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WO2009117535A1 - Multiend package of multifilament polyester bicomponent yarn - Google Patents

Multiend package of multifilament polyester bicomponent yarn Download PDF

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Publication number
WO2009117535A1
WO2009117535A1 PCT/US2009/037589 US2009037589W WO2009117535A1 WO 2009117535 A1 WO2009117535 A1 WO 2009117535A1 US 2009037589 W US2009037589 W US 2009037589W WO 2009117535 A1 WO2009117535 A1 WO 2009117535A1
Authority
WO
WIPO (PCT)
Prior art keywords
poly
threadline
bundle
terephthalate
threadlines
Prior art date
Application number
PCT/US2009/037589
Other languages
French (fr)
Inventor
Young D. Nguyen
Raymond S. P. Leung
Paul Wu
Original Assignee
Invista Technologies S.A R.L.
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 Invista Technologies S.A R.L. filed Critical Invista Technologies S.A R.L.
Priority to JP2011500940A priority Critical patent/JP2011518261A/en
Priority to US12/922,564 priority patent/US20110133011A1/en
Priority to BRPI0907082-6A priority patent/BRPI0907082A2/en
Priority to CN2009801184531A priority patent/CN102037171B/en
Priority to EP09723024A priority patent/EP2265753A4/en
Publication of WO2009117535A1 publication Critical patent/WO2009117535A1/en
Priority to HK11110757.9A priority patent/HK1156370A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/36—Cored or coated yarns or threads
    • D02G3/362—Cored or coated yarns or threads using hollow spindles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H51/00—Forwarding filamentary material
    • B65H51/015—Gathering a plurality of forwarding filamentary materials into a bundle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H54/00—Winding, coiling, or depositing filamentary material
    • B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
    • B65H54/026—Doubling winders, i.e. for winding two or more parallel yarns on a bobbin, e.g. in preparation for twisting or weaving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H55/00—Wound packages of filamentary material
    • B65H55/005—Wound packages of filamentary material with two or more filaments wound in parallel on the bobbin
    • 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
    • D01D5/32—Side-by-side structure; Spinnerette packs therefor
    • 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
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/36—Cored or coated yarns or threads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/30—Handled filamentary material
    • B65H2701/31—Textiles threads or artificial strands of filaments
    • B65H2701/313—Synthetic polymer threads
    • B65H2701/3132—Synthetic polymer threads extruded from spinnerets

Definitions

  • This invention relates to a multiend package of multicomponent yams, the yarn being separable into individual ends upon unwinding. More specifically, this invention relates to a multiend package of polyester bicomponent continuous filament yarns, and the separable yarns on such a package. The invention also relates to a method of making the multiend package of separable polyester bicomponent continuous filament yarns.
  • filament yarn production involves extruding multiple filaments from a spinneret, then either combining all the filaments into a single threadline which is then wound onto a single package, or dividing the filaments into multiple filament threadlines which are then each wound onto single packages. In either case, one multicomponent threadline is wound onto one package. This is also known as having one "end" per package.
  • Polyester bicomponent filaments are elastomeric filaments which have stretch and recovery characteristics due to their three-dimensional crimp. Polyester bicomponent filaments have been disclosed, for example in United States Patent No. 3,671 ,379. High speed spinning of polyester bicomponent filaments including poly(ethylene terephthalate) and poly(trimethylene terephthalate) have been disclosed, for example in United States Patent No. 6,692,687. Single-end polyester bicomponent fiber packages have been disclosed, for example in United States Patent No. 6,824,869.
  • United States Patent No. 5,524,841 discloses the winding of a plurality of textile strands or yarns and winding improvements which enhance the separation of multiple textile strands during unwinding of a wound package.
  • the invention is suggested to be useful in processes involving winding of mono- or multifilament natural or synthetic materials or yarns such as nylon, polyester, boron or carbon fiber or strands but is discussed generally in the context of its use in the manufacture and processing of glass fiber.
  • United States Patent No. 5,665,293 relates to the field of synthetic filament production and discloses a method of making spun yarn packages of multiple individually separable yarn ends. The method is suitable for melt-spinnable polymers, disclosed in the patent to be nylons such as nylon-6 and nylon-6,6, polyesters, and polyolefins such as polypropylene.
  • United States Patent Nos. 6,562,456 and 5,723,080 disclose an elastane multifilament yarn which is splittable into individual filaments when unwound from a bobbin, and a process for producing such yarn.
  • a 165 dtex yarn with 68 filaments of polyester bicomponent continuous filament is extruded from a spinneret, after quenching, oiling, drawing, interlacing, the single threadline with 165 dtex- 68 filaments is wound into a tube — single end package.
  • a multiend package of yarn that is, a single yarn package on which two or more ends of yarn have been wound, would be a way to significantly increase yarn manufacturing productivity while decreasing investment intensity and cost of manufacture.
  • a multiend package of yarn would also be beneficial for reducing the cost of downstream processing operations such as beaming or core spinning because less equipment and capital investment would be required.
  • the technical challenges of producing a multiend package in which the yarns are consistently separable upon unwinding are considerable, particularly for bicomponent continuous filament yarns which have crimp and stretch and recovery properties. Nevertheless, methods to prepare multiend packages of separable polyester bicomponent yarns are sought, as are the separable yarns themselves.
  • the threadline bundle is separable into at least two individual threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • the process including:
  • each threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • the threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • a threadline bundle including at least two threadlines, each threadline includes multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, wherein the threadline bundle is separable into at least two threadlines, and the bicomponent filament includes poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • An additional embodiment provides a multiend package including a threadline bundle wound onto a tube core, wherein the threadline bundle is separable into at least two threadlines, each threadline including multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • FIG. 1 is a schematic representation of the yarn spinning and winding system of some embodiments.
