WO2009076990A1 - Processus de préparation de fibres synthétiques à aptitude à la teinture augmentée - Google Patents
Processus de préparation de fibres synthétiques à aptitude à la teinture augmentée Download PDFInfo
- Publication number
- WO2009076990A1 WO2009076990A1 PCT/EP2007/063930 EP2007063930W WO2009076990A1 WO 2009076990 A1 WO2009076990 A1 WO 2009076990A1 EP 2007063930 W EP2007063930 W EP 2007063930W WO 2009076990 A1 WO2009076990 A1 WO 2009076990A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- polyester
- fibres
- yarns
- synthetic fibres
- process according
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 49
- 230000008569 process Effects 0.000 title claims abstract description 39
- 229920002994 synthetic fiber Polymers 0.000 title claims abstract description 32
- 238000002360 preparation method Methods 0.000 title claims abstract description 7
- 230000001965 increasing effect Effects 0.000 title description 6
- 229920000728 polyester Polymers 0.000 claims abstract description 60
- 239000000203 mixture Substances 0.000 claims abstract description 43
- 239000000835 fiber Substances 0.000 claims abstract description 41
- 229920000642 polymer Polymers 0.000 claims abstract description 29
- 238000001125 extrusion Methods 0.000 claims abstract description 18
- 238000009987 spinning Methods 0.000 claims abstract description 13
- 238000004043 dyeing Methods 0.000 claims description 15
- 238000009998 heat setting Methods 0.000 claims description 13
- OGQYPPBGSLZBEG-UHFFFAOYSA-N dimethyl(dioctadecyl)azanium Chemical compound CCCCCCCCCCCCCCCCCC[N+](C)(C)CCCCCCCCCCCCCCCCCC OGQYPPBGSLZBEG-UHFFFAOYSA-N 0.000 claims description 10
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical group [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 claims description 8
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 229920005629 polypropylene homopolymer Polymers 0.000 claims description 4
- 229920005606 polypropylene copolymer Polymers 0.000 claims description 3
- 229920001935 styrene-ethylene-butadiene-styrene Polymers 0.000 claims 2
- -1 polyethylene terephthalate Polymers 0.000 abstract description 44
- 229920000139 polyethylene terephthalate Polymers 0.000 abstract description 14
- 239000005020 polyethylene terephthalate Substances 0.000 abstract description 13
- 229920000098 polyolefin Polymers 0.000 abstract description 13
- 229920001577 copolymer Polymers 0.000 abstract description 9
- 239000004743 Polypropylene Substances 0.000 description 36
- 229920001155 polypropylene Polymers 0.000 description 36
- 239000000975 dye Substances 0.000 description 24
- 238000004519 manufacturing process Methods 0.000 description 15
- 239000004594 Masterbatch (MB) Substances 0.000 description 13
- 239000004793 Polystyrene Substances 0.000 description 11
- 239000000986 disperse dye Substances 0.000 description 11
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 10
- 229920002223 polystyrene Polymers 0.000 description 10
- 239000006185 dispersion Substances 0.000 description 9
- 239000004952 Polyamide Substances 0.000 description 7
- 229920002647 polyamide Polymers 0.000 description 7
- 238000012545 processing Methods 0.000 description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 6
- 239000000980 acid dye Substances 0.000 description 6
- 238000004040 coloring Methods 0.000 description 6
- 239000011159 matrix material Substances 0.000 description 6
- 239000007858 starting material Substances 0.000 description 6
- 239000005977 Ethylene Substances 0.000 description 5
- SJEYSFABYSGQBG-UHFFFAOYSA-M Patent blue Chemical compound [Na+].C1=CC(N(CC)CC)=CC=C1C(C=1C(=CC(=CC=1)S([O-])(=O)=O)S([O-])(=O)=O)=C1C=CC(=[N+](CC)CC)C=C1 SJEYSFABYSGQBG-UHFFFAOYSA-M 0.000 description 5
- 239000002253 acid Substances 0.000 description 5
- 239000000155 melt Substances 0.000 description 5
- 239000003607 modifier Substances 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000003086 colorant Substances 0.000 description 4
- 239000004014 plasticizer Substances 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000004753 textile Substances 0.000 description 4
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000000693 micelle Substances 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 3
- 238000009732 tufting Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- 229920013645 Europrene Polymers 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 150000001336 alkenes Chemical class 0.000 description 2
- 125000000217 alkyl group Chemical group 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 239000000981 basic dye Substances 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 125000002091 cationic group Chemical group 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 229920006018 co-polyamide Polymers 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 150000004696 coordination complex Chemical class 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 230000000593 degrading effect Effects 0.000 description 2
