Poly(trimethylene arylate) fibers, process for preparing, and fabric prepared therefrom

Abstract

A fine denier poly(trimethylene arylate) spun drawn fiber is characterized by high denier uniformity. A process for preparing uniform fine denier yarns at spinning speeds of 4000 to 6000 m/min is further disclosed. The poly(trimethylene arylate) fiber hereof comprises 0.1 to 3% by weight of polystyrene. Fabrics prepared therefrom are also disclosed.

1 . A process comprising extruding a polymer melt comprising 0.1 to 3% by weight, based on the total weight of polymer, of polystyrene dispersed in poly(trimethylene arylate), through an orifice forming a continuous filamentary extrudate, quenching the extrudate to solidify it into a continuous filament, wrapping the continuous filament around a first driven roll heated to a temperature in the range of 60 to 100° C. and rotating at a first rotational speed, followed by wrapping the filament around a second driven roll heated to a temperature in the range of 100 to 130° C. and rotating at a second rotational speed wherein the ratio of the first rotational speed to the second rotational speed lies in the range of 1.75 to 3; and, thereby forming a spun drawn filament having a denier of ≦3, a denier coefficient of variation of ≦3%, and a birefringence of ≦0.055. 
     
     
         2 . The process of  claim 1  wherein the poly(trimethylene arylate) is poly(trimethylene terephthalate). 
     
     
         3 . The process of  claim 1  wherein the polymer melt consists essentially of 0.5 to 3% by weight of polystyrene dispersed in poly(trimethylene arylate). 
     
     
         4 . The process of  claim 2  wherein the polymer melt consists essentially 0.5 to 3% by weight of polystyrene dispersed in poly(trimethylene terephthalate). 
     
     
         5 . The process of  claim 2  wherein the polymer melt comprises 0.5 to 2% by weight of polystyrene dispersed in poly(trimethylene terephthalate). 
     
     
         6 . The process of  claim 1  wherein the first driven roll is heated to a temperature in the range of 70 to 100° C. 
     
     
         7 . The process of  claim 1  further comprising wrapping the filament around a third driven roll rotating at a third rotational speed, and wherein the ratio of the third rotational speed to the second rotational speed is <1. 
     
     
         8 . The process of  claim 1  further comprising accumulating the filament at a rate of at least 4,000 m/min.