  • FIG. 2 is a schematic representation a side view of a high speed winder used with spinning and winding system of some embodiments.
  • FIG. 3 is a schematic representation of the preparation of core-spun polyester bicomponent from a multi-end package.
  • FIG. 4 is a schematic representation of hollow spindle covering using polyester bicomponent from a multi-end package.
  • FlG. 5 is a schematic representation of a knitting process using polyester bicomponent from a multi-end package.
  • a package comprising multiple ends of polyester bicomponent filament yarn can be made in such a way that the yarn is separable into multiple individual threadlines, each threadline comprising multiple bicomponent filaments, upon unwinding.
  • the multiend package can be used directly in processes such as beaming, circular knitting, weaving, or core spinning in place of multiple single end packages, which provides convenience and cost savings.
  • the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
  • POY Partially Oriented Yarn: Filament yarns in which the draw ratio is less than normal so that only partial longitudinal orientation of the polymer molecules.
  • FDY Fluly Drawn Yarn: As opposed to POY, filament yarns in which the draw ratio is normal so that full longitudinal orientation of polymer molecules.
  • DW Densk Winding: The operation of stretching continuous filament yarn to align of order molecular and crystalline structure. The drawn yarn is taken up on a parallel tube or cheese, resulting in a zero-twist yarn.
  • DTY(Draw Texturing Yarn) Filament yarn in which the manufacture is the simultaneous process of drawing to increase molecular orientation and imparting crimp to increase bulk.
  • DT(Draw Texturing) In the manufacture of thermoplastic fibers, the simultaneous process of drawing to increase molecular orientation and imparting crimp to increase bulk.
  • Multifilament A yarn consisting of many continuous filaments or strands, as opposed to monofilament which is one strand. Most textile filament yarns are multifilament.
  • the fiber is composed of more than one polymer.
  • these polymers are primarily poly(ethylene terephthalate) (2GT), poly(trimethylene terephthalate) (3GT), and poly(tetramethylene terephthalate) (4GT) or a combination of such members.
  • Core Spun Yarn A yarn made by twisting fibers around a filament, thus concealing the core.
  • the core yarn is an elastic yarn (such as 2GT 3GT bicomponent) to obtain stretch-recovery characteristics and twisting fibers are cotton fibers to obtain desirable touch aesthetic.
  • the core yarn for CSY is spandex yarn, which packages size is much smaller than polyester bicomponent yarn. Therefore, the creel or space in the CSY machine is not available for placing one yarn package on one spinning position when polyester bicomponent yarn replacing spandex yarn.
  • Elastomeric fiber Synthetic fibers having properties of natural rubber such as high stretchability and recovery.
  • Hard yarn As opposed to elastomeric fiber, synthetic fibers having no properties of natural rubber such as stretchability and recovery.
  • Spandex A manufactured fiber in which the fiber- forming substance is a long chain synthetic polymer composed of at least 85% of a segmented polyurethane.
  • bicomponent filament means a continuous filament in which two polymers of the same general class are intimately adhered to each other along the length of the fiber, so that the fiber cross-section is for example a side-by-side, eccentric sheath-core, or other suitable cross-section from which useful crimp can be developed.
  • side-by-side means that the two components of the bicomponent fiber are immediately adjacent to one another and that no more than a minor portion of either component is within a concave portion of the other component.
  • Eccentric sheath-core means that one of the two components completely surrounds the other component but that the two components are not coaxial.
  • threadline means a group of two or more bicomponent filaments. The filaments of the threadline are processed together, as a group.
  • end means an individual fiber, yarn, or threadline.
  • threadline is interchangeable with “end”.
  • a single threadline is typically wound onto a single tube core to produce a "single end” package.
  • the single end package produced by the conventional procedure is also referred to as "one end per package.”
  • threadline bundle means at least two threadlines which have been combined together to form one multicomponent entity, the threadline bundle.
  • the threadline bundle remains capable of being separated into at least two individual threadlines (ends).
  • threadline bundle also means a yarn which is comprised of at least two ends.
  • bin means a continuous strand of textile fibers, filaments, or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric.
  • multiend package means a threadline bundle wound onto a tube core.
  • the polyester bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, in a weight ratio of from about 30:70 to about 70:30.
  • the polymers may be, for example, poly(ethylene terephthalate) and poly(trimethylene terephthalate), poly(trimethylene terephthalate) and poly(tetramethylene terephthalate), or poly(trimethylene terephthalate) and poly(trimethylene) terephthalate, for example of different intrinsic viscosities, although different combinations are also possible.
  • compositions can be similar, for example a poly(trimethylene terephthalate) homopolyester and a poly(trimethylene terephthalate) copolyester, optionally also of different viscosities.
  • Other polyester bicomponent combinations are also possible, such as poly(ethylene terephthalate) and poly(tetramethylene terephthalate), or a combination of poly(ethylene terephthalate) and poly(ethylene terephthalate), for example of different intrinsic viscosities, or a poly(ethylene terephthalate) homopolyester and a poly(ethylene terephthalate) copolyester.
  • the notation "//" is used to separate the two polymers used in making a bicomponent filament.
  • poly(ethylene terephthalate)//poly(trimethylene terephthalate) indicates a bicomponent filament comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate).
  • polyesters can be copolyesters, and "poly(ethylene terephthalate),” “poly(tetramethylene terephthalate)”, and “poly(trimethylene terephthalate)” include such copolyesters within their meanings.
  • a copoly(ethylene terephthalate) can be used in which the comonomer used to make the copolyester is selected from the group consisting of linear, cyclic, and branched aliphatic dicarboxylic acids (and their diesters) having 4-12 carbon atoms (for example butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1 ,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids (and their diesters) other than terephthalic acid and having 8-12 carbon atoms (for example isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched aliphatic diols having 3-8 carbon atoms (for example 1 ,3-propane diol, 1 ,2-propanediol, 1 ,4-butaned
  • the comonomer can be present to the extent that it does not compromise the benefits of the invention, for example at levels of about 0.5-15 mole percent based on total polymer ingredients.