- 235000014113 dietary fatty acids Nutrition 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 125000003700 epoxy group Chemical group 0.000 description 2
- 239000000194 fatty acid Substances 0.000 description 2
- 229930195729 fatty acid Natural products 0.000 description 2
- 230000009477 glass transition Effects 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 238000009940 knitting Methods 0.000 description 2
- 230000001050 lubricating effect Effects 0.000 description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000002114 nanocomposite Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000000985 reactive dye Substances 0.000 description 2
- 238000000518 rheometry Methods 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- 239000012086 standard solution Substances 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 125000000542 sulfonic acid group Chemical group 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- 238000009941 weaving Methods 0.000 description 2
- 229940083957 1,2-butanediol Drugs 0.000 description 1
- LDVVTQMJQSCDMK-UHFFFAOYSA-N 1,3-dihydroxypropan-2-yl formate Chemical compound OCC(CO)OC=O LDVVTQMJQSCDMK-UHFFFAOYSA-N 0.000 description 1
- PXGZQGDTEZPERC-UHFFFAOYSA-N 1,4-cyclohexanedicarboxylic acid Chemical compound OC(=O)C1CCC(C(O)=O)CC1 PXGZQGDTEZPERC-UHFFFAOYSA-N 0.000 description 1
- 229940043375 1,5-pentanediol Drugs 0.000 description 1
- JCTXKRPTIMZBJT-UHFFFAOYSA-N 2,2,4-trimethylpentane-1,3-diol Chemical compound CC(C)C(O)C(C)(C)CO JCTXKRPTIMZBJT-UHFFFAOYSA-N 0.000 description 1
- SVTBMSDMJJWYQN-UHFFFAOYSA-N 2-methylpentane-2,4-diol Chemical compound CC(O)CC(C)(C)O SVTBMSDMJJWYQN-UHFFFAOYSA-N 0.000 description 1
- 229920006310 Asahi-Kasei Polymers 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000004150 EU approved colour Substances 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- ALQSHHUCVQOPAS-UHFFFAOYSA-N Pentane-1,5-diol Chemical compound OCCCCCO ALQSHHUCVQOPAS-UHFFFAOYSA-N 0.000 description 1
- 238000010793 Steam injection (oil industry) Methods 0.000 description 1
- 239000004784 Superba Substances 0.000 description 1
- 241000324401 Superba Species 0.000 description 1
- 230000006750 UV protection Effects 0.000 description 1
- YIMQCDZDWXUDCA-UHFFFAOYSA-N [4-(hydroxymethyl)cyclohexyl]methanol Chemical compound OCC1CCC(CO)CC1 YIMQCDZDWXUDCA-UHFFFAOYSA-N 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 125000005250 alkyl acrylate group Chemical group 0.000 description 1
- 125000005233 alkylalcohol group Chemical group 0.000 description 1
- 229920000469 amphiphilic block copolymer Polymers 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- VQLYBLABXAHUDN-UHFFFAOYSA-N bis(4-fluorophenyl)-methyl-(1,2,4-triazol-1-ylmethyl)silane;methyl n-(1h-benzimidazol-2-yl)carbamate Chemical compound C1=CC=C2NC(NC(=O)OC)=NC2=C1.C=1C=C(F)C=CC=1[Si](C=1C=CC(F)=CC=1)(C)CN1C=NC=N1 VQLYBLABXAHUDN-UHFFFAOYSA-N 0.000 description 1
- 239000007844 bleaching agent Substances 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical class C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- BMRWNKZVCUKKSR-UHFFFAOYSA-N butane-1,2-diol Chemical compound CCC(O)CO BMRWNKZVCUKKSR-UHFFFAOYSA-N 0.000 description 1
- 235000019437 butane-1,3-diol Nutrition 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 125000000271 carboxylic acid salt group Chemical group 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000002666 chemical blowing agent Substances 0.000 description 1
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- 238000013329 compounding Methods 0.000 description 1
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- 150000002009 diols Chemical class 0.000 description 1
- 238000009967 direct dyeing Methods 0.000 description 1
- YRIUSKIDOIARQF-UHFFFAOYSA-N dodecyl benzenesulfonate Chemical compound CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 YRIUSKIDOIARQF-UHFFFAOYSA-N 0.000 description 1
- 229940071161 dodecylbenzenesulfonate Drugs 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000012757 flame retardant agent Substances 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 229920001002 functional polymer Polymers 0.000 description 1
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- TUJKJAMUKRIRHC-UHFFFAOYSA-N hydroxyl Chemical compound [OH] TUJKJAMUKRIRHC-UHFFFAOYSA-N 0.000 description 1
- 229920006150 hyperbranched polyester Polymers 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 230000016507 interphase Effects 0.000 description 1
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000000434 metal complex dye Substances 0.000 description 1
- 229920005623 miscible polymer blend Polymers 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002086 nanomaterial Substances 0.000 description 1
- 239000002105 nanoparticle Substances 0.000 description 1
- RXOHFPCZGPKIRD-UHFFFAOYSA-N naphthalene-2,6-dicarboxylic acid Chemical compound C1=C(C(O)=O)C=CC2=CC(C(=O)O)=CC=C21 RXOHFPCZGPKIRD-UHFFFAOYSA-N 0.000 description 1
