Note: Descriptions are shown in the official language in which they were submitted.
.3
~4-54-8064
1 - .
CONJUGATE FILAMENTS AND PROCESS FOR PRODUCING Shoe
.
ACT r rot
A. Field of the In nit n
This in7e~tion relates to novel oonJugato
scents and to novel proxy for predawn conjugate
filament. In particular, the inanition relates to
novel pol~smid0 oon~ugate filaments hiving 8 hire level
of "hlgh-load" crimp end to a novel process for
producing such locknuts.
The tern ~hlgh-load primp" a used herein mean
crisp go helical coils) bring deYelop~d anger us-
tanned during performance of the hlgh-load trip tout
hereafter defined. Toe tern "lulled crimp" Ann
crop develcpod Audrey retained during performance of
the low-load primp test hereinafter dined
B.
Con~ugatQ filaments and their preparation are
jell known in tube art. Typically, their preparation
Cooper two completely skipper and discontinuous
2Q operations; a melt spinning operation in which two dip-
fervent polymers are co-extruded Jo Norm pun Lila-
~nt3 which Ore wound onto u bobbin to form a package,
and a ~trct¢hln~ operation in high the aspen Lila-
Manitoba art ~lth~r~a Roy two bobbin, stretched end thin
wound onto a second bobbin to onoc Cain o'er a package.
Thy polymeric my din Roy one another with ro~pect
to, for axamplo, their ohe~lcal structure ox see
US. Patent 4,019,~11) or the polr~era my have the Sue
tractor and by di~r~r~nt byway ox a difference in
relative Yisco~ity ox Lee US. Patent 3,536~02) or
because on oilier contain us ~ddlti~e that oh~nge~
lo ~orphologJ and the other polymer does not go I
US Potent 4,271,233). US Potent 4,244,907 end 4,202,854
do~cribo process for prying conjugate fila~nts
Nhoreln, lnst~ad of riding two polymers, a single
polymer 18 extruded to Ford ~onooo~pQnent molten
strew that 18 treated, such I by abutting thy try
~L22~ 3
14-54-8064
--2--
to one-~lded cooling before it it co~pletelr ~olidlried
I eye US Patent 4,244~907) or to one-8ided heat1nB
i~medl~tely sorter it it solidified (e.g., Lee Us Potent
4,202,854) In thwack instances the filament I trashed
immediately after the one-slded treatment.
Conjugate fulminate prepared by the prior nut
processes, in general, lack the ability to develop crimp
characteristic of the type required of filament used
in the construction of stretch" garments such a lies
hose, pantyhose, sthlotlc Y~sr, leotards, etc. For they'll
reason most illuminate heretofore used commercial for
stretch garment &pplicatlons are monoco~ponent nylon 66
or nylon 6 filaments that Howe been mechsnlcally false-
twist twittered. Although the polyamide conjugate fife-
mints d~crlbed in US Patents 3~399,108 and ~418~19g
have the ability to develop adequate crimp having char-
acteriatics of the type required for stretch Ryan.
application, the filaments are lacking in other rest
pocket 88 compared to the f~lse-twist textured monocom-
potent nylon rilaménts. For example, the monocompon~nt
filaments hsvo lower boiling Tory shrinkage values end,
therefore, offer greater d1m~nslonal stability to garb
mints, such a hose, where the crop it developed slier
the hose are knitted ~180~ two crimp of the manocom-
put flls~nnts can be duped I toe dye both during
conventional garment dyeing operation , in Boyle
Atari at atmospheric prowar), where the crop of
these conjugate fullness require a special treatment,
i.e., superheated ~tQQ~ (118C~.
SYRIA OF THE IN~ENTIQN
The present inanition relate to Noel prick
for producing conjugate ~lla~ents End to Noel conjugate
filaments. More speciflcallr, the invention provides R
simple and economical process or produolng Charlotte
filaments hiving impaired properties, arch I wrap
charactari~ticsO In particular in one embodiment, the
invention provides polyamide conjugate filaments
having requisite high-load crimp and boiling water
.
~L~2~L3
--3--
shrinkage characteristics for stretch garment applications
and, especially, for ladies' leg hose. The invention also
provides a process for producing such polyamide filaments.
In accordance with one embodiment of the present
invention, there is provided a substantially torque-free
filament comprising a first longitudinal polyamide segment
and a second longitudinal polyamide segment arranged in an
eccentric configuration along the length of the filament and
differing from each other in longitudinal dimensional change
characteristics, the filament having a high-load crimp test
value of at least 12% and a boiling water shrinkage test
value such that the quotient obtained by dividing said crimp
test value by said shrinkage test value is at least one.
According to another aspect of the invention, the
lo process comprises stretching a fresh filament at a stretch
ratio greater than 1.0 and less than that which would cause
the filament to break, said filament being melt spun at a
spinning speed of at least 1829 mum (meters per minute and
comprising a first longitudinal polymeric segment and a
second longitudinal polymeric segment arranged in an eccen-
trig configuration along the length of the filament and dip-
foreign from each other in dimensional change characters-
tics, said difference and said stretch ratio being selected
to provide a filament having a low-load crimp test value of
at least 12% and, preferably, at least 20%. sty "fresh" fife-
mint is meant a filament which has not been allowed to age
under conditions such that when stretched no substantial
improvement is obtained as compared to characteristics
obtained when a filament spun under the same conditions is
aged for four I hours at 70~ relative humidity and at a
lo Lo
-pa-
temperature of 25C prior -to stretching to the same stretch
ratio. Fresh filament characteristics can, in some in
stances, be preserved at least temporarily by collecting and
maintaining the filament under an hydrous conditions until it
is drawn as shown, for example, in Example 12 herein. Al-
though applicants do not wish to be limited by theory, the
use of a fresh filament is believed to provide desirable
results due to crystalline characteristics at the time of
stretching.
Preferably, the process is a spin-stretch process
wherein the stretching of the filament is accomplished in-
line during melt spinning after the filament is formed and
before it is collected.
According to a preferred embodiment of the
invention, the spin-stretch process comprises co-extruding
two molten fiber-forming polymers having different
I I
14-54-8064
--4--
terminal velocity distances to form R molten trim in
which the polymer are arranged in On eccentric con-
figuration long the length thereof, tooling and swilled
King slid molten try in R quenching zone to for
filament (solidified molten stream), sttenu~ti~g sod
ac¢eler~tlng said molten stream by withdrawing the
filament from the quenching zone at a speed I
spinning speed) of at least lB29 my end then trothing
the filament at a stretch ratio greater than 1.0 online
before it it collected and, preferably, soon as pox-
sidle Starr the Molten trim has ~olldified, the pus-
swizzling conditions and polymers being selected to pro-
wide filament having a lulled crimp test value of it
least 12g sod preferably 20%. Preferably, at least one
of two polymers it a polyamide nod most preferably it
nylon 66~ As used herein, the tory solid lied morns
the molten stream has cooled sufficiently Jo that it no
10~8~ Tokyo (i.e. ~U8eB) to other fila~enta or to yarn
guide surfs. Puller h~vlng "dl~rerent terminal Ye-
I Lucite distances are characterized in that under thoparticular pint retch conditions explored to wrier the
molten stream the polymer solidly et different dip-
Tony from their point of extrusion (i.e., at different
distances Roy the ~plnnsret). The moronity ox
terminal elicit destiny i 8 hereinafter sorbed
According to the 208t preferred embodi~nt ox
the ~pln-stretch process, both puller era polyR~ides
end the proces~lng conditions and polyamide so select-
Ed to provide a conjugate filament Helen a hl6h-load
crimp test value of at toast 12~ Ed a boiling Tory
~hrln~ge tot Allah such that two quotlont obtained by
dl~dln~ said crimp Taft Yule by Ovid boiling Qatar
shrinkage test flu 18 at least 1Ø This quotient it
referred to Harlan a the "CROUPS rails". In general,
the highest helical crimp tot values end orate boil-
no water shrinkage test vowel pro attained by Buckwheat-
in hl~hly crystalline ho~opolya~idos~ such a nylon 66
14-54-8064
-5-
and to a lesser extent nylon 6. Pre~sr~bly, both hobo-
payloads are ox the tame che~lc~l structure, that I
consist of recurring ~truotur~l units Or the same comma-
eel formula. Most preferably each polyamide it nylon
66,
The cougar filament prepared in acoordanco
with the present invention ha little or no torque (i.
eye are substantially torque-free) and, therefore, offer
certain Advents over ~alse-t~st textured filets
high contain substantlsl torque (lye. are torquo-l~vo-
lo One Advents 18 tout conjugate fila~nt~ Jay bused in the Norm ox a id denier jingle yarn (eye. 140
downer fluent yarn), errs friction felicitated
~ilsments cannot normally be used in this form because
ox torque, but rather art used in the form ox` a plod
yarn where two 70 denier singles yarn ox oppo~lte ion-
qua are plied to form a t40 denier yarn ox balanced
torque.