  • Isophthalic acid, pentanedioic acid, hexanedioic acid, 1 ,3-propane diol, and 1 ,4-butanediol are exemplary comonomers.
  • the copolyester(s) can also be made with minor amounts of other comonomers, provided such comonomers do not have an adverse effect on the physical properties of the fiber.
  • Such other comonomers include 5-sodium-sulfoisophthalate, the sodium salt of 3-(2- sulfoethyl) hexanedioic acid, and dialkyl esters thereof, which can be incorporated at about 0.2-5 mole percent based on total polyester.
  • the (co)polyester(s) can also be mixed with polymeric secondary amine additives, for example poly(6,6'-imino-bishexamethylene terephthalamide) and copolyamides thereof with hexamethylenediamine, preferably phosphoric acid and phosphorous acid salts thereof.
  • the polyester bicomponent filament can also comprise conventional additives such as antistats, antioxidants, antimicrobials, flameproofing agents, lubricants, dyestuffs, light stabilizers, and delustrants such as titanium dioxide as long as they do not detract from the benefits of the invention.
  • conventional additives such as antistats, antioxidants, antimicrobials, flameproofing agents, lubricants, dyestuffs, light stabilizers, and delustrants such as titanium dioxide as long as they do not detract from the benefits of the invention.
  • outer cross-section shape of the bicomponent filament which can be non-round, round, substantially oval, triangular, "snowman,” and the like.
  • substantially oval means that an area of a cross- section of the filament, measured perpendicular to the longitudinal axis of the fiber, deviates by less than about 20% from that of an oval shape.
  • the general term “oval” includes “ovoid” (egg-shaped) and “elliptical” within its meaning.
  • Such a shape typically has two axes at right angles through the center of the shape, a major axis (A), and a minor axis (B), where the length of the major axis A is greater than the length of the minor axis B.
  • A major axis
  • B minor axis
  • the oval is described by a locus of points whose sum of whose distances from two foci is constant and equal to A.
  • one end of the oval can be larger than the other, so that the sum of the distances from two foci is not necessarily constant and can vary by 20% or more from elliptical.
  • a "snowman" cross-section shape can be described as a side-by-side cross-section having a long axis, a short axis, and at least two maxima in the length of the short axis when plotted against the long axis.
  • the cross-section periphery of the bicomponent filament may have or may lack constant curvature.
  • the cross-section shape of the bicomponent filament may have or may lack grooves in the cross-section periphery. Examples of cross-section shapes which have grooves are "snowman,” “scalloped-oval,” and "keyhole.”
  • polymer interface means the boundary between the polymers of the bicomponent filament.
  • the polymer interface may be substantially linear or curved.
  • the bicomponent filament may have a polymer interface substantially perpendicular to or substantially parallel to the major axis of the cross-section.
  • the bicomponent filament has a crimp potential from about 30% to about 90%, for example from about 60% to about 80%.
  • the crimp comes from different shrinkage of polymers, bi-component fiber is made from different polymers and develops crimp as a result of the different shrinkage rates. Specifically, the crimp is maximized upon application of heat to the bicomponent filament.
  • polyester yarn may be included in some embodiments. Color can be added to polyester by the use of dyes and/or pigments. For example, black yarn may be prepared by the addition of carbon black. These additives are generally added into polymers and mixed together before passing through the spinneret.
  • FIG. 1 shows one embodiment of a yarn spinning apparatus 10 for providing a process for producing a multiend package which includes melt spinning two or more compositionally different polymers 12A and 12B from a single precoalescent or post- coalescent spinneret 14 to form multiple side-by-side or eccentric sheath-core polyester bicomponent filaments.
  • a plurality of yarn ends16a-16f is produced each including of multiple filaments. Finish may be supplied by a spin finish applicator 19.
  • the yarn ends 16a-16f pass through the quench cabinet 18.
  • the yarn ends may then be drawn at G1-G3 and passed through an interlacer 20 including a pressurized fluid. Two or more of the yarn ends are then combined at a convergence guide to form multiend bundles and wound onto packages 28a. These multiend bundles can be separated in to the original yarn ends.
  • FIG.2 provides more detail.
  • Each of 16a and 16b, 16c and 16d, and 16e and 16f are combined to form multiend bundles 24c, 24b, and 24a, respectively, which are wound to form multiend packages 28c, 28b, and 28a, respectively.
  • multiend packages 28c, 28b, and 28a are wound to form multiend packages 28c, 28b, and 28a, respectively.
  • two threadlines are available from each multiend package. Each of these threadlines are available to go to different spinning positions for downstream processing.
  • Example 1 Multiend package of 2 threadlines of 55dtex and 34 filaments
  • each threadline with 68 filaments is prepared from a single spinneret and separated into two threadlines with 34 filaments each. Then, each threadline has 34 filaments. For a yarn spinning apparatus with six spinnerets, the six threadlines become twelve threadlines at one spinning position.
  • Each threadline (12 total with 34 filaments each) has its own yarn path on rolls and all facilities. All 12 threadlines are independent. After passing through the interlace jet, 2 threadlines converge into one threadline by a convergent guide, then this converged threadline is wound to one yarn package by take up winder. This provides six multiend packages with each having two ends from threadlines having 55dtex and 34 filaments each.
  • Example 2 Multiend package of 2 threadlines of 27dtex and 17 filaments
  • each threadline with 34 filaments is prepared from a single spinneret and separated into two threadlines with 17 filaments each. Then, each threadline has 17 filaments.
  • the six threadlines become twelve threadlines at one spinning position.