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 229940006093 opthalmologic coloring agent diagnostic Drugs 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- WCVRQHFDJLLWFE-UHFFFAOYSA-N pentane-1,2-diol Chemical compound CCCC(O)CO WCVRQHFDJLLWFE-UHFFFAOYSA-N 0.000 description 1
- GLOBUAZSRIOKLN-UHFFFAOYSA-N pentane-1,4-diol Chemical compound CC(O)CCCO GLOBUAZSRIOKLN-UHFFFAOYSA-N 0.000 description 1
- 229920003208 poly(ethylene sulfide) Polymers 0.000 description 1
- 238000006068 polycondensation reaction Methods 0.000 description 1
- 229920006149 polyester-amide block copolymer Polymers 0.000 description 1
- 229920006393 polyether sulfone Polymers 0.000 description 1
- 229920000151 polyglycol Polymers 0.000 description 1
- 239000010695 polyglycol Substances 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 230000004224 protection Effects 0.000 description 1
- 239000011814 protection agent Substances 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 238000010019 resist printing Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 238000009977 space dyeing Methods 0.000 description 1
- 238000002798 spectrophotometry method Methods 0.000 description 1
- 238000010025 steaming Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000004758 synthetic textile Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- 239000000984 vat dye Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
Classifications
-
- 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
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
- D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
-
- 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
- D01D5/08—Melt spinning methods
-
- 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
Definitions
- the present invention relates to a process for the preparation of synthetic fibres for yarns, in which a polymer mass is melted under pressure and then forced through a spinning block to form fibres, and in which the fibre bundle thus obtained is cooled.
- the invention also relates to the synthetic fibres for yarns, made in this way.
- This invention further relates to a rug or carpet comprising such a synthetic fibres.
- Synthetic fibres are some of the starting materials used in the rug and carpet (textile floor coverings) industry, along with natural fibres such as cotton, wool and silk, for example.
- synthetic starting materials are supplied in the form of granulates or particles, examples being polyamides (PAs), polyesters (PET or PESs), polypropylene (PP) and polyethylene (PE). These starting materials are converted into synthetic fibres by melting, and the semi- finished product thus obtained is used as the starting material for further processing in the textile industry.
- Synthetic textile fibres can be either staple fibres or filaments, depending on their length: - staple fibres or simply "fibres" have a fairly short length of a tens or hundreds of millimetre, while - filaments have a continuous length of thousands of metres.
- Fibres can be spun into yarns in spinning mills. Filaments, on the other hand, are taken together to form a bundle of fibres, or in particular a bundle filaments, at the bottom of a spinning shaft. The number of filaments involved here varies according to the quality and the application envisaged. Yarns are used to make woven fabrics, carpets, knitwear and clothes. Synthetic fibres are marketed in various forms, such as continuous fibres (CF), bulked continuous fibres (BCF), staple fibres, tapes and monofilaments, which have the following characteristics:
- - continuous fibres are endless untextured yarns;
- - bulked continuous fibres are endless but textured or bulked yarns, which have been made fuller by texturing or bulking;
- - staple fibres are filaments that have been cut into fibres for further processing and can be used either in spinning mills or for making non- woven materials;
- - tapes are made by cutting a film and are often used as a starting material in the production of packaging materials or for the backing and/or binding of carpets, and;
- - monofilaments are threads consisting of only one fibre.
- polypropylene homopolymer In the production of synthetic fibres for yarns for rugs and carpets, polypropylene homopolymer is often used and has economic and physical advantages, e.g. stain free and a low cost compared to other polymers.
- Polypropylenes are translucent white in their natural condition and can be coloured via different methods.
- the fibres are, coloured in the mass by, for example, adding a masterbatch containing organic and/or mineral pigments to the melt in order to obtain the desired colour of the final carpet fibre.
- Another method for colouring synthetic fibres is dyeing the fibres after spinning, however, in contrary with most other artificial fibres, polyolefins are not easily dyeable by the common dyes, known by those skilled in the art.