The high-load primp test (hereafter defined)
I used heroin to determine the ~ultsbillty ox conjure
fulminate for howler sod other stretch guaranty spool-
Sheehan. Thy higher the Hollywood rip toot value the
more suitable the foliate it *or stretch garment apply-
cations. For Hoosier, two lost value should be at lest
12~ and, preferably at lout 15~. Although in practice
two hove art norD~lly placed in a dye bath ~aint~ln~d at
or near the ambient typewriter and thin the temperature
of thy both it subsequently Rudy to thy boll to isle-
tonsil develop thy crisp end dye the host, thy huh
load crlDp tout it such queer end o'er to us than
crop teats oonduct~d in Boolean Atari. The hlgh-load
trip test oorr~latos very pull to Boolean Qatar crop
texts for slants preread prom two hooopolya~id~ ox
two I shekel structure but Or dif~sr~nt terminal
voloolt7 distances. Filament suns of thy prevent inn-
lion Hayakawa been clouted into idle hove and haYedaY~lopod e~c~llunt crop charscterlstlc~ and ~shibltod
6~.~3
14~54-~064
. -6-
acc0ptabl~ boiling water shrunk characteristics when
thy hove were plywood without restraint in e dye bath.
RIFE DESCRIPTION OF THE DRAWING
Figure 1 it a squeamish representation of
equipment useful in practicing the cpln-stratch prows
of two present invention; and
Figure 2 it representation of the cross-
section of a conjugate filament prepared by the up n-
stretch prows ox thy invention.0 LO
INVENTION
The prows ox the present invention provide
Colgate illuminates having improved prop~rt~s~. For
eagle the prows of the invention own by utilized to
provide polyamide keynote fila~onts which are par-
titularly useful or ladies' leg host Appalachian.
isle thy process of this lnvontion my by used to pro-
pyre s conjugate filament keep Ed of three or o'er
~ib~r-~or~i~g polymer gent the t~o-s~g~nt Lila-
I Kent it preformed ionic it offers ocono~ic advantag~,~over other multt-se~ont f~lam~nta~ I the nabber of
aegmeQt~ lncro~8a8 two prows becomes more end Roy
complicated end 1~8~ and lo practical. Aocordln~
the ~n~ntlon it d~scrlbed Huron with reassurance to thy
t~c-seg~ent conjugate nut.
A used heroin two tory ~C~OAJU~f~te lunate"
Deane a out Go~pri8ing a first longitudinal polyp
Merle 80g~0nt and a ~ocond lonsitudlnal polymeric Lee-
sent arranB~d in an ecc~ntrio csn~iguratlon long thy
length ox two slant and diSrering Roy aye other it
longitudinal dio~naional one characteristic The
try ~occ~ntric~ 8B Tad grin ~nclude3 both id
idea and rapturously Thor strutter By do
~orlng in "longitudinal dlmens~onAl change character-
italic nut that when thy nut it structurallyrol~edl or spool, go espo~uro to bullying Tory Yule
under no tenon, Only I thy aunt rink or other-
6113
14~54~8064--7--
Nose changes in length to a different extent than the
other segment(s), as evidenced by the filament assuming
a helical configuration or if the segments ~epnrate, by
a difference in their individual lengths. The formation
of helical crimp or filament splitting in the foregoing
test, of course, confirms the presence of at lest two
eccentrically arranged segments as jell as their differ-
in dimensional change characteristics. Conjugate fife-
mints having ReBments differing from each other in ion-
gitudinal dimensional change characteristics can by pro-
duped by methods well known in the art, such as, by us-
in polymer having different roulettes viscosities (e.g.
see US. Patent 3,536,802). There may be a distinct line
ox demarcation between the segments at their interface
or, in sore instances, merely a ersdient change in come
position of the filament across its cross-section.
In a preferred embodiment of thy invention, the
process is carried out using the equipment arrangement
shown in Figure 1. Referring to Figure 19 polyamide A
and B of different tarminsl velocity distances are co-
extruded at about the same melt temperature at a given
speed (extrusion speed) in molten form through circular
capillaries 2 sod 3, respectlYel~, of spinnerets 1. The
molten polymers converge blow the spinnerets face to
form molten stream 4 in which polyamides A and B sure
arranged, as segments, in a side-by-side configuration
For purposes of illustration the formation of only one
filament is shown in Fig. 1. It will be understood, ho-
over, in actual prsctlce of the invention the ~pinneret
Jill normally hove provisions for forming a plurality of
molten streams; that is, the spinnerets will have a plus
reality of capillary pairs 2 and 3. Molten stream 4 it
then quenched by conventional means to form a filament
(i.e., solidified molten stream). The filament it then
passed into contact lath finish applicator means 5 which
applies a liquid finish to the filament. Where there it
a plurality of filaments, the filaments are conveniently
converged on applicator jeans 5. The filament it then
pasted around feed roll 6 with a partial wrap, around
61~
14 54-~064
--8--
stretch roll 7 with a partial wrap, heated by heating
means 8 (e.g., a heated tube through which the filament
passes) and finally collected by collecting means 9
(e.g., a bobbin on which the filament is wound). Roll 6
it rotated at a peripheral speed of at least 1829 mum.
Roll 7 it rotated at a peripheral speed greater than
that of roll 6 but usually no greater than twice that of
roll 6. The partial wraps are of an angle sufficient to
prevent slippage of the filament on the rolls. When the
filament is collected on a bobbin, it should be collect
ted at a speed less than the peripheral speed of roll throb permitting the filament to relay (retract) be-
fore it it collected; otherwise difficulty is encoun-
toned in removing the bobbin from the chuck on which it
is rotated, particularly, where the filament or yarn
makes a large number of wraps on the bobbin to form the package. In instance where the filament makes only a
small number of wraps on the bobbin, heating of the lit-
amen by meats 8 may be omitted. The filament collected
on the bobbin normally has both original crimp (visible
crimp) which manifests it elf when the spinning tensions released and latent crimp which can be developed by
subunit treatment of the yarn.
Figure 2 show the cro~9-~ection of a typical
CODju~ate filament prepared in accordance with the pro-
cuss of the insinuation earn the ratio of Semite A to segment B used in forming the filament it
In accordance with the preferred embodiment of
the invention, the spin-stretch process is carried out
under processing conditions and using polga~lde3 80 a
to provide a filament having a high-load crimp text
value of at least 15~ and a CRIMP/BWS ratio Alec of at
least 2 and most preferably Allis of at Lotte 20g and
3, respectively. The oiling discussion kinder the
effect of changing the indicated procassin~ variable
Chile leaving all other variables constant.