  • Each threadline (12 total with 17 filaments each) has its own yarn path on rolls and all facilities. All 12 threadlines are independent. After passing through the interlace jet, 2 threadlines converge into one threadline by a convergent guide, then this converged threadline is wound to one yarn package by take up winder. This provides six multiend packages with each having two ends from threadlines having 27dtex and 17 filaments each.
  • Example 3 Multi-end package for core spinning
  • FIG. 3 shows a multiend package 28c for core spinning process.
  • the yarn is driven by two delivery rollers 38 so that the two multicomponent yarns 16a and 16b from multiend package 28c are separated and unwound tangentially to the roller guides 30 which direct the separated multicomponent yarn 16a and 16b to its corresponding front roller 35 of spinning position where the polyester multiple component yarns are combined with the staple roving fiber 2 to provide separate core-spun yarn packages 4.
  • Example 4 Multi-end package for hollow spindle covering
  • FIG. 4 shows a multiend package for hollow spindle covering process.
  • the multiend package 28 is driven by two delivery rollers 38 and the two multicomponent yams 16a and 16b are delivered tangentially to individual guide eyelets 42 of corresponding spinning position.
  • the separated multicomponent yarns 16a and 16b separately pass from second delivery rollers 40 than pass through a spinning spindle 44 which has a hollow tube at the center and carries a non-elastic yarn package outside 46.
  • the spinning action of the spindle releases the non-elastic yarn and wraps around the multicomponent yarn and is taken up by third delivery rollers 41 to a covered package 48 for other applications.
  • Example 5 Multi-end package for circular knitting
  • FIG. 5 shows a multiend package 28 for circular knitting.
  • the multiend yarns 16a and 16b on the package 28 are delivered by two delivery rollers 38 at a constant speed and separated to individual stop motion devices 54 for corresponding knitting position.
  • the separated yarns 16a and 16b pass from roller guides 50 to a yarn feeder 52 to the knitting needles 58.
  • hard yarn packages 60 provide hard yarn with a feed speed control apparatus 56 to the yarn feeder 52 for knitting a garment or fabric including a hard yarn and an elastic bicomponent yarn.
  • Examples 3, 4, and 5 have a device which drives the multiend package at a constant and pre-determined speed to deliver the multicomponent yarn tangentially.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Multicomponent Fibers (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

Abstract

Included are multiend packages of multicomponent yarns, where the yarn is separable into individual ends upon unwinding. The multicomponent yarn may be a bicomponent yarn, such as a yarn including compositionally different polyesters in a side-by-side or eccentric sheath-core configuration. Uses of such multiend packages are also included.

Description

MULTIEND PACKAGE OF MULTIFILAMENT POLYESTER BICOMPONENT YARN
FIELD OF THE INVENTION
[0001] This invention relates to a multiend package of multicomponent yams, the yarn being separable into individual ends upon unwinding. More specifically, this invention relates to a multiend package of polyester bicomponent continuous filament yarns, and the separable yarns on such a package. The invention also relates to a method of making the multiend package of separable polyester bicomponent continuous filament yarns.
BACKGROUND OF THE INVENTION
[0002] Typically, filament yarn production involves extruding multiple filaments from a spinneret, then either combining all the filaments into a single threadline which is then wound onto a single package, or dividing the filaments into multiple filament threadlines which are then each wound onto single packages. In either case, one multicomponent threadline is wound onto one package. This is also known as having one "end" per package.
[0003] Polyester bicomponent filaments are elastomeric filaments which have stretch and recovery characteristics due to their three-dimensional crimp. Polyester bicomponent filaments have been disclosed, for example in United States Patent No. 3,671 ,379. High speed spinning of polyester bicomponent filaments including poly(ethylene terephthalate) and poly(trimethylene terephthalate) have been disclosed, for example in United States Patent No. 6,692,687. Single-end polyester bicomponent fiber packages have been disclosed, for example in United States Patent No. 6,824,869.
[0004] United States Patent No. 5,524,841 discloses the winding of a plurality of textile strands or yarns and winding improvements which enhance the separation of multiple textile strands during unwinding of a wound package. The invention is suggested to be useful in processes involving winding of mono- or multifilament natural or synthetic materials or yarns such as nylon, polyester, boron or carbon fiber or strands but is discussed generally in the context of its use in the manufacture and processing of glass fiber.
[0005] United States Patent No. 5,665,293 relates to the field of synthetic filament production and discloses a method of making spun yarn packages of multiple individually separable yarn ends. The method is suitable for melt-spinnable polymers, disclosed in the patent to be nylons such as nylon-6 and nylon-6,6, polyesters, and polyolefins such as polypropylene. [0006] United States Patent Nos. 6,562,456 and 5,723,080 disclose an elastane multifilament yarn which is splittable into individual filaments when unwound from a bobbin, and a process for producing such yarn.
[0007] Conventionally, a 165 dtex yarn with 68 filaments of polyester bicomponent continuous filament is extruded from a spinneret, after quenching, oiling, drawing, interlacing, the single threadline with 165 dtex- 68 filaments is wound into a tube — single end package.
[0008] A multiend package of yarn, that is, a single yarn package on which two or more ends of yarn have been wound, would be a way to significantly increase yarn manufacturing productivity while decreasing investment intensity and cost of manufacture. A multiend package of yarn would also be beneficial for reducing the cost of downstream processing operations such as beaming or core spinning because less equipment and capital investment would be required. However, the technical challenges of producing a multiend package in which the yarns are consistently separable upon unwinding are considerable, particularly for bicomponent continuous filament yarns which have crimp and stretch and recovery properties. Nevertheless, methods to prepare multiend packages of separable polyester bicomponent yarns are sought, as are the separable yarns themselves.