- Dyes have been developed permitting direct dyeing of the polyolefin fibre with hydrocarbon soluble dyes with long alkyl-chains.
- blends are stabilised by the use of a compatibilizer, known by those skilled in the art, with or without reactive groups or grafts, are made in situ by maleic anhydride or maleated polypropylene, or a radical initiator during the blending step of the polymers.
- a compatibilizer known by those skilled in the art, with or without reactive groups or grafts, are made in situ by maleic anhydride or maleated polypropylene, or a radical initiator during the blending step of the polymers.
- US 4.764.551 describes a blend of a poly-alfa olefin and an ethylene dialkylaminalkylacrylamide copolymer, and an alkali metal salt of an organic carboxylic acid dyeable with acid dyes.
- US 5.576.366 and WO 95/33882 describes a blend of polyolef ⁇ n with ethylene alkylacrylate, a small amount of polyester and a hydrophilic modifier comprising of a monoglyceride and a salt of a linear alkyl.
- the blend is dyeable with disperse dyes. Sulfonic acid groups may be added to the polyester for cationic dyes.
- US 6.555.038 describes a method for producing aqueous liquor dyeable modified polypropylene threads.
- a CR polypropylene is mixed with a reaction partner which can react with CR polypropylene.
- Suitable reaction partners are difunctional carboxylic acids or corresponding carboxylic acid derivatives. Acid dyes, dispersion dyes, reactive dyes as well as cationic dyes are used.
- US 6.312.631 describes a polyolef ⁇ n composition having enhanced dyeing capability containing a polyolef ⁇ n and a migratable amphiphile and 0.01 to 1000 ppm of a transition metal. Acid dyes, reactive dyes and basic dyes are used.
- WO 97/47684 describes a blend of polypropylene, a co-polyamide and EVA.
- the blend is dyeable with disperse dyes.
- US 4.520.155 discloses a polyolef ⁇ n composition dyeable with acid dyes, basic dyes, disperse dyes, soluble vat dyes, azoic dyes and premetallized dyes.
- US 6.646.026 discloses a new method of dyeing polymers by dispersing nano materials into the polymers to form polymer nanocomposites.
- the polymer nanocomposites obtained are dyeable using conventional methods.
- US 6.444.758 describes the incorporation of amphiphilic blockcopolymers in order to increase the surface energy of polymeric substrates.
- a dyeable polypropylene fibre is disclosed. Disperse dyes and acid dyes are revealed as the colouring agents.
- WO 2006/038061 describes the colouring process of polypropylene/polystyrene support in which the support is coloured by means of polypropylene/polystyrene support, especially fibres, by means of an aqueous composition comprising 0,1 to 4
- the polystyrene/polypropylene weight ratio comprised between 1 :20 and 1 :4.
- WO 03/029536 describes a blend of a polyolefm and a fibril forming polymer, whereby the exterior surface of the fibres is substantially devoid of fibrils. Between 5
- polyamides and polyesters are used as fibril forming polymers.
- Preferred polycondensation products are polyethylene terephtalate, polybuthylene terephtalate and polytrimethylene terephtalate.
- the blend may contain between 0 and 20% of an interphase modifier (compatibilizer) selected from several polyolefm polymers reacted with acids or anhydrides.
- US 6.537.660 describes a fibre including 2% - 95 % block copolymer of at least one polymer block comprising 50 to 100 % by weight of olefinic monomers units and one polymer block comprising 0,1 to 100 % by weight of (meth)acrylic monomer units.
- US 6.054.215 describes disperse dyeable polypropylene fibers manufactured by making polypropylene resin composition chips by dispersing 100 parts by weight polypropylene, 1 -10 parts by weight of semi-cristalline functional high polymer, 0.05 - 5 parts by weight of amorphous functional polymer and 0.1 - 3 parts by weight additives.
- the novel fibre has the aromatic, ester, ether and hydroxyl radical all together.
- US 6.165.584 describes a resin comprising the reaction product of a polypropylene and the ethylene alkyl acrylate copolymer.
- the fibre comprises a polyester, a hydrophilic modifier or a polyamide.
- the aim of the present invention is to provide an alternative method for the preparation of synthetic fibres for yarns, in particular for use in carpet manufacturing, with enhanced dyeability. Further object of the invention is to obtain a synthetic fibre, which is easy to dye and with good properties.
- the aim of the invention is achieved with a process for the preparation of polyolefm based synthetic fibres for yarns, in which a polymer mass is melted under pressure and then forced through a spinning block to form fibres, and in which the fibre bundle thus obtained is cooled, wherein prior to extrusion a mixture of PET (polyethylene terephthalate) or co-polyester and SEBS (styrene ethylene butylenes styrene-copolymer) is added to the molten polymer stream, so that the dyeability of the synthetic fibres is improved.
