a draftable spinnable staple fiber sliver
FR2261356A1 (en) * 1974-02-15 1975-09-12 Du Pont

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1035908A (en) * 1962-07-31 1966-07-13 British Nylon Spinners Ltd Improvements in or relating to methods and apparatus for the production of heterofilaments and heteroyarns
DE1510195A1 (en) * 1963-05-31 1969-12-18 Ernst Bienz Process for the production of a draftable spinnable staple fiber sliver and system for carrying out the process, as well as a draftable spinnable staple fiber sliver
FR1581284A (en) * 1967-09-05 1969-09-12
FR2261356A1 (en) * 1974-02-15 1975-09-12 Du Pont

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0447110A2 (en) * 1990-03-07 1991-09-18 Hoechst Celanese Corporation Producing a copolyester from a lower dialkyl ester of terephthalic acid, a glycol and a dicarboxylic acid
EP0447110A3 (en) * 1990-03-07 1992-03-11 Hoechst Celanese Corporation Producing a copolyester from a lower dialkyl ester of terephthalic acid, a glycol and a dicarboxylic acid
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US5418045A (en) 1992-08-21 1995-05-23 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric
US5336552A (en) 1992-08-26 1994-08-09 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5425987A (en) 1992-08-26 1995-06-20 Kimberly-Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith
CN105155008A (en) * 2015-09-14 2015-12-16 江苏乘鹰新材料股份有限公司 Preparation method and special spinneret plate of stereo color elastic fiber

Also Published As

Publication number Publication date
DK502580A (en) 1981-05-27
AU6434880A (en) 1981-06-04
NO803349L (en) 1981-05-27

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