SUMMARY OF THE INVENTION
[0009] In some embodiments is a process for producing a multiend package, the process includuing:
A) melt-spinning two or more compositionally different polyesters from a single pre- coalescent or post-coalescent spinneret to form multiple side-by-side or eccentric sheath- core polyester bicomponent filaments;
B) grouping the filaments into at least two threadlines, each threadline including more than one filaments;
C) taking up the threadlines at speeds greater than about 300 meters per minute;
D) interlacing each threadline;
E) combining the threadlines into a threadline bundle; and
F) winding the threadline bundle onto a tube core at speeds greater than about 300 meters per minute; wherein the threadline bundle is separable into at least two individual threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members. [0010] In another embodiment is a process for producing a multiend package, the process including:
A) melt-spinning two or more compositionally different polyesters from multiple pre- coalescent or post-coalescent spinnerets in a single spinning position to form multiple side- by-side or eccentric sheath-core polyester bicomponent filaments;
B) grouping the filaments into at least two threadlines, each threadline consisting of multiple filaments;
C) taking up the threadlines at speeds greater than about 300 meters per minute;
D) interlacing each threadline;
E) combining multiple groups of at least two threadlines into multiple threadline bundles; and
F) winding each threadline bundle onto a tube core using conventional multi-package winders; wherein each threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
[0011] In a further embodiment is a process for producing a multiend package, the process including:
A) forming at least two threadlines from two or more side-by-side or eccentric sheath- core polyester bicomponent filaments;
B) combining the threadlines into a threadline bundle; and
C) winding the threadline bundle onto a tube core; wherein the threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
[0012] Also included is a threadline bundle including at least two threadlines, each threadline includes multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, wherein the threadline bundle is separable into at least two threadlines, and the bicomponent filament includes poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members. [0013] An additional embodiment provides a multiend package including a threadline bundle wound onto a tube core, wherein the threadline bundle is separable into at least two threadlines, each threadline including multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic representation of the yarn spinning and winding system of some embodiments.
[0015] FIG. 2 is a schematic representation a side view of a high speed winder used with spinning and winding system of some embodiments.
[0016] FIG. 3 is a schematic representation of the preparation of core-spun polyester bicomponent from a multi-end package.
[0017] FIG. 4 is a schematic representation of hollow spindle covering using polyester bicomponent from a multi-end package.
[0018] FlG. 5 is a schematic representation of a knitting process using polyester bicomponent from a multi-end package.
DETAILED DESCRIPTION OF THE INVENTION
[0019] It has now been found that a package comprising multiple ends of polyester bicomponent filament yarn can be made in such a way that the yarn is separable into multiple individual threadlines, each threadline comprising multiple bicomponent filaments, upon unwinding. The multiend package can be used directly in processes such as beaming, circular knitting, weaving, or core spinning in place of multiple single end packages, which provides convenience and cost savings. The bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
[0020] For the purposes of the present invention, the following terms are defined below: [0021] POY (Partially Oriented Yarn): Filament yarns in which the draw ratio is less than normal so that only partial longitudinal orientation of the polymer molecules.
[0022] FDY (Fully Drawn Yarn): As opposed to POY, filament yarns in which the draw ratio is normal so that full longitudinal orientation of polymer molecules.
[0023] DW (Draw Winding): The operation of stretching continuous filament yarn to align of order molecular and crystalline structure. The drawn yarn is taken up on a parallel tube or cheese, resulting in a zero-twist yarn.
[0024] DTY(Draw Texturing Yarn): Filament yarn in which the manufacture is the simultaneous process of drawing to increase molecular orientation and imparting crimp to increase bulk.
[0025] DT(Draw Texturing): In the manufacture of thermoplastic fibers, the simultaneous process of drawing to increase molecular orientation and imparting crimp to increase bulk.
[0026] Multiple: Having or involving many individuals, filaments, threadlines and ends.
[0027] Multifilament: A yarn consisting of many continuous filaments or strands, as opposed to monofilament which is one strand. Most textile filament yarns are multifilament.
[0028] Multicomponent: The fiber is composed of more than one polymer. In some embodiments, these polymers are primarily poly(ethylene terephthalate) (2GT), poly(trimethylene terephthalate) (3GT), and poly(tetramethylene terephthalate) (4GT) or a combination of such members.
[0029] Core Spun Yarn: A yarn made by twisting fibers around a filament, thus concealing the core. One example is where the core yarn is an elastic yarn (such as 2GT 3GT bicomponent) to obtain stretch-recovery characteristics and twisting fibers are cotton fibers to obtain desirable touch aesthetic.
[0030] Dimensions appropriate for direct use in making core spun yarn: Conventionally, the core yarn for CSY (Core Spun Yarn) is spandex yarn, which packages size is much smaller than polyester bicomponent yarn. Therefore, the creel or space in the CSY machine is not available for placing one yarn package on one spinning position when polyester bicomponent yarn replacing spandex yarn.
[0031] Elastomeric fiber: Synthetic fibers having properties of natural rubber such as high stretchability and recovery. [0032] Hard yarn: As opposed to elastomeric fiber, synthetic fibers having no properties of natural rubber such as stretchability and recovery.
[0033] Spandex: A manufactured fiber in which the fiber- forming substance is a long chain synthetic polymer composed of at least 85% of a segmented polyurethane.
[0034] As used herein, "bicomponent filament" means a continuous filament in which two polymers of the same general class are intimately adhered to each other along the length of the fiber, so that the fiber cross-section is for example a side-by-side, eccentric sheath-core, or other suitable cross-section from which useful crimp can be developed.
[0035] As used herein, "side-by-side" means that the two components of the bicomponent fiber are immediately adjacent to one another and that no more than a minor portion of either component is within a concave portion of the other component. "Eccentric sheath-core" means that one of the two components completely surrounds the other component but that the two components are not coaxial.