- the polymer mass comprises from about 80 % to about 99 % w/w polypropylene homopolymer or polypropylene copolymer.
- PET or co-polyester and the SEBS copolymer permit the production of a fibre with a strongly increased dispersible dye uptake, a high rubbing fastness, good colour light fastness and good resilience for use in the carpet and rugs production. Further, due to the method according to this invention the yarn is very easy to produce and gives no odour problems during spinning.
- the mixture comprises from about 1 to about 15 % w/w PET or co-polyester and from about 0 to about 5 % w/w SEBS.
- PET may be used in the blend, but most preferably an amorphous co -polyester polymer is used in order to decrease the processing temperature at the yarn extrusion step.
- Said amorphous co -polyester has in a preferred embodiment of the process according to the invention a glass transition temperature inferior to 100 0 C, and preferably around 80 0 C in order to obtain a fast dye uptake in standard atmospheric pressure procedures.
- the SEBS may contain functional groups like e.g. sulfonic acid groups, or an epoxygroup, but preferably unmodified SEBS is used to improve the dispersion of the PET or co -polyester in the polyolefin matrix.
- the mixture comprises from about 0 to about 3 % w/w amphiphile.
- the amphiphile is added in order to control the melt viscosity of the co-polyester in the masterbatch and to improve its dispersion in the polyolefin matrix.
- Said amphiphile is preferably a metal alkylbenzenesulfonate and has preferably a low molecular weight, most preferred are sodium stearate and his fatty acid homologues and sodium dodecylbenzene sulfonate and its alkylbenzene sulfonate homologues.
- the presence of the amphiphile improves the dispersion of the co-polyester during extrusion and the dye uptake during the dye process.
- said process further comprising heatsetting the obtained fibre bundle at a temperature in the range of 130 0 C to 150 0 C. After heatsetting the fibre demonstrates an improved elastic behaviour.
- the said process further comprises dyeing the fibre bundle with a disperse dye to provide dyed fibres.
- Another aspect of the present invention relates to polyolefin based synthetic fibres for yarns wherein a process as described above preferably produces the synthetic fibres in question
- the obtained fibre is preferably absolutely colourless before dyeing and insensitive towards yellowing, typical for some polyamide containing polyolef ⁇ n blends.
- the mechanical properties of the obtained fibre allow twisting, cabling, heatsetting, weaving or tufting, knitting and all other textile operations without creating supplementary problems.
- the fibre according to the invention can be used for the manufacturing of interior textile, rugs, carpets and upholstery.
- a further aspect of this invention relates to a rug or carpet, wherein said rug or carpet comprises polyolef ⁇ n based synthetic fibres as described above.
- a polymer mass is first melted under pressure and then forced through a spinning block to form fibres, after which the resulting bundle of fibres is cooled.
- a continuous process produces the synthetic fibres.
- the individual filaments may be of any cross-sectional shape, including trilobal, round, multilobal, deltashape, hollow, core - shell, etc... .
- the carpet yarns are between 600 and 6000 dtex and are composed of 50 to 420 filaments. These values are only given as an example, and are no limits.
- a synthetic starting material preferably polypropylene homopolymer or polypropylene copolymer for example, polypropylene containing a variable amount of ethylene, or other alfa olefin, supplied in granulate or particulate form, is melted under pressure in a melting device, which may be an extruder, for example.
- a melting device which may be an extruder, for example.
- a mixture of a PET or co - polyester and SEBS is added to the molten polymer stream. Said mixture may be added directly on a BCF carpet yarn extrusion line, or preferably a masterbatch may be prepared in order to add the mixture and eventually other additives to the polypropylene before extrusion.
- a compound containing all the fibre constituents may also be prepared.
- the SEBS copolymer may contain reactive groups, for example sulfonic acid or carboxylic acid or carboxylic acid salt groups, and most preferably epoxy groups, but unmodified SEBS performs very well.
- PET or co - polyester and the SEBS copolymer permit the production of a fibre with a strongly increased dispersible dye uptake, a high rubbing fastness, good colour light fastness and good resilience for use in the carpet and rugs production. After heatsetting between 130 0 C and 150 0 C, the obtained fibre demonstrates an elastic behaviour which may increase the comfort of the user.
- the obtained fibre is further processed in order to make space dyed yarn and printed and dyed carpets with disperse dyes. Following processes are given as an illustration but are not limiting the scope of this invention and other applications in apparel and upholstery are possible.
- PET may be used in the blend, but most preferably an amorphous co-polyester polymer is used in order to decrease the processing temperature at the yarn extrusion step.
