US2005147784A1PendingUtilityA1

Process for preparing poly(trimethylene terephthalate) fiber

39
Priority: Jan 6, 2004Filed: Jan 6, 2004Published: Jul 7, 2005
Est. expiryJan 6, 2024(expired)· nominal 20-yr term from priority
Inventors:Jing-Chung ChangRichard Lee Dommel
D02G 1/02D01F 6/62D02G 1/20D02J 1/08D10B 2503/04D10B 2331/04
39
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

The present invention relates to a process for spinning poly(trimethylene terephthalate) filaments/yarn. The poly(trimethylene terephthalate) has a number average molecular weight of at least about 26500 and a melt viscosity of at least about 350 Pascals at 250° C. and 48.65 per second shear rate. It is spun and the filaments are converged into yarn. The filaments have a denier greater than 1 and the yarn has a denier greater than 210.

Claims

exact text as granted — not AI-modified
1 . A process comprising: 
 (a) spinning molten poly(trimethylene terephthalate)polymer having a number average molecular weight of at least about 26500 and a melt viscosity of at least about 350 Pascals at 250° C. and 48.65 per second shear rate;    (b) converging the filaments into yarn;    (c) cooling the filaments; and    drawing the filaments at a speed of greater than 3000 meters per minute to produce filaments having a filament denier greater than 1 and yarn having a yarn denier greater than 210.    
   
   
       2 . The process of  claim 1 , wherein the number average molecular weight is from about 26500 to about 50000.  
   
   
       3 . The process of  claim 1 , wherein the number average molecular weight is from about 27500 to about 45000.  
   
   
       4 . The process of  claim 1 , wherein the number average molecular weight is from about 29000 to about 40000.  
   
   
       5 . The process of  claim 1 , wherein the melt viscosity is from about 350 to about 1000 Pascals at 250° C. and 48.65 per second shear rate.  
   
   
       6 . The process of  claim 1 , wherein the melt viscosity is from about 400 to about 900 Pascals at 250° C. and 48.65 per second shear rate.  
   
   
       7 . The process of  claim 1 , wherein the melt viscosity is from about 450 to about 800 Pascals at 250° C. and 48.65 per second shear rate.  
   
   
       8 . The process of  claim 1 , wherein the melt viscosity is from about 500 to about 700 Pascals at 250° C. and 48.65 per second shear rate.  
   
   
       9 . The process of  claim 1 , wherein the filament denier is at least 3.  
   
   
       10 . The process of  claim 1 , wherein the filament denier is at least 10.  
   
   
       11 . The process of  claim 1 , wherein the filament denier is at least 15.  
   
   
       12 . The process of  claim 1 , wherein the yarn denier is at least 250.  
   
   
       13 . The process of  claim 1 , wherein the yarn denier is at least 500.  
   
   
       14 . The process of  claim 1 , wherein the yarn denier is at least 1000.  
   
   
       15 . The process of  claim 1 , wherein the filaments are drawn at a speed of greater than 3500 meters per minute.  
   
   
       16 . The process of  claim 1 , wherein the filaments are drawn at a speed of greater than 4000 meters per minute.  
   
   
       17 . The process of  claim 1 , wherein the filaments are drawn at a speed of greater than 5000 meters per minute.  
   
   
       18 . The process of  claim 1 , wherein the filaments are drawn at a speed of at least 5100 meters per minute.  
   
   
       19 . The process of  claim 1 , wherein the filaments are drawn at a speed of at least 5500 meters per minute.  
   
   
       20 . The process of  claim 1 , further comprising coating the filaments with a spin finish and optionally preintermingling the filaments.  
   
   
       21 . The process of  claim 1 , further comprising bulking the drawn filaments.  
   
   
       22 . The process of  claim 21 , further comprising entangling the filaments.  
   
   
       23 . The process of  claim 21 , wherein the drawn filaments are bulked to form 3-dimensional curvilinear crimp therein.  
   
   
       24 . The process of  claim 23 , wherein the bulking comprises blowing and deforming the filaments in a hot-fluid jet bulking unit.  
   
   
       25 . The process of  claim 1 , wherein the filaments are drawn at a draw ratio of about 1.1 to about 4.0.  
   
   
       26 . The process of  claim 25 , wherein the draw ratio is about 1.2 to about 3.0.  
   
   
       27 . The process of  claim 25 , wherein the draw ratio is about 1.4 to about 2.2.  
   
   
       28 . The process of  claim 1 , wherein the poly(trimethylene terephthalate) has an intrinsic viscosity of about 0.95 to about 1.10.  
   
   
       29 . The process of  claim 28 , wherein the intrinsic viscosity is about 0.98 to about 1.04.  
   
   
       30 . The process of  claim 28 , wherein the intrinsic viscosity is about 1.00 to about 1.02.  
   
   
       31 . A process comprising: 
 (a) extruding molten poly(trimethylene terephthalate)polymer having an intrinsic viscosity in the range of about 0.95 to about 1.10, a water content of less than about 100 ppm, a number average molecular weight of about 26500 to about 50000 and a melt viscosity of about 350 to about 1000 Pascals at 250° C. and 48.65 per second shear rate through a spinneret to form filaments;    (b) converging the filaments into yarn;    (c) cooling the extruded filaments;    (d) coating the cooled filaments with a spin finish; optionally pre-intermingling the filaments;    (e) optionally heating the coated filaments to a temperature greater than the glass transition temperature of the polymer filaments, but less than about 200° C.;    (f) drawing the optionally heated filaments at a speed of greater than 3000 meters per minute to produce filaments having a denier greater than 1 and yarn having a yarn denier greater than 210;    (g) bulking the drawn filaments such that the filaments are blown and deformed in three dimensions with a hot bulking fluid to form bulked continuous filaments having random 3-dimensional curvilinear crimp;    (h) cooling the bulked continuous filaments to a temperature less than the glass transition temperature of the polymer filaments; and    (i) entangling the bulked continuous filaments.    
   
   
       32 . The process of  claim 31 , wherein the water content is less than about 50 ppm.  
   
   
       33 . The process of  claim 31 , wherein the water content is less than about 40 ppm.  
   
   
       34 . The process of  claim 31 , wherein the bulked continuous filaments of (g) are entangled before the cooling in (h).  
   
   
       35 . The process of  claim 31 , wherein the filaments are drawn at a speed of at least 3000 meters per minute.  
   
   
       36 . The process of  claim 31 , wherein the filaments are drawn at a speed of greater than about 3500 meters per minute.  
   
   
       37 . The process of  claim 31 , wherein the filaments are drawn at a speed of at least about 4000 meters per minute.  
   
   
       38 . The process of  claim 31 , wherein the filaments are drawn at a speed of at least 5000 meters per minute.  
   
   
       39 . The process of  claim 31 , wherein the filaments are drawn at a speed of at least 5100 meters per minute.  
   
   
       40 . The process of  claim 31 , wherein the filaments are drawn at a speed of at least 5500 meters per minute.  
   
   
       41 . The process of  claim 31 , further comprising ply-twisting and heat setting the filaments into yarn.  
   
   
       42 . Carpet made from the ply-twisted, heat-set poly(trimethylene terephthalate) yarn of  claim 41.

Join the waitlist — get patent alerts

Track US2005147784A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.