[0036] As used herein, "threadline" means a group of two or more bicomponent filaments. The filaments of the threadline are processed together, as a group. As used herein, "end" means an individual fiber, yarn, or threadline. As used herein, "threadline" is interchangeable with "end". In conventional fiber spinning and winding processes, a single threadline is typically wound onto a single tube core to produce a "single end" package. The single end package produced by the conventional procedure is also referred to as "one end per package."
[0037] As used herein, "threadline bundle" means at least two threadlines which have been combined together to form one multicomponent entity, the threadline bundle. The threadline bundle remains capable of being separated into at least two individual threadlines (ends). As used herein, threadline bundle also means a yarn which is comprised of at least two ends.
[0038] As used herein, "yarn" means a continuous strand of textile fibers, filaments, or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric.
[0039] As used herein, "multiend package" means a threadline bundle wound onto a tube core.
[0040] The polyester bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, in a weight ratio of from about 30:70 to about 70:30. The polymers may be, for example, poly(ethylene terephthalate) and poly(trimethylene terephthalate), poly(trimethylene terephthalate) and poly(tetramethylene terephthalate), or poly(trimethylene terephthalate) and poly(trimethylene) terephthalate, for example of different intrinsic viscosities, although different combinations are also possible. Alternatively, the compositions can be similar, for example a poly(trimethylene terephthalate) homopolyester and a poly(trimethylene terephthalate) copolyester, optionally also of different viscosities. Other polyester bicomponent combinations are also possible, such as poly(ethylene terephthalate) and poly(tetramethylene terephthalate), or a combination of poly(ethylene terephthalate) and poly(ethylene terephthalate), for example of different intrinsic viscosities, or a poly(ethylene terephthalate) homopolyester and a poly(ethylene terephthalate) copolyester. As used herein, the notation "//" is used to separate the two polymers used in making a bicomponent filament. Thus, for example, "poly(ethylene terephthalate)//poly(trimethylene terephthalate)" indicates a bicomponent filament comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate).
[0041] One or both of the polyesters can be copolyesters, and "poly(ethylene terephthalate)," "poly(tetramethylene terephthalate)", and "poly(trimethylene terephthalate)" include such copolyesters within their meanings. For example, a copoly(ethylene terephthalate) can be used in which the comonomer used to make the copolyester is selected from the group consisting of linear, cyclic, and branched aliphatic dicarboxylic acids (and their diesters) having 4-12 carbon atoms (for example butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1 ,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids (and their diesters) other than terephthalic acid and having 8-12 carbon atoms (for example isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched aliphatic diols having 3-8 carbon atoms (for example 1 ,3-propane diol, 1 ,2-propanediol, 1 ,4-butanediol, 3-methyl-1 ,5-pentanediol, 2,2-dimethyl-1 ,3-propanediol, 2- methyl-1 ,3-propanediol, and 1 ,4-cyclohexanediol); and aliphatic and araliphatic ether glycols having 4-10 carbon atoms (for example, hydroquinone bis(2-hydroxyethyl) ether, or a poly(ethyleneether) glycol having a molecular weight below about 460, including diethyleneether glycol). The comonomer can be present to the extent that it does not compromise the benefits of the invention, for example at levels of about 0.5-15 mole percent based on total polymer ingredients. Isophthalic acid, pentanedioic acid, hexanedioic acid, 1 ,3-propane diol, and 1 ,4-butanediol are exemplary comonomers. [0042] The copolyester(s) can also be made with minor amounts of other comonomers, provided such comonomers do not have an adverse effect on the physical properties of the fiber. Such other comonomers include 5-sodium-sulfoisophthalate, the sodium salt of 3-(2- sulfoethyl) hexanedioic acid, and dialkyl esters thereof, which can be incorporated at about 0.2-5 mole percent based on total polyester. For improved acid dyeability, the (co)polyester(s) can also be mixed with polymeric secondary amine additives, for example poly(6,6'-imino-bishexamethylene terephthalamide) and copolyamides thereof with hexamethylenediamine, preferably phosphoric acid and phosphorous acid salts thereof. Small amounts, for example about 1 to 6 milliequivalents per kg of polymer, of tri- or tetra- functional comonomers, for example trimellitic acid (including precursors thereto) or pentaerythritol, can be incorporated for viscosity control.
[0043] The polyester bicomponent filament can also comprise conventional additives such as antistats, antioxidants, antimicrobials, flameproofing agents, lubricants, dyestuffs, light stabilizers, and delustrants such as titanium dioxide as long as they do not detract from the benefits of the invention.
[0044] There is no particular limitation on the outer cross-section shape of the bicomponent filament, which can be non-round, round, substantially oval, triangular, "snowman," and the like. As used herein, "substantially oval" means that an area of a cross- section of the filament, measured perpendicular to the longitudinal axis of the fiber, deviates by less than about 20% from that of an oval shape. The general term "oval" includes "ovoid" (egg-shaped) and "elliptical" within its meaning. Such a shape typically has two axes at right angles through the center of the shape, a major axis (A), and a minor axis (B), where the length of the major axis A is greater than the length of the minor axis B. In the special case of a perfect ellipse, the oval is described by a locus of points whose sum of whose distances from two foci is constant and equal to A. In the more general case of an ovoid, one end of the oval can be larger than the other, so that the sum of the distances from two foci is not necessarily constant and can vary by 20% or more from elliptical. As used herein, a "snowman" cross-section shape can be described as a side-by-side cross-section having a long axis, a short axis, and at least two maxima in the length of the short axis when plotted against the long axis.
[0045] The cross-section periphery of the bicomponent filament may have or may lack constant curvature. The cross-section shape of the bicomponent filament may have or may lack grooves in the cross-section periphery. Examples of cross-section shapes which have grooves are "snowman," "scalloped-oval," and "keyhole." [0046] As used herein, "polymer interface" means the boundary between the polymers of the bicomponent filament. The polymer interface may be substantially linear or curved. For cross-section shapes having a major and minor axis, the bicomponent filament may have a polymer interface substantially perpendicular to or substantially parallel to the major axis of the cross-section.