One Senate of the conjugate filament is pro-
fireball formed from a rapidly crystallizable fiber for
in polyamide and the other from a lets rapidly crystal-
` ~26~3 1~-54-8064
I
livable ~iber-forming polyamide. ho difference in or-
stalli~ability may be achieved by selecting pol~amldes
having different terminal velocity distances. In general
as the difference between their terminal velocity dip-
lances increases, the high-load crimp test value in-
creases to or approaches a maximum value and thereafter
remains substantially the tame. In general, polymers be-
come lest crystallizable as the ratio of homopolymeric
segments to copolymeric segment increase, for example,
the crystal liability of nylon 66> nylon 66-6 (95:5)>
nylon 66-6 (90:10)> nylon 66-6 (85:15). Therefore, high-
lye crystalline homopolyamides such as nylon 66 and nylon
6 are preferred, with nylon 66 giving the highest high-
load crimp test values ant therefore, Boone thy prefer-
red polyamide for use in practicing the invention. Nylon
copolymers are designated herein in a conventional men-
nor, for sample, "pylon 66-6n ennui the copolymer Jon-
Sistine of randomly occurring 66 units,
-NH~CH2)6N~CO(CH2)4C0-, end 6 units, -NH(CH2)5C0-, ox
Ed for example, by c4polymerizing he~amethylene dram-
minim adiposity and caprolsctam. Mole ratios when given
are given in parenthetic felon the copolymer dyes-
nation, for example, (95:5) mean a mole ratio of 95:5,
respectively.
When the polyamide used to form one of the Peg-
Monet of the conjugate filmed it composed of structure-
at replating units of the same chemical formula as the
poly~mlde used to form the other segment, selection of
polyamides differing from each other in relative Vacua-
fly values viol provide the desired result in this pro-
cuss. When nylon 66 polyamides of different relative
viscosities (REV) are used to form the segments, the dip-
furriness in REV Steen the two nylon 66'~ should be at
least 5, preferably at least 15 and most preferably at
least 30 with the REV of the high REV nylon 66 being at
least 30 and, preferably, at least 50 sod most prefer-
ably at least 65.
While nylon 66 it the preferred pulled,
other polyamides Jay be used in practicing the
Lo 3
~4-54-806~
-- 1 0--
invention. Examples of other suitable homopolyamldes
include nylon 6 and nylon 610. Example of suitable
Capella asides include, but are not limited to, those
described in US. 3,399,108, 3,418,199, 3,558,760 and
3,667,207. Example of such copolyamides are: nylon
6-66, nylon 66-610; nylon 66-610-611-612; nylon 66-612;
O O
nylon 66-6I INCH C- units); nylon 66-6
O O
(6T--NH(CH2)6NH~ C- units) nylon 66-6-612; nylon
6-66-610 and nylon 6-612.
The spinnaret may be designed 90 that in form-
in a molten stream each of the molten polymers may by
extruded through a separate capillary in such a manner
that the molten polymers converge at the spinnerets face
to form the molten stream or the polymers may be coy-
brined and then extruded through a common spinnerets cap-
illary to form the molten stream. However, it it prefer-
red that each ox the molten polymer be extruded through
a separate capillary and Convair below the spinnerets
face to form the molten stream a shown in Fig. 1. Us-
lets the molter polymers converge at or below the face
of the spinnerets the one segment (e.g. the lo REV Beg-
mint) tends to wrap around the other segment (eye. high
REV segment), which in turn tends to reduce the ultimata
crimp of the filament.
The filament my be ox any desired crQss-sec-
lion, eye,, circular, trilobal, etc. Herr, it it more
economical to manufacture spinnerets having circular
capillaries. Filaments having a cro~s-section resulting
from the use of capillaries which are circular in cross-
section are shown in Fig Z.
The volume ratio of the polyamide egment3 can
vary o'er a wide range. As a practical matter the Peg-
mint system normally Jill be within the range of 3:1 Tao In the case where both segments are nylon 66, a
ratio of 1:1 to 1:3 (high to low relative viscosity) is
preferred with the greatest amount of crisp being ox-
twined with ratio of bout ~0:70 (high to low relative
3L3
1~-54-8064
_ 1 1 _
viscosity).
Cooling of the molten streams normally occur
in a quench chamber, commonly referred to a a chimney.
The term "quench" as used herein means the cooling of
the molten stream sufficiently to provide solidified
streams (i.e., filaments). Although cooling ox the
streams may be assisted by a transverse (or concurrent)
stream of flowing air, such a stream it not required in
order to provide filaments having high levels of high-
load crimp.
In conventions processes, the filament Are
Swede from the quenching chamber through what it called
a "steam conditioning" tube. Stem is circulated through
the tube sod comes into intimate contact with the fife-
mints. The purpose of the storm is to facilitate subset
quint processing of the filament. It has been found,
however, that the use of conditioning steam Thea the
spin-stretch process of this invention si~nificflntly
Rudy high-load crimp, i.e., to a level substantially
below 10%. Accordingly, conditioning steam should not be
used with the process when higb-loQd crimp it desired
or, if it is used, it should be used very ~pQringly.
Finish (aqueous or an hydrous) Jay be applied to
the ~ila~ants by conventional means, for example, by
passing the fluent o'er a roll which transfer finish
on to the laments from a.reserYoir it which thy roll
it partially submerged and notating. Alter~ati~ely, a
stationary Y-shapsd guide Jay be used. The guide is en-
ranged a that filaments ride in the Y and a finish is
30 metered to the ~ila~ent~ via a small tub. A ~lnish it
not necessary in order to obtain the desired filament
propertiso. Hoover, if n finish it not used, two fife-
mints ~ecoms statically corralled and difficult to hsndl~,
for example, when unwinding the from a bobbin. As a
35 practical matter, the finish it prsf0rably an nqu~ous
finish ( water per ye or a valor bss0 finish in viol- ox
two environmental considerations involved in the use of
non-sque~us phenols .
The fluent spa conveniently converged on the
26~
14-54-8064
-12-
finish applicator mean (e.g. the above mentioned finish
guide). If desired, the filament may be converged by
means of a conventional convergence elide after being
quenched and prior to A finish being applied thereto.
The molten streams are attenuated and acceder-
axed from the spinnerets (or, when formed below the spin-
beret, from their point of formation) by a feed roll
which withdraws the quenched streams (filaments) from
the quenching zone at spinning speed greater than the
extrusion speed. The extrusion speed is the linear speed
at which the molten polyamide is theoretically traveling
through the spinnerets capillary or capillaries and is
calculated prom the dimensions of the capillary, the en-
trusion rate and the density of the polyamide. When more
than one capillary it used to form the filament, the
linear speeds era averaged and the average speed it u Ed
as the extrusion speed. The term "jet attenuation" (JAY)
as used herein represents the quotient obtained by dip
voiding the spinning speed (SO) by the extrusion -speed
(EN). It has been found that increasing jet attenuation
ha little effect on the hillside crimp. In general, in
order to obtain filaments having a high level of high-
load crimp, the spinning speed must be at least 1829mpm.
Preferably, spinning speed of at least 2286 mum and
most prefer Al at least 2743 pi are used in prsQticing
the process of the invention. In general, increasing the
spinning speed sod other preseason speeds accordingly
improves the economics of the process.
In accordance with a preferred embodiment ox
the present invention, the filaments are stretched in-
line before belle collected, for example, before being
wound onto a bobbin. Normally, if the filaments are got-
looted and then subsequently stretched in a separate opt
oration, the filaments Jill not posses significant
level of Hollywood crimp even though they may posses a
moderate level of lulled crimp. It has been discovered
however, that if the filn~ents are spun and collected
under an hydrous conditions end kept under Andre con-
~,~ dictions for a limited period of time until subsequently
26~3 14-54-8064
--1 3-
stretched, it it possible to obtain filaments having aloud crimp level in excess of 8g even though the
stretching of the filaments it accomplished in an opera-
lion subsequent to and separate from the spinning opera-
lion. However, such conditions are usually not practioalfrom the standpoint of commercial operations.
The stretching it preferably accomplished using
a roll arrangement a shown in Figure 1 wherein roll 6
is a feed roll and roll 7 it a stretch roll. The stretch
roll is operated at a peripheral speed higher than the
peripheral speed of the feed roll. With the roll arrant
junta shown in Figure 1 the filaments are stretched as
they learn feed roll 6. In general, as the stretch ratio
it increased from 1, the level of highroad crisp impart-
Ed to the filaments increases through a maximum level
and thereafter decreases slightly. Normally, Mom
high-load crisp text value ore attained when the fife-
mints are stretched at a ratio greater than 1Ø In many
instances use of a stretch ratio greater than 2.0 can
not be used without breaking filament. It is contempla-
ted that, if desired, the stratchinR of the fila~entsmay occur downstream of the feed roll; for example, bet-
wren two pairs of roll where the first pair it rotating
at the game peripheral speed as that of the lead roll
and the second pair at a higher peripheral speed. Pro-
fireball, the filament are strQtchad as 900n as possibly
after being quenched. As a practical tatter, it spinning
speeds of at least 1829 pi the stretching Jill occur
within a fraction of a second after quenching. However,
as mentioned above, the stretching can be delayed for
10~8 periods of lima it ~inutas, even hours), pry-
ding the filaments are kept under an hydrous conditions.