- Sufficient (co-)polyester fibrils should be at the fibre surface in order to facilitate the colour uptake.
- Amphiphiles may be present to increase the wet-ability of the fibre (anti static and dyeability improvement) and permit to control the rheology of the co-polyester because they act as a plasticizer or even by degrading the polyester polymer chain during the melt phase.
- the amorphous co -polyester is composed of terepthalic acid and may contain isopthalic acid and other aromatic dicarboxylic acids (example 2,6-napthalene dicarboxylic acid) or aliphatic dicarboxylic acid (1,4 -cyclohexane -dicarboxylic acid) and as a diol may contain ethylene glycol, 1,4 -cyclohexane dimethanol, 2,2- dimethylpropane- 1 ,3 -diol, propylene glycol, butylene glycol, 1 ,2 -butanediol, 1,3 - butanediol, 1,4 -butanediol, 1,2 -pentanediol, 1,4 -pentanediol, 1,5 -pentanediol, 1,6 -hexanediol, 2,2,4 -trimethyl-1,3 -pentanediol
- the used amorphous co-polyester has a sufficient low shear viscosity at 250 0 C, this will permit a good blending in industrial single screw extruders used in BCF carpet yarn production lines.
- the melt viscosity is determined with the standard MFI test, but at extrusion temperature (250 0 C) and 2,16 kg pressure.
- the glass transition temperature (Tg) should preferably be inferior to 100 0 C, and most preferably around 80 0 C, in order to obtain a fast dye uptake in standard atmospheric pressure procedures.
- the hardness of the polyester copolymer should be as high as possible, since a number of the co-polyester micelles of the PP/co- polyester/SEBS blend are at the surface of the fibre, permitting very fast colour uptake during dyeing, but could render the fibre fragile against rubbing in dry or humid test conditions.
- a SEBS copolymer As a compatibilizer and a fibre modifier, a SEBS copolymer is used in the blend.
- This SEBS copolymer has a preferred styrene content from 10 to 35 % Styrene.
- the following products are used in the examples tested: ASAHI KASEI CORPORATION, tuftec H 1062 (medium Styrene), tuftec H 1221 (low Styrene), and POLIMERI EUROPA Europrene SOL TH 2311 (high Styrene).
- SEBS SEBS
- co-polyester and polyolefin should be selected in order to obtain a very fine dispersion of the micelles in the polyolefin matrix.
- shear viscosity of all constituents of the blend should be as close as possible at the processing temperature.
- the use of a static mixer to improve further the dispersion of the blend, installed between the extruder and the spinnerets, could further enhance the process.
- blends like for example, without limitation, slipagents, pigments, TiO 2 as an anti lustre agent, flame retardant agents, anti oxidants, UV protection agents, other polymers like EVA, EMA, EEA, mineral particles like calcium carbonate or talc, chemical blowing agents, etc...
- a part of the polyester or co -polyester may be replaced by a medium molecular weight polystyrene.
- SEBS is used as a compatibilizer, polystyrene is very well dispersed in the fibre and will enhance the dyeability. The polystyrene will not degrade the rubbing fastness of the fibre.
- the amount of polystyrene is preferably between 0 % and 5% and most preferably between 0 % and 2 %. All polypropylene in the test was standard grade fibre forming polypropylene from Basell (Basell Moplen HP552R with a MFI of 25 at standard conditions).
- Fatty acid esters from alkyl alcohols or from polyols could be added and could under certain conditions react by transesterification in the extruder during the production of the masterbatch containing the (co-)polyester and the other additives. This masterbatch will be used in the final processing with the polyolefm during the yarn extrusion step.
- a blend of Eastman co-polyester Eastar EB022 with 5 % N 5 N' - ethylene -bis- stearamide has a MFI at 250 0 C and 2,16 kg of 24,4. No degradation of the polyester has been detected.
- a masterbatch containing the co-polyester, the SEBS copolymer, eventually some polyolefm and the metal alkylbenzene sulfonate is preferred to obtain a homogeneous polymer blend with fine micelles of the co- polyester in the polyolefm matrix.
- Sodium dodecylbenzene sulfonate is known in itself as a dye enhancing compound in polyolef ⁇ ns (WO 1985/004889).
- the blends of sodium dodecylbenzene sulfonate and a co-polyester permit to control the rheology of the co -polyester containing masterbatch. Measurements at 230 0 C and at 250 0 C reveal a decreasing viscosity.