[0047] The bicomponent filament has a crimp potential from about 30% to about 90%, for example from about 60% to about 80%. The crimp comes from different shrinkage of polymers, bi-component fiber is made from different polymers and develops crimp as a result of the different shrinkage rates. Specifically, the crimp is maximized upon application of heat to the bicomponent filament.
[0048] Different colors of polyester yarn may be included in some embodiments. Color can be added to polyester by the use of dyes and/or pigments. For example, black yarn may be prepared by the addition of carbon black. These additives are generally added into polymers and mixed together before passing through the spinneret.
[0049] FIG. 1 shows one embodiment of a yarn spinning apparatus 10 for providing a process for producing a multiend package which includes melt spinning two or more compositionally different polymers 12A and 12B from a single precoalescent or post- coalescent spinneret 14 to form multiple side-by-side or eccentric sheath-core polyester bicomponent filaments. A plurality of yarn ends16a-16f is produced each including of multiple filaments. Finish may be supplied by a spin finish applicator 19. The yarn ends 16a-16f pass through the quench cabinet 18. The yarn ends may then be drawn at G1-G3 and passed through an interlacer 20 including a pressurized fluid. Two or more of the yarn ends are then combined at a convergence guide to form multiend bundles and wound onto packages 28a. These multiend bundles can be separated in to the original yarn ends.
[0050] FIG.2 provides more detail. Each of 16a and 16b, 16c and 16d, and 16e and 16f are combined to form multiend bundles 24c, 24b, and 24a, respectively, which are wound to form multiend packages 28c, 28b, and 28a, respectively. When the package is placed on the creel for unwinding, two threadlines are available from each multiend package. Each of these threadlines are available to go to different spinning positions for downstream processing. [0051] The features and advantages of the present invention are more fully shown by the following examples which are provided for purposes of illustration, and are not to be construed as limiting the invention in any way.
EXAMPLES
Example 1 - Multiend package of 2 threadlines of 55dtex and 34 filaments
[0052] In order to prepare a multiend package of two threadlines each of 55 dtex and 34 filaments, each threadline with 68 filaments is prepared from a single spinneret and separated into two threadlines with 34 filaments each. Then, each threadline has 34 filaments. For a yarn spinning apparatus with six spinnerets, the six threadlines become twelve threadlines at one spinning position.
[0053] Each threadline (12 total with 34 filaments each) has its own yarn path on rolls and all facilities. All 12 threadlines are independent. After passing through the interlace jet, 2 threadlines converge into one threadline by a convergent guide, then this converged threadline is wound to one yarn package by take up winder. This provides six multiend packages with each having two ends from threadlines having 55dtex and 34 filaments each.
Example 2 - Multiend package of 2 threadlines of 27dtex and 17 filaments [0054] In order to prepare a multiend package of two threadlines each of 27 dtex and 17 filaments, each threadline with 34 filaments is prepared from a single spinneret and separated into two threadlines with 17 filaments each. Then, each threadline has 17 filaments. For a yam spinning apparatus with six spinnerets, the six threadlines become twelve threadlines at one spinning position.
[0055] Each threadline (12 total with 17 filaments each) has its own yarn path on rolls and all facilities. All 12 threadlines are independent. After passing through the interlace jet, 2 threadlines converge into one threadline by a convergent guide, then this converged threadline is wound to one yarn package by take up winder. This provides six multiend packages with each having two ends from threadlines having 27dtex and 17 filaments each.
Example 3 - Multi-end package for core spinning
[0056] FIG. 3 shows a multiend package 28c for core spinning process. The yarn is driven by two delivery rollers 38 so that the two multicomponent yarns 16a and 16b from multiend package 28c are separated and unwound tangentially to the roller guides 30 which direct the separated multicomponent yarn 16a and 16b to its corresponding front roller 35 of spinning position where the polyester multiple component yarns are combined with the staple roving fiber 2 to provide separate core-spun yarn packages 4.
Example 4 - Multi-end package for hollow spindle covering
[0057] FIG. 4 shows a multiend package for hollow spindle covering process. The multiend package 28 is driven by two delivery rollers 38 and the two multicomponent yams 16a and 16b are delivered tangentially to individual guide eyelets 42 of corresponding spinning position. The separated multicomponent yarns 16a and 16b separately pass from second delivery rollers 40 than pass through a spinning spindle 44 which has a hollow tube at the center and carries a non-elastic yarn package outside 46. The spinning action of the spindle releases the non-elastic yarn and wraps around the multicomponent yarn and is taken up by third delivery rollers 41 to a covered package 48 for other applications.
Example 5 - Multi-end package for circular knitting
[0058] FIG. 5 shows a multiend package 28 for circular knitting. The multiend yarns 16a and 16b on the package 28 are delivered by two delivery rollers 38 at a constant speed and separated to individual stop motion devices 54 for corresponding knitting position. The separated yarns 16a and 16b pass from roller guides 50 to a yarn feeder 52 to the knitting needles 58. Separately, hard yarn packages 60 provide hard yarn with a feed speed control apparatus 56 to the yarn feeder 52 for knitting a garment or fabric including a hard yarn and an elastic bicomponent yarn.
[0059] Examples 3, 4, and 5 have a device which drives the multiend package at a constant and pre-determined speed to deliver the multicomponent yarn tangentially. The draft of multicomponent yarn: delivery speed of the multiend package relative to that of non- elastic yarns, is normally at a range of 1X to 1.2X, typically 1.01 X to 1.1 X for better processing efficiency.
[0060] While there have been described what are presently believed to be the preferred embodiments of the invention, those skilled in the art will realize that changes and modifications may be made thereto without departing from the spirit of the invention, and it is intended to include all such changes and modifications as fall within the true scope of the invention.