Under such conditions an an hydrous finish or no finish
at all must be used. Accordingly, where the filaments
are lagged or a substantial period of tire (in excess
of 4 seconds) before being trotted, such a in a stun-
for bus type tower or by eon of rolls around which
the filaments wake a plurality of passes, an Andre
finish it preferably used to be certain the level of
14-54-8064
I
high-load crimp I not significantly reduced. Where the
period of time between quenching and stretching icky jig-
nificantly Brighter than about 4 seconds, the filament
may also need to be kept in an an hydrous environment
Whether or not an an hydrous finish and/or an hydrous en-
vironment provide satisfactory results can easily be
determined experimentally. Where the filaments are
stretched within a few seconds after quench the use of
an aqueous finish and ambient conditions has very
little, if any, effect on the high-load crimp level
obtained by the process.
In com~srcial practice of the process, it Jill
normally be desirable to wind the filament onto a bob-
bin by mean of a winder with the nuder being operated
at the lowest speed that Can be used and still provide
sufficient tension on the yarn to obtain an acceptable
- package on the bobbin. Normally, a yarn tension button
0.05 and 0,1 grams per denier is used. generally, the
difference button the peripheral speed of the stretch
roll and the winder it in the range of 2 to 12%. This
difference in qpeeda cause the yarn to roles between
the stretch roll and winder. Conventional winder are
available and may be used in practicing the process,
which permit yarn tensions to be preset, here the
25 speed ox the lender automatically adjusts to mQi~tain
the preset tension. In certain instances it may be de-
slrable to heat the yarn as it it rheology, depending on
factors such as total yarn denier, package size process
King speeds and the like. The heating of the yarn Jay be
accomplished by exposing the yarn to radiant heat or by
passing the filaments through a tube heated with air. It
is also contemplated that the yarn Jay be heated by
~alntaining the stretch roll at a suitable temperature
to heat the filaments. The yarn, of course, should not
be heats in a manner or to a temperature that Gould
significantly reduce its crimp. In this reward it ha
been found that the UREA of ~qtsam to heat the yarn tends
to significantly reduce the Hollywood crisp level.
Therefore, the use of steam to effect the heat relax-
,,
:1~26~L~L3
14-54-8064
-15-
lion of the illuminate to not recommended where high
levels of Hollywood crimp are desired.
Measurements
-
A. Restive viscosity REV values, when given
herein, are riven without units. First, the intrinsic
viscosity [n] of thy polymer it determined and then the
relative viscosity (REV) is calculated from the equation:
[n]-(0.184)tRV)0 941: Solon for REV:
REV e raised to the following power:
in 0.491
The intrinsic Vacuity it dote wined from the equation:
slim in t/to C
I
where to it the flow time at 25C through a vi~cometer
of 90% formic acid (pure solvent) and t it the flow time
through the same viocometer of a 901ution of the polymer
hazing the concentration (c) in grays of polymer I
of pure solvent. In deterring the L no of the high REV
polymer a concentration of 0.25 grimly ml it used; in
determining the [no of the lo REV polymer a concentra:
20 lion of 0.50 Grimm ml is used.
I. High-load crimp text values, when given
herein, art riven in terms of percent (~) and are deter-
mined on 8 sample of filament(s) prior to da~elopment of
its latent crimp, as ~0110~8:
(1) Determine the denier of the sample
(2) Calculate thy number of revolution on a
dewier reel that Gould be required to make
a skein pa continuous bundle ox ~ilamcnts
in the form of collapsed coil) having a
denier of 4000.
Jo. ox Revolutions - 4000
Denier of sample
(3) Prepare a kiwi Hugo a denier of 4000
f r ox to e sample.
(4) Vertically hang the skein from a station-
cry hook by placing the skein over the
hook being Charlie to avoid stretching or
tangling of the skein. Nook a low ~eixh~
14-54-8064
-16-
wire hook (reshaped paper clip) through
the bottom of the skein.
(5) With the skein hanging vertically from the
hook, suspend a 800~ weight from the wire
hook (the skein now has the appearance Or
a single 8000 denier 9 trend).
(6) After the weight has been suspended for
0.5 minutes remove the 800g weight and
replace it with a 20~ weight.
(7) Suspend the skein with the 20g weight in a
120C forced draft oven for 5 minutes.
(8) Remove the skein from the oven, let it
cool for one minute and hang it once again
over the stationary hook with the 20g
weight suspended from the skein via the
wire hook.
(9) then without removing the 20g weight,
determine the length of the doubled skein
to the nearest 0.1 cm. Record this length
I
(10) Remove the 20g weight and replace it with
an 800g weight; after 30 second determine
the length of the skein to the nearest 0.1
cm. Record this l~nRth (Lo).
% High-load Crimp 100
C. Low-load crisp test value, when given
herein, are given in terms of percent (~) and are
determined from a sample of filament before develop-
men of it latent crimp, as follows:
(1) Determine the denier of the sample
I Calculate the number of revolution on a
denier reel that Gould be required to make
a skein (a continuous bundle of filament
in the form of a collapsed coil) Hun a
denier of 5412.
No. of Revolutions 5412
.. .. _
Denier of Apple
26~13
14-54-~064
-17-
(3) Prepare a skein having a denier of 5412
from the sample.
(4) Vertically hang the skein from a station-
cry hook by placing the skein over the
hook being careful to avoid stretching or
tangling of the skein. Hook a low weight
vine hook (reshaped paper clip) through
the bottom of the skein.
(5) With the skein hanging vertically from the
stationary hook, suspend a lug weight
from the wire hook (the skein now has the
appearance ox a single 10824 denier
strand), and altar 0.5 minutes measure the
length of the doubled skein to the nearest
Loom and record this length a Lo.
Remove the loose weight.
(6) Suspend the skein in a 120C forced draft
oven for 5 minute
(7) Remove the skein from the oven, let it
cool for one minute, attached a log Nat
to the skein via the wire hook and hang it
one again over the stationary hook with
the log weight upended prom thy wit rho
hook.
I Then, without removing the 10~ weight
determine the length of the doubled skein
to the nearest Clam Record this length
a Lo.
(g) Remove the log weight and replace it with
the lug weight; after 30 second
determine the length of the skein to the
nearest 0.1 cm. Record this length as Lo.
% Low-Load Crimp~L3-L2 x 100
Lo
D. Boiling water shrinkage values, when even
herein, are given in terms of percent (%) And ore
determined:
I Determine the denier of the simple.
(2) Calculate thy nabber of revolutions on a
~2~13
14-54-8064
-18-
denier reel that would be required to make
a skein having a denier of 2250.
Rivulet on 8 _ 2250
denier of sample
(3) Prepare a skein having a denier of 2250.
(4) Vertically hang the skein from a station-
cry hook by placing the skein over the
hook being careful to avoid stretching or
tangling of the skein. Hook a low weight
hook (reshaped paper clip) through the
bottom of the skein.
(5) With the skein hanging vertically from the
stationary hook, suspend a lSOOg weight
from the wire hook (the skein now has the
appearance of a 4500 denier strand).
(6) After the weight ha been suspended for 10
seconds, determine the length of the
doubled skein to the nearest 0.1 cm and
record this length as H (initial length).
I Replace the 1500g weight with a 6.1g
weight and immerse the skein in a boiling
water bath for 1 minute.
(8) Remove the skein from the bath, then
remove the 6.lg wright and permit the
skein to air dry After the skein it dry,
condition at standard atmospheric
conditions (72% RHO for 12 hours.