- the two components are blended in a double screw blender at 250 0 C, and the MFI is determined at two temperatures:
- a Rieter industrial BCF yarn extrusion unit at a temperature of 250 0 C, 90 % polypropylene with a MFI of 25 is blended with 10 % w/w of a masterbatch, composed of 70 % co-polyester (Eastman Eastar EB062) and 30 % SEBS (Europrene SOL TH 2311). An equivalent of 0,1% TiO 2 is added through the way of a second TiO 2 containing masterbatch.
- Extrusion parameters are the usual one known by those skilled in the art. Extruder temperature was 250 0 C. The winder speed after the cooling drum was 2200 meter per minute. The yarn was a 1250 dtex, 69 filament, trilobal type.
- a spinoil with sufficient hydrophilic properties should be selected (emulsion type), since the surface properties of the filaments are clearly modified compared to a mass dyed polypropylene fibre.
- This yarn has been cabled at 210 twist/meter and has been heatset on a Superba machine with saturated steam at 134 0 C for one minute. A frise effect is obtained by use of a stuffer box with steam injection.
- Colour uptake Yield has been determined by light reflection measurements of the fibres and by spectrophotometric measurements of the dyebath before and after dyeing. In all cases colour yields are superior to 85 %.
- a Rieter industrial BCF yarn extrusion unit at a temperature of 250 0 C, 90 % polypropylene with a MFI of 25 is blended with 10 % of a masterbatch, composed of 50 % co-polyester (Eastman Eastar EB022), 20 % polystyrene (Polimeri Europa, medium molecular weight PS (Mn: ⁇ 62 000; Mw: ⁇ 118 000; Mz: ⁇ 190 000) and a MFR at 200 0 C - 5 kg. (ISOl 133) of 25) and 30 % SEBS (Marubeni, Tuftec H1062). Extrusion parameters are the ones mentioned in example 1.
- the yarn is a 2150 dtex 96 trilobal filament yarn and is used as such in further trials.
- a masterbatch containing 7 parts of amorphous co-polyester (Eastman Eastar EB022), 3 parts of SEBS and 1 part of sodium dodecyl benzene sulfonate is prepared in a double screw extruder Leistrits (27 mm, 32 L/D) at a temperature of 220 0 C.
- the masterbatch components are blended with polypropylene at a ratio 11 % masterbatch and 89 % polypropylene and extruded on an industrial BCF carpet yarn Rieter production line at 250 0 C extruder temperature at a yarn winder speed of 2200 m/minute.
- the obtained yarns can be used with and without heatsetting, but some properties are only revealed after heatsetting.
- yarns are further processed as described in following known processes by those skilled in the art of polyamide dyeing.
- the synthetic fibres for yarns according to this invention have an enhanced dyeability. Following is an example (in different stages) of a colouring method of the synthetic fibres produced by the process according to this invention.
- Fibres made according a process as described above - in a dtex that may vary between 1200 and 4500 - were knitted into socks on e.g. 1/5" gauge circular knitting machines containing 186 needles each and making between 180 and 270 rpm.
- the socks were rolled on a cone to form rolls of between 30 and 50 kg.
- a tank containing water at room temperature was agitated.
- 1 to 10 g/1 of an anionic or non-ionic surfactant was added, together with an acid in an amount as to achieve a pH of between 4 and 6.
- 10 to 15 g/1 of a printing thickener was added, before adding the necessary amount of separately in hot water diluted disperse dyes, in this case between 0,1 and 1 g/1.
- the disperse dyes in this case being of a type like e.g. Huntsman's Terasil C.
- the dye bath was as described for the padder, except for the amount of printing thickener which was much higher, i.e. between 30 and 50 g/1. Also much more - 2 to 15 g/1 - of separately diluted disperse dyes of the same type were added.
- the rolls of socks described in stage 1 were put on the rack of a space dyeing machine - 3 or 4 next to each other, according to their width - and melt or sewed to a leader fabric and later to the next roll, thus allowing a continuous process of dyeing, steaming, rinsing, lubricating, drying and winding back onto rolls.
- the socks were gradually wound off and first led in the dyebath of the padder (in this case a horizontal K ⁇ sters type), after which they were squeezed between its rollers in order to obtain a dye-bath pick-up of between 70 and 120% on the weight of the socks.
- a ground-shade was provided to the socks.
- Pre -washing cold or warm
- the speed of the machine may vary between 15 and 40 meters per minute.
- the socks were then led between up to 4 pairs of printing-rollers, in this case placed vertically above each other and engraved with a design. Each pair of rollers contains a part of the design and puts on a specific colour.
- the socks were subsequently led into a steamer at atmospheric pressure at a temperature of between 95 and 105 0 C, this during a period of 4 to 7 minutes.
- the socks were washed and squeezed in up to 4 cold or warm water rinsing baths and were then led through a bath containing a lubricating product and squeezed again before drying during 30 to 90 seconds at 105 to 130 0 C, preferably 110 0 C.