Claims

What is claimed is:
1. A process for producing a multiend package, the process comprising:
A) melt-spinning two or more compositionally different polyesters from a single pre- coalescent or post-coalescent spinneret to form multiple side-by-side or eccentric sheath- core polyester bicomponent filaments;
B) grouping the filaments into at least two threadlines, each threadline including more than one filaments;
C) taking up the threadlines at speeds greater than about 300 meters per minute;
D) interlacing each threadline;
E) combining the threadlines into a threadline bundle; and
F) winding the threadline bundle onto a tube core at speeds greater than about 300 meters per minute; wherein the threadline bundle is separable into at least two individual threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
2. The process of claim 1 , further comprising drawing the threadlines with a draw ratio greater than about 1.2 and winding the threadline bundle at speeds greater than about 420 meters per minute.
3. The process of claim 2, further comprising heat-treating the threadlines at a temperature between about 100 0C and about 200 0C.
4. A process for producing a multiend package, the process comprising:
A) melt-spinning two or more compositionally different polyesters from multiple pre- coalescent or post-coalescent spinnerets in a single spinning position to form multiple side- by-side or eccentric sheath-core polyester bicomponent filaments;
B) grouping the filaments into at least two threadlines, each threadline consisting of multiple filaments;
C) taking up the threadlines at speeds greater than about 300 meters per minute;
D) interlacing each threadline;
E) combining multiple groups of at least two threadlines into multiple threadline bundles; and
F) winding each threadline bundle onto a tube core using conventional multi-package winders; wherein each threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
5. The process of claim 4, further comprising drawing the threadlines with a draw ratio greater than about 1.2 and winding the threadline bundle at speeds greater than about 420 meters per minute.
6. The process of claim 5, further comprising heat-treating the threadlines at a temperature between about 100 0C and about 200 0C.
7. A process for producing a multiend package, the process comprising
A) forming at least two threadlines from two or more side-by-side or eccentric sheath- core polyester bicomponent filaments;
B) combining the threadlines into a threadline bundle; and
C) winding the threadline bundle onto a tube core; wherein the threadline bundle is separable into at least two threadlines and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
8. The process of claim 7, wherein the package has dimensions appropriate for direct use in making core spun yarn.
9. The process of claim 8, wherein the package has dimensions to fit the apparatus for core spinning spandex yarn.
10. The process as in one of claims 1-9, wherein the bicomponent filament comprises poly(ethylene terephthalate) and poly(trimethylene terephthalate).
11. The process as in one of claims 1-9, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(trimethylene terephthalate).
12. The process as in one of claims 1-9, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(tetramethylene terephthalate).
13. A threadline bundle comprising at least two threadlines, each threadline comprising multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, wherein the threadline bundle is separable into at least two threadlines, and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
14. The threadline bundle of claim 13, wherein the filaments have a cross-section shape selected from the group consisting of round, oval, or snowman or a combination of such members.
15. The threadline bundle of claim 13, wherein the filaments have a non-round cross- section shape.
16. The threadline bundle of claim 13, wherein the denier of each threadline is between about 10 and about 300.
17. The threadline bundle of claim 13, wherein the denier per filament is between about 0.50 and about 20.
18. The threadline bundle of claim 13, wherein the threadline has a crimp potential of at least 30%.
19. The threadline bundle of claim 13, wherein the bicomponent filament comprises poly(ethylene terephthalate) and poly(trimethylene terephthalate).
20. The threadline bundle of claim 13, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(trimethylene terephthalate).
21. The threadline bundle of claim 13, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(tetramethylene terephthalate).
22. A multiend package comprising a threadline bundle wound onto a tube core, wherein the threadline bundle is separable into at least two threadlines, each threadline comprising multiple side-by-side or eccentric sheath-core polyester bicomponent filaments, and the bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members.
23. The package of claim 22, wherein the package has dimensions appropriate for direct use in making core spun yarn.
24. The multiend package of claim 22 or 23 wherein the bicomponent filament comprises poly(ethylene terephthalate) and poly(trimethylene terephthalate).
25. The multiend package of claim 22 or 23, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(trimethylene terephthalate).
26. The multiend package of claim 22 or 23, wherein the bicomponent filament comprises poly(trimethylene terephthalate) and poly(tetramethylene terephthalate).
27. The multiend package made by the process of claim 1 or 4 or 7.
28. The threadline bundle of the multiend package made by the process of claim 1 or 4 or 7.
PCT/US2009/037589 2008-03-20 2009-03-19 Multiend package of multifilament polyester bicomponent yarn WO2009117535A1 (en)

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JP2011500940A JP2011518261A (en) 2008-03-20 2009-03-19 Multi-end package of multifilament polyester bicomponent yarn
US12/922,564 US20110133011A1 (en) 2008-03-20 2009-03-19 Multiend package of multifilament polyester bicomponent yarn
BRPI0907082-6A BRPI0907082A2 (en) 2008-03-20 2009-03-19 Process of producing a multi-end bundle, string bundle, multi-bundle bundle, multi-bundle bundle made by the process and multi-bundle bundle bundle bundled through the process.
CN2009801184531A CN102037171B (en) 2008-03-20 2009-03-19 Multi-end package for multifilament polyester bicomponent yarn
EP09723024A EP2265753A4 (en) 2008-03-20 2009-03-19 MULTIFILAMENT BICOMPONENT POLYESTER THREAD WITH MULTIPLE ENDS
HK11110757.9A HK1156370A1 (en) 2008-03-20 2011-10-11 Multiend package of multifilament polyester bicomponent yarn

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BRPI0907082A2 (en) 2015-07-07
HK1156370A1 (en) 2012-06-08
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US20110133011A1 (en) 2011-06-09
KR20110002031A (en) 2011-01-06

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