(9) Again suspend the lS00g weight from the
skein while the skein is hanging
vertically from the stationary hook.
(10) After 10 seconds, determine the length of
the doubted skein to the nearest Owl cm
and record this length as Lo final
length).
boiling water shrinkage (BUS) x 100
E. Terminal Velocity Distance: According to
one aspect of the invention, the process is carried out
by co-extruding Thor a spinnerets two polymer (ebb t
Lo 14-54-~064
_ 19_
Polymer A and Polymer B) having different Terminal Veto-
city Distances, Polymer A and Polymer being joined to
form a molten stream that is solidified in a quenching
zone to form a filament and being attenuated and act
5 celebrated by withdrawing the filament from the quenching zone at a speed (spinning speed) of at least 1829 mum.
The velocity of a molten stream continually increase up
to the point at which it solidifies at which point it
velocity corresponds to the spinning speed. The Terming
10 at Velocity Distance of Polymer A is determine under theism conditions used when co-e~trudin~ Polymer A and B
except in this instance only Polymer A is extruded. A
laser Doppler Velocimeter using a Hun laser with opt-
its for 9 mm beam separation and 250 mm focal length and
15 using a counter type signal processor Model 1980 built
by SUE, Inc., St. Paul, Minnesota (or equivalent incitory-
mint) is used to determine the point at which the molten
stream consisting entirely of Polymer A attains its Max
mum or terminal velocity. The distance from the pun
I beret to this point it measured and recorded as the
Terminal Velocity Distance of Polymer A, The Terminal
Velocity Distance of Polymer B is then determined in the
same manner. The actual Terminal Velocity Distance
values are not important so long as the values ore
25 different.
The following examples are given to further
illustrate the invention, In the felon examples
yarns are made using the same general apart and
procedure described in E~smpla 1. The specific con-
30 dictions utilized are given in each example along with test results obtained. Example 1
This example illustrates the preparation of
conjugate filaments of the present invention in which
35 high rslati~e viscosity nylon 66 it used to form one ox
the segments and a Lowry relative viscosity nylon 66 is
used to form tube other segment.
A high relative viscosity nylon 66 ~R~82) and
A lower molt viscosity nylon 66 (RV~41) having different
~2;~6~3 14-54-8064
--20--
terminal velocity distances are co-extruded in a wide
by-side configuration in a 1:1 ratio u3in~ the apparatus
arrangement shown in Fig. 1, except that instead of one
pair of capillaries the spinnerets has seven (7) pairs Or
circularly spaced holes (capillaries) each having a die-
meter of 20 miss (0.51mm). The extrusion temperature it
285 C and the extrusion rate it 0. 011896 cc/sec/capil-
lazy. A convergence guide (metered finish pin) it lo-
acted 91.44 cm from the face of the spinnerets The fin-
is pin is rectangular in shape with its long axis being
parallel to the threadlike. The pin is grooved to no-
chive and converge the seven filaments. Aqueous finish
is metered to the groove and into contact with the con-
verged filaments. The filaments are quenched enroot to
the finish pin by means of a cross-flow (2.83 cam) of
ambient air. The filaments in the form of a yarn are
withdrawn from the finish pin at 2858 mum (i.e.spinning
speed) by mean of a driven roll (feed roll) around
which the yarn makes a partial wrap. The feed roll it
Z0 19 cm in diameter and located 6.1 m from the face of the
spinnerets The yarn is withdrawn from the feed roll at
4572 mum by means of a stretch roll around which the
yarn also makes 8 partial wrap. The stretch roll is also
19 cm in diameter. The distance between the center of
the two roll 19 I cm. The feed roll and stretch roll
are arranged to prevent slop of the yarn on the
rolls. The yarn it withdrawn from the stretch roll and
wound onto a bobbin by means of a conventional winder at
a yarn tension of log. Enroot to the bobbin from the
stretch roll the yarn passe between, but not in contact
with, two strip heaters (30.48 cm by 10.16 cm) placed
6.35 mm apart face-to-face and heated to about 275 C.
The yarn relaxes between the stretch roll and bobbin an
amount equal to the quotient obtained by dividing the
difference between the peripheral speed of the stretch
roll (So) and the winding speed (So) by So i.e.:
I relaxation I I x 100.
In this instance the hot relaxati on is 0.098 or 9.8d.
~6~3 14 54-8064
-21-
A second bobbin of yarn it prepared and
collected under identical conditions, except in this
instance the heaters are eliminated from the process.
The prosing conditions used in making the two bobbins
of yarn are summered below:
Spinnerets capillaries (Hi/Lo) mm 0.51/0.51
Melt ratio (Hi/Lo) 50/50
Nylon types (Hi/Lo) 66/66
Nylon REV' 3 (Hi/Lo) 82/41
Revs Difference 41
Feed roll speed tmpm) 2858
Stretch roll speed (mpm)4572
In-line stretch (X) 1.6
In-line relaxation, Hot/Cold Given in Table 1
The effect of eliminating hot relaxation is
shown in Table I
TABLE 1
High- Low-
Load Load
In-Line Cri~pCrimp WISE Tenacity
Item Rowley % % god
lo Hot/9.8 19.0 69 5.1 2.6
lo Cold/7.8 20.9 71 6.0 2.7
The results given in Table 1 show that the use
of host in relaxation ha a slight adverse effect on
crimp and strength properties and a slight beneficial
effect on BUS. The us of heat in relaxation can be
avoided except to the extent larger packages are
required
EMPLOY
.
This example shows that in the absence of an
in-line stretch, yarns of high-load crimp sure not
obtainable even sty high pinion speeds. Yearn are
prepared as described in Example 1 using the following
conditions:
LZ2~3
1~-54-8064
. -22-
Spinnerets capillaries (Lyle) mm 0.45/0.45
Melt ratio (Hi/Lo) 50/50
Nylon type (Hi/Lo) 66/66
Nylon Revs (Hi/Lo) 71/39
Revs Difference 32
Feed roll speed (mum) Given in Table 2
Stretch roll speed (mum) ditto
In-line stretch (X) ditto
In-line relaxation, Hot/Cold Cold
Test results are given in Table 2.
TABLE 2
Feed Stretch High- Low-
Roll Roll In-line Load Load
Speed Speed stretch Crimp Crimp Tenacity
Item my mum (X) d % god
- -
PA 3201 32011.0 2.9 23 1.7
2B 3658 36581.0 3~4 26 1.8
2C 4115 41151.0 2.5 24 1.9
ED 4572 45721.0 3.1 23 1.8
YE 4572 45721.0 2.4 Al 1.9
UP 3048 45721.5 19.1 64 2.4
I 3048 45721.5 19.4 I 2.5
EXAMPLE 3
This example shows that substantial changes in
the jet attenuation (JAY) factor has little effect on
high-load crimp and tenacity. 'lams era prepared as
described in Example 1 using thy following condition:
Spinnerets capillarie~-~Hi~Lo) mm Given in Table
Melt ratio (Hi/Lo) 50/50
Nylon types (isle) 66/66
Nylon RV'9 (Hi/Lo? Given in Table 3
REV Difference ditto
Feed roll speed (mum) 3356
Stretch roll speed (mum) SKYE
In-line stretch (~) 1.5
In-line relaxation, Hot Cold Hot (9.0~)
Test results are inn in Table 3.
~L~Z~i~L~L3 14 5 4 - 8 o 6 4
- 23-
TABLE 3
--
Capillary
Spinnerets High-
Diameter Load
(Hoyle - Revs Crimp Tenacity
5 Item mm isle) REV % god _
PA O. 25/o. 25 84~4~ 41 17. 7 2. 8
3B 0.51~0.51 82/42 40 18.3 2.7
The results riven in Table show that inquiry-
in the JAY by a factor of four gives only a slight
increase in high-load crimp.
EXAMPLE 4
_ _
hi example shows the effect on crimp and ten-
amity of varying feed roll speeds (spinning pods from
15 145~6 to 4572 mum, stretch roll speeds from 2743 to 5486
mum and in-line stretch ratios from lo to 1.85. The
highest Hollywood crimp values are obtained at spinning
speeds tweed roll speeds ox 2743 mum and higher and
in-line stretch ratios of 1.2 or higher.