- the coloured socks were finally rewound onto cones forming rolls again.
- Stage 4 The threads of the coloured socks on rolls were then rewound onto cones, a process which occurs at a speed of between 500 and 1100 m/min. this process is facilitated by the lubricating agent added in the previous stage.
- Stage 5 The thus obtained coloured threads or yarns were then - partly through an intermediate operation, such as air-entangling or cabling and heat-setting - used as pile material for tufted or woven carpets. They may in the intermediate operation be mixed with other types of yarns, such as e.g. nylon or standard solution dyed polypropylene.
- an intermediate operation such as air-entangling or cabling and heat-setting - used as pile material for tufted or woven carpets.
- They may in the intermediate operation be mixed with other types of yarns, such as e.g. nylon or standard solution dyed polypropylene.
- carpets thus made have been proven to posses good colour-fastnesses.
- the score for light-fastness was at least 5/6, mostly better. Rubbing fastnesses dry and wet were awarded between 4 and 4/5-5.
- the said carpets also proved to be bleach-resistant, in a way equal to standard solution dyed polypropylene.
- yarns according to this invention - dyed and printed in the above described way - are combined with ecru PA yarns through air-entangling or cabling and heat-setting and made into carpets by tufting or weaving to be dyed a second time with conventional acid or metal complex dyes such as Tectilon or Lanacrone (by Huntsman), they do not take up the colorants of the second dyebath, i.e they are overdyeable with such colorants and retain their original colour.
- the ecru PA yarns of course are coloured by this second dyeing operation.
- Ecru carpets made of yarns according to this invention can be printed with a light and bright colourdots and subsequently overdyed with a dark flood.
- Both print - and dyebaths contain disperse dyestuffs. This mechanical resist printing is strong enough to prevent serious contamination of the printed colours by the dark flood without the help of a chemical additive traditionally needed for this method of printing on PA carpets or yarns.
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Abstract
Cette invention se rapporte à un processus de préparation de fibres synthétiques à base de polyoléfine pour fils, dans lequel une masse polymère est fondue sous pression puis poussée à travers un bloc de filage pour former des fibres, et dans lequel le faisceau de fibres ainsi obtenu est refroidi. Avant l'extrusion, un mélange de PET (polyéthylène téréphtalate) ou de copolyester et de SEBS (copolymère styrène éthylène butylènes) est ajouté au flux polymère en fusion, de sorte que l'aptitude à la teinture des fibres synthétiques soit améliorée. L'invention se rapporte également aux fibres synthétiques pour fils, fabriquées de cette manière. Cette invention se rapporte en outre à un tapis ou une moquette comprenant de telles fibres synthétiques.
Priority Applications (2)
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PCT/EP2007/063930 WO2009076990A1 (fr) | 2007-12-14 | 2007-12-14 | Processus de préparation de fibres synthétiques à aptitude à la teinture augmentée |
BE2008/0668A BE1018358A3 (nl) | 2007-12-14 | 2008-12-12 | Procede voor de bereiding van synthetische vezels voor garen met verhoogde verfbaarheid. |
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PCT/EP2007/063930 WO2009076990A1 (fr) | 2007-12-14 | 2007-12-14 | Processus de préparation de fibres synthétiques à aptitude à la teinture augmentée |
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WO2009076990A1 true WO2009076990A1 (fr) | 2009-06-25 |
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WO2013120983A1 (fr) * | 2012-02-16 | 2013-08-22 | Dsm Ip Assets B.V. | Procédé d'amélioration de la coloration d'un article en uhmwpe, article coloré et produits contenant l'article |
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CN109715869A (zh) * | 2016-10-25 | 2019-05-03 | 东丽株式会社 | 聚合物合金纤维及包含其的纤维结构体 |
CN109715869B (zh) * | 2016-10-25 | 2022-05-10 | 东丽株式会社 | 聚合物合金纤维及包含其的纤维结构体 |
CN108330559A (zh) * | 2017-01-20 | 2018-07-27 | 东丽纤维研究所(中国)有限公司 | 一种可染聚烯烃纤维 |
CN109487364A (zh) * | 2017-09-11 | 2019-03-19 | 东丽纤维研究所(中国)有限公司 | 一种可染聚烯烃纤维 |
CN109487364B (zh) * | 2017-09-11 | 2021-09-28 | 东丽纤维研究所(中国)有限公司 | 一种可染聚烯烃纤维 |
CN110670159A (zh) * | 2019-09-30 | 2020-01-10 | 安徽农业大学 | 一种高吸湿再生pet纤维长丝制备工艺 |
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