In a first series of runs, yarn are prepared
a described in Example l using the following
conditions:
Spinnerets capillaries (Hi/Lo) my 0.51/0.51
... Melt ratio (Hi/Lo) 50/50
pylon type (Hi/Lo) 66/66
Nylon Ryes (Hi/Lo) 66/42
REV Difference 24
Feed roll speed (mpm)Given on Table PA
Stretch roll speed (mpm)dit~o
In-line stretch (~) ditto
In-l~no relaxation, Hot/Cold Cold
Test result art given in Table PA.
~6~L3
14-54-~064
-24-
TABLE PA
Fused Stretch High
Roll RollIn-lin~ Load
Speed Speed Stretch Crimp tenacity
5 It~mmpm mum OX) Jo god _
AYE 2743 1. 25 5- 3 2.7
AHAB 2743 1.5 3-7 3~4
AWOKE 2743 1.6 3.7 3~5
AUDI 2743 1.85 3-9 3. a
In a second series ox run, yarns ore prepared as
1 0
described in Example 1 Using the follo~rin~ conditions:
Spinnerets cripplers (Hi/Lo) my 0.51/0.51
Melt ratio (Hi/Lo) 50/50
pylon types (Hi/Lo) 66/66
Nylon Revs (Noel) S0/48
Ryes Difference 12
Peed roll speed mum Given in Tails 4B
Stretch roll speed pi ditto
In e stretch (~) ditto
In-line relaxation, Hot/Cold Cold
MU
Text royalty are gin in Table 4B.
TABLE 4B
Feed Stretch High-
toll Roll In-line Load
Spud Speed Stretch Crimp Tenacity
Item mum mum (X) I' god
25 --
BYWAY 2494 2743 1.1 . 3.6 2.1
I 2286 2743 1.2 7.9 2.1
4BC 2110 2743 1.3 10.5 2.2
4BD 1960 2743 1.4 . 11.5 2.8
ABE 1829 2743 1.5 8.9 2.6
4BF 2910 3201 1.1 5. 3 2.1
30 4BG 2667 3201 1.2 12.1 2.3
4B~ 2462 ~201 1.3 14.4 2. 3
4B1 2286 3201 1.4 14.7 2.6
4BJ 2133 3201 1.5 14. 2 2.6
4BK ~325 3658 1.1 5.4 I 2
BLUE 3048 3658 1.2 12- 3 2. 3
IBM 2814 3658 1.3 16.4 2. 3
35 4B11 2613 3658 1.4 15- 3 2~6
4B0 2439 EYE 1.5 15.0 2.8
UP 3741 4115 1.1 6-7 I.
4~Q }429 4115 1.2 1 I 5 2.3
48R 3166 4115 1.3 15^ 3 2~4
4BS 293g 4115 1.4 16.4 2~6
4BT 2743 4115 1.5 15~7 2.7
~LZZ~i~13
14-54-8064
-25-
In a third series of runs yarn are prepared a in
Squire I except the melt ratio is different and the BY
difference between the polymers it much higher. The
following conditions are used:
Spinnerets capillaries (}Lyle) mm 0.51/0.51
Melt ratio (Hi/Lo) 40/60
Nylon type (Hi/Lo) 66/66
Nylon REV' R ( Hi/Lo) 70/42
Revs Difference 28
Feed roll speed (mum) Given in Table 4C
Stretch roll speed (mum) ditto
In-line stretch (~) ditto
In-line relaxation, Hot/Cold Cold
Test results are given in Table 4C.
TABLE 4C
Feed Stretch High-
Roll RollIn-line Lead
Speed Speed Stretch Crimp Tenacity
Item mum mum (I pod
KIWI 3429 4115 1.20 14-9 1.8
4CB 3292 4115 1.25 16.5 1.9
4CC 3166 4115 1.30 19.4 lo
4CD 3048 4115 1.35 19.8 I
ICE 2940 4115 1.40 21.3 2.1
4CF 3809 4572 1.20 15.2 1.9
4CG 3658 4572 1.~5 18.0 Z.0
4CM 3516 4572 1.30 19.2 lo
SUE 3383 4572 1.35 21.8 2.0
4CJ ~264 4572 1.40 22.5 2.1
I 3155 4572 1.45 24.1 2.1
CLUE 3048 4572 1~50 23.4 2.2
In a fourth series of runs yarns Are prepared a
in series 4C using the following conditions:
Spinnerets capillaries (Hi/Lo) mm 0.51/0.51
Melt ratio (Hi/Lo) 50j50
Nylon types (Hotly 6~/66
Nylon REV (Hoyle 63/36
Revs Difference 27
weed roll speed (mum) Sweeney in Table ED
Stretch roll speed (mum) ditto
6~3
1~-54-8064
-26-
In-line stretch (X) ditto
In-line relaxation, Hot/Cold Cold
Test results ore given in Table ED.
TALE ED
Feed Stretch High- Low-
Roll Roll In-line Load Load
Speed Speed Stretch Crimp Crimp Tenacity
Its mum mum (~)_% % god
IDA 4156 45721.1 4~9 34 2.4
4BD 3810 45721.2 12.8 57 2.5
10 4DC 3517 45721.3 18.0 63 2.5
ODD ~265 45721.4 19.2 66 2.7
ED 3048 45721.5 19.7 68 20 7
4DF 2858 45721.6 17.6 67 2-9
4DG 4572 50291.1 3'9 41 2.2
4DH 4191 50291.2 11.7 58 2.5
DOW 3869 50291.~ 17-5 64 2.7
15 4DJ 359~ 50291.4 19.9 67 2.8
4DK 3353 50291.5 19.5 67 2.8
4DL 3144 50291.6 19.4 68 3.0
In a it errs ox runs, yarn are prepared as
in series ED except the melt ratio it different. The
oiling conditions are used:
Spine ret capillaries (Hi/Lo) my 0.41/0.51
Melt ratio (Hi/Lo) 40/60
pylon types (Hi/Lo) 66/66
pylon Revs (Hi/Lo) 72/41
RV'c Difference 31
Fused roll speed (mum) Given in Table YE
Stretch roll speed my ditto
In-line stretch I ditto
In-line relaxation, Hot/Cold Cold
Test results are given in Table YE.
Lo
14-54-8064
-27-
TABLE YE
Feed Stretch High-
Roll RollIn-line Loud
Speed Speed Stretch Crimp tenacity
Item mum (~) % god
S
AYE 3870 4572 1.20 15-3 1.9
DEB 3516 4572 1~30 20.0 2.0
EKE 3388 4572 1.35 22.7 2.2
TED ~266 4572 1.40 22.1 2.2
LEE 3155 4572 1.45 21.4 2.3
OF 3048 4572 1.50 21.2 2.6
10 PEG 2950 4572 1.55 21.9 2.5
EYE 2858 4572 1.60 21.4 2.4
I 3726 5029 1.35 21.5 2.2
EDGY 3594 5029 1.40 22.3 2.4
MEL 3354 5029 1.50 22.3 2.5
REM 3244 5029 1.55 21.8 2.7
EYE 3146 5029 1.60 20.7 2.7
In a ~isth series of runs, yarn are prepared a
in series ED except 8 stretch roll speed of 5486 mum it
used. The conditions used are:
Spinnerets capillaries isle) mm 0.25/0.25
Melt ratio (Hi/Lo) 50/50
Nylon typos (Hoyle) 66/66
Nylon REV (Hi/Lo) 75t41
REV Difference 34
Feed roll pod (mum) Given in Table OF
Stretch roll pod (mum) ditto
In-line stretch (~) ditto
In-llne relaxation ~ot~Cold jot ~8~0~)
Test results are given in Table OF.
TABLE OF
.
Feed Stretch High-
Roll Roll Kline Load
Speed Speed Stretch Crisp Tenacity
Item my pi I) % g d
FOE 3786 5486 1.45 17.6 I
OF 3658 5486 1.50 17.0 I
4~C 3543 5486 1.55 16.1 I
4FD 3429 5486 1.60 15.5 3.4
EYE 3328 5486 1165 15.2 3.6
I: ill
14~54-~064
-28-
EXAMPLE 5
____
This example shows the effect of varying throve in
the 24 to 34 range. Yarns are prepared as in 13xample 1
using the following conditions:
Spinnerets capillaries (Hi/Lo) mm 0. 25/0. 25
Melt ratio (Hi/Lo) 50/50
Nylon types (Hi/Lo) 66/66
Nylon REV (Hoyle Given in table 5
Revs Difference ditto
Feed roll speed (mum) 3048
Stretch roll speed (mum) 4572
In-line stretch (X) 1.5
In-line relaxation, Hot/Cold Cold (6. I
jest results are Ivan in Table 5.
TABLE 5
Hoyle-
Ladled
Ryes Crimp Crimp BUS
Item(Hi/Lo) go
. . _ _ . _ _ . , .
PA 62/38 24 15.160 5-3
I 72/38 34 18.065 5.1
5C 75/46 29 17.165 5.0
ED 54/22 I - 18.0
The results in Table 5 shod that in general
increasing the REV increases high-load crimp.
EXAMPLE G
In this example yarn are prepared a in Example 5
In this instance the REV of the high REV polyamide it
varied while the REV of the Low REV polyamide is held
constant 'rho conditions used are:
Spinnerets capillaries (Hi/Lo) mm 0.51/0.51
Melt ratio they'll) 40/60
Nylon type (Hi/Lo) 66/66
Nylon Revs they'll) Given in Table 6
Revs Difference ditto
I Lo 14-54-80~4
-29-
Feed roll speed (mum) 3155
Stretch roll spend (mum) 4572
In-line stretch (X) 1.45
In-line relaxation, Hot Cod Hot
Test royalty are given in Table 6.
TARE 6
High- Low-
Load Load
Revs Crimp Crimp
Item (Hi/Lo) REV
PA 67/49 18 16.5 65
6B 90/49 41 24.9 72
As in Example 5, the results Shari that hlgh-load
crimp inquiry en with increases in WRY.
EXAMPLE 7
This example show the effect of varying the melt
ratio on Hollywood crimp and low-load crimp. The Aryan
are prepared as in Example 6 urine the following
conditions:
Spinnerets capillaries (Hoyle) mm 0. 23/0. 23
Melt ratio (Hi/Lo) Coven in Table 7
Ilylon types (Hi/Lo) 66/66
Nylon Ryes they'll) 62/39
RV'3 Difference I
Feed roll speed (mum) 2857
Stretch fall speed (mum) 4115
line stretch (X) 1.4
In-line relaxation, Hot Cold Cold
Test results are gin in Table 7.
I 3
14-54-8064
I
TABLE 7
High- Low-
Melt Idea Load
Ratio Crimp Crimp
Item (Hi/Lo)
_
PA 65/35 8.3 54
7B 63/37 9.6 58
7C 60/4010.5 59
ED 58/4212.0 60
YE 55/4513.5 62
OF 53/4714.3 64
7G 50/5015.0 64
OH 50/5015.2 62
I 47/5~16.8 64
7J 45/5517,9 66
OK 42/5818.0 67
AL 40/6018.8 69
The result show that changing the melt ratio has a
significant effect on high-load crimp and relatively
little effect on low-load crimp.
EXAMPLE 8
This example illustrates the effects of steam con-
ditioning the yarn on crimp. Yarn are prepared a in
Example 1 except that the filaments are posed through a
tube (steam conditioning tube) having a diameter of 12.7
I and a length of 1~2.9 an. The tube it placed 132 cm
from the face of the spinnerets Steam it introduced
into the tubs through port toasted near the filament
inlet end of the tube. The following cQnditio~s are
used:
Spinnerets capillaries Thea) mm 0.41/0.51
Melt ratio (Hi/Lo) 50/50
pylon types (Hi/Lo 66/66
Nylon TV ' 9 ( Hi/Lo) 89t44
Revs Difference 45
Feed roll speed pi 2358
Stretch roll speed pun 4572
In e stretch I 1.6
In-line relaxation, Hot/Cold Cold t7.1,~
Test royalty are ivy in Table 8.
:~261~3
14-54-~064
~31-
TABLE 8
High- Lo-
Load Loud
Tube Crop Crimp BUS
Item Fluid % % %
- - _
PA Ambient Air 2 21.3 72 6.4
8B StQam9 136 No 3~3 42 8.5
8C Steam, 153 kN~2 2.0 24 8.8
ED team, 205 Kim 201 27 8.9
Thy negative erf~ots of team oonditlonlng on
hlgh-lo~d orl~p 18 dra~tlcally one in Table 8.
EXAM
This example illustrates the Use I 8Pinn~retQ
constructed in such a Jay that the polymer try
converge a 8 point other thin belch the spinnQret aye.
In one servos of run , two yarns ox different
denier (BAA find AYE) art prepared as in Example 1 except
in this in~tQnoe a apinneret 18 used in hick the two
angled capillaries (polymer Tracy) join it the
splnneret ice rather thin below the sp~nn~r~t aye a
20 shown in Foe I The following conditions are used
Spine ret o~p~llarie~ (Hugely) I 0 owe
welt ratio (Hi/Lo) 50/50
Nylon typo (Hi/Lo) 66/66
Nylon REV I 8 Hello 61/4
REV' B Dlfr~renee 14
Food roll spend (~pJ13 2939
Stretch roll stood pi 4115
In-line tryout (~) 1.4
Olin relaxation, Hot/Cold Cold
Test results spa gin in Table PA.
TABLE PA
i --_
High- Lo-
Load Load
Denier/ Crimp Crop Tenacity
ICKY Fly pod _
. . _ . _
I 20/7 14.5 69 3.0
AYE 40/13 13.9 68 2.8
I 3 14-54 8064
-32-
In another series of runs, two yearn (BYWAY and EBB)
are prepared a above except that in this instance each
filament it formed by combining the polymer stream
above the ~pinneret face and then extruding the combined
streams through a common capillary of the 3plnneret.
Also, the nylon 66' 9 have a REV of 28 ln~tesd ox 14.
The following conditions are used:
Spinnerets capillaries (mm) 0.51
welt ratio (Hi/Lo) 50/50
Nylon types (Hi/Lo) 66/66
Nylon RV'9 (Hi/Lo) 69/41
Revs Difference 28
Feed roll speed pi 3048
Stretch roll speed (mum) 4572
In-line stretch (X) 1.5
In-line relaxation, Hot/Cold Cold
Test results are Boone in Table go.
TAB
Nigh- No-
Load Load
Denier/Crimp Crimp Tenacity
Item Fits. % pod
BYWAY 22/7 22.3 76 2.7
grub 40/1~ 15.6 73 2.9
, the results given in Table PA and 9B show that
spinnerets constructions other toad those where the polo-
~r9 Sonora below the ~pinneret may srfecti~aly be
used in practicing the present invention.
A comparison of the crimp values in Table I with
those in Table go show that in this instance increasing
the REV result in an inquiry in crisp values.
EMPLOY 10
____
his esa~ple illustrates the preparation of years in
acco~dsnce with the invention wherein the high viscosity
and/or lo vacuity polyamide it a polyamide other than
nylon 66.
In one series of runs, yarns are Dada from nylon 610
and nylon 66 usln~ the felon condition:
~LX;26~L13 14-54-8064
I
Spinnerets capillaries they'll) mm 0. 25/0. 25
Melt ratio (Hi/Lo) 50/50
Nylon types (Hoyle 610/66
Nylon Revs (Hi/Lo) Given in Table 10
Revs Difference ditto
Feed roll spied (mum) 2858
Stretch roll speed (mum) 4572
In-line stretch (X) 1.6
In-line relaxation, HottCold Cold
Text results are even in Table loan
TABLE AYE
High- Low-
Load Load
Revs Crimp Crimp BUS
Item (Hi/Lo)~RV d go
-- _ _
loan 63/4~ 15 17.4 64 7.2
lob 56/48 8 9.8 5 I 3
The results in Table lo show that acceptable
crimp values are obtained using nylon 610 in combination
loath nylon 66 (Item loan). The results also show the
importance of the TV. vote that in run lob the REV is
not of a sufficient magnitude to obtain a significant
high-load value.
In another series of runs, yarns are made from
Z5 ~ylsn 66 and nylon 6 urn the following conditions:
Spinnerets capillaries (Hi/Lo) mm 0.51/0.51
Melt ratio ~HitLo~&iven in Table lob
Nylon type (Hoyle
Nylon Revs (Hi/Lo)Given in Table lob
ROY Difference ditto
Feed roll speed (mpm)ditto
Stretch roll speed (mum) 4572
In-line stretch Given in Table lob
In-line relaxation, Hot/Co1d Cold
35 Text results are given in Table lob
fL7~26~L~3L3
14-54 806
-34-
TABLE lob
Feed High- Low-
Roll In-line Loud Load
Revs MeltSpeedStretch Crimp Crimp
Item Hi/Lo~RV Ratio mum X Jo
_
lob 67/38 29 40/60 3048 1.5 13-9 68
lob 67/~8 29 50/50 3048 1.5 12.9 I
lob 78/36 42 50/50 2858 1.6 16.6 63
In another series of runs, yarns are made from nylon
6 using the following conditions:
Spinnerets capillariestHi/Lo) mm 0.51/0.51
Melt ratio (Hi/Lo) Given in Table lo
Nylon types (Hi/Lo) 6/6
Nylon REV ' 3 ( Hi/Lo) 57/~8
Revs Difference 19
Feed roll speed (mum) 3048
Stretch roll speed (mum) 4572
Online stretch (X) 1.5
In-line relaxation, Hot/Cold Cold
Text result are given in Table lock
TABLE lo
High- Lo w-
Loud Load
Melt Crimp Crimp
Item Ratio Jo
lock 50/50 14.6 62
lock 40/60 16-9 ' 64
In another series of runs, yarns are Invade from
nylon 66 and a nylon 66-61~ (50:50) copolymer using the
following conditions:
Sp~nneret capillaries (Hi/Lo) mm 0. 51/0. 51
Melt ratio (Hi/Lo) Given in Table lo
Nylon types (Hi/Lo) 66/66-612 (50: 50)
3 14-54-~064
Nylon Revs (Hi/Lo) 78/36
Revs Difference 42
Feed roll speed (mum) 2858
Stretch roll speed (mum) 4572
In-line stretch (X) 1.6
In-line relaxation, Hot/Cold Cold
Test results are even in Table lode
TABLE 10D
High- Low-
Load Load
Melt Crimp Crimp BUS
Item Ratio TV
.
lode 50/50 12.8 59 10.6
lode 40~60 15-3 6210.3
In another series of runs, yarns are prepared
under the same condition employed in Series lo except
in thy instance the copolymer is the high I polymer
and the homopolymer is the low REV polymer. The
felon conditions are used:
Spinnerets capillaries (Howe) mm Q.25/0.25
welt ratio (Hoyle
Nylon types (Hoyle (50:50)/66
Nylon Revs (Hi/Lo)Given in Table lye
Revs Difference ditto
Feed roll pod (mpm)2858
Stretch roll speed (mum) 4572
In-line stretch (X) 1.6
In-line relaxation Hot/Cold Cold
Text results are given in Table lye.
TALE EYE
Howe Low-
Load Load
Ryes Crimp Crimp BWSCRIMP~
Item Halo WE
lea 72/46 2611.7 54 20.4Q.57
Lowe 82~49 331~.5 55 18.20.74
lZ261~3
14-54-8064
-36-
The result shown in Table lye show the adverse
effects on BUS value when the copolyamide I used a
the high REV component.
In another series of runs, yarns are prepared
under the some conditions employed in Series lye except
in this instance the polyamides are:
nylon types they'll) 6-66(15:853/66
nylon Revs (Hi/Lo) Given in Table lo
Test results are given in Table loft
TABLE OF
Hick- Lo-
Load Load
Revs Crimp Crimp BUS
Item (Hi/Lo) % % %
15 loft 93~48 4518.9 64 7.7
loft G8/48 201~.5 50 8.1
EXAMPLE 11
In this example various aspen conjugate yarn
were prepared at lo spinning speeds using the equipment
described in Example 1 sod conditions given in Tails
lea. The aspen yarn are lagged at ambient conditions
end then subsequently stretched it a separate operation
been stretch rolls under conditions riven in Tails
lob. Text results art Allah given in Table lob.
TILE lit
Feed Stretch
Roll Roll
Polymers TV' 9 Speed Speed
Yarn (Hoyle) isle? mum mum Stretch
A 66-610*/66 65/55 10 640 640 zone
30 B 66/66 . 79/55 24 640 640 None
C 66/66-6*~ 45/~6 9 474 474 Move
50:50
15:85
2~1~3
14-54-8064
-37-
TABLE lob
High-
Load
StretchStretgh Crimp BUS
Yarn Tempt . C % _ %
5 A 4 112 0.8 15-~
A . 4 55 6.6 30-5
A 4 Ambient* 6.4 , ~0.9
B 4 112 0.8 11.1
4 55 0.8 12.2
B 4 Ambient* 0.8 12.2
C 2.5 Ambient Ø8 13.0
10 C 4.0 Ambient 0.9 12.9
O'er n cold pin
The result in Table 11~ show that when the
yarn it spun at lo speeds and then stretched in a
subsequent operation, the yarn does not have significant
high-load crimp.
EXAMPLE 12
This example demonstrate thy effect on Hollywood
crimp of using an aqueous finish (A) versus an
an hydrous finish (Ashy) in instances where the
I stretching of the filaments it an incline stretch Years
a post stretch in a separate operation.
A series of yarns are prepared a in Example 1
using-the following conditions: .
Spinnerets capillaries (Helm 0.25/0.25
Melt ratio Haulage
yule type (Hoyle
Nylon Ye (HiJLo3GiYen in table 12
Revs Difference ditto
Feed Roll speed mum ditto
Stretch roll speed (~pmj ditto
In-line stretch ditto
In-line relaxation, Hot Cold Cold
Text results are inn in Table 12.
~2216~L~3
14-54-8064
-38-
TABLE 12
Feed Sir. High- Ion
REV' B Roll toll Inn Post Load Load
Fin. (Hi/ Speed Speed Stretch Stretch Crimp Crimp
Item Type Lo) mum mum I (X)
AYE Ashy 69/49 2858 45721.6 - 17.2 64
12B A 69/49 2858 4572 1.6 - 19.2 66
12C Ashy 69/49 2858 28581.0 1.6* 9.4 50
12D A 69/49 2858 2858 1.01.6* I 27
EYE Ashy 77/47 2858 45721.6 - 16.7 66
12F A 77/47 2858 4572 1.6 - 16.2 67
12G Ashy 77/47 2858 28581.0 1.6** 11.6 60
12H A 77/47 2858 2858 1.01.6** 2.5 30
12I Ashy 77/47 2858 28581.0 1.6**~ 9-0 45
12J A 77/47 2858 2858 1.01.6*** 2.3 21
*As-spun yarns are collected and sealed in small
plastic bugs until post stretched 3-1/4 ho
later. , -
**Same as * except post stretch I hr. after
collection of as-spun yarns instead of ~-1/4
hour.
***Same as ** except post stretched 24 hours
after collection.
Post stretching is done between two pairs of
rotating rolls, a first pair rotating at a
peripheral speed of 2858 mum and a second pair
rotating at a peripheral speed of 4572 mum.
The result in Table 12 show that considerable
high-load crimp it lost if the yarn it lagged before
stretching. Compare items AYE and B to 12C and D and
12~ and F to 12G through J. The results alto show that
moisture has an adverse effect on the power crimp of
lagged yarn (compare 12C to 12D~ and worsens with time
(compare 12D to 12H to 12J).
In the foregoing examples the importance ox
selecting and correlating processing conditions and of
selecting polymers with respect to melt viscosities,
malt viscosity differences, polymer type, etc. on high-
load crimp glues it demonstrated.
