Process for forming synthetic fiber and fiber, yarns and carpets produced thereby

Abstract

Processes for forming synthetic fibers from polymer melts containing a first fiber forming polymer, a spin assist additive, and optionally a pigment additive are provided. Also provided are synthetic fibers of a first fiber forming polymer, a spin assist additive, and optionally a pigment additive, as well as articles of manufacture such as yarns, carpets and fabrics made up of these synthetic fibers.

1 . A process for forming a synthetic fiber, said process comprising the steps of:
 (a) producing a polymer melt comprising a first fiber forming polymer and a spin assist additive, wherein the spin assist additive is present in a range from about 0.5 to about 5 percent by weight; and   (b) forming a synthetic fiber from the polymer melt.   
     
     
         2 . The process of  claim 1 , wherein the spin assist additive is a polyamide comprising at least one aliphatic diamine and at least two distinct aromatic dicarboxylic acids, and copolymers and blends thereof. 
     
     
         3 . The process of  claim 2 , wherein the at least one aliphatic diamine is selected from a group consisting of 2-methyl-1,5-pentamethylene diamine, hexamethylene diamine, 2-methyl hexamethylene diamine, 3-methyl hexamethylene diamine, 2,5-dimethyl hexamethylene diamine, 2,2-dimethylpentamethylene diamine, 5-methylnonane diamine, dodecamethylene diamine, 2,2,4- and 2,4,4-trimethyl hexamethylene diamine, 2,2,7,7-tetramethyl octamethylene diamine and diaminodicyclohexyl methane. 
     
     
         4 . The process of  claim 2 , wherein the aromatic dicarboxylic acids are selected from a group consisting of terephthalic acid, isophthalic acid and naphthalene dicarboxylic acid. 
     
     
         5 . The process of  claim 2 , wherein the spin assist additive is selected from the group consisting of nylon DT/DI, nylon DT/6I, nylon DI/6T and nylon 6T/6I, and copolymers and blends thereof. 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . The process of  claim 1 , wherein the first fiber forming polymer is selected from the group consisting of a polyamide, polyester, polyolefin and combinations thereof. 
     
     
         9 . The process of  claim 8 , wherein the first fiber forming polymer is polyethylene terephthalate or nylon-6,6. 
     
     
         10 . (canceled) 
     
     
         11 . The process of  claim 1  further comprising addition of a pigment additive to the polymer melt, wherein the pigment additive is an organic or inorganic pigment and the pigment is present in a range from about 0.01 to about 5 percent by weight. 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . The process of  claim 1 , wherein forming a synthetic fiber comprises extruding said polymer melt through a spinneret to form one or a plurality of filaments, and drawing the one or a plurality of filaments to form a synthetic fiber. 
     
     
         15 . The process of  claim 14 , wherein the fiber can be drawn at a draw ratio of 2.65 or higher. 
     
     
         16 . The process of  claim 15 , wherein the number of broken filaments observed in a two minute interval while drawing the one or a plurality of filaments to form a synthetic fiber is less than 10. 
     
     
         17 . A synthetic fiber comprising:
 (a) a first fiber forming polymer; and   (b) a spin assist additive present in the synthetic fiber at a range from about 0.5 to about 5 percent by weight, wherein the spin assist additive is a polyamide comprising at least one aliphatic diamine and at least two distinct aromatic dicarboxylic acids, and copolymers and blends thereof.   
     
     
         18 . (canceled) 
     
     
         19 . The synthetic fiber of  claim 17 , wherein the at least one aliphatic diamine is selected from a group consisting of 2-methyl-1,5-pentamethylene diamine, hexamethylene diamine, 2-methyl hexamethylene diamine, 3-methyl hexamethylene diamine, 2,5-dimethyl hexamethylene diamine, 2,2-dimethylpentamethylene diamine, 5-methylnonane diamine, dodecamethylene diamine, 2,2,4- and 2,4,4-trimethyl hexamethylene diamine, 2,2,7,7-tetramethyl octamethylene diamine and diaminodicyclohexyl methane. 
     
     
         20 . The synthetic fiber of  claim 17 , wherein the aromatic dicarboxylic acids is selected from a group consisting of terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid and 5-sulfoisophthalic acid. 
     
     
         21 . The synthetic fiber of  claim 17 , wherein the spin assist additive is selected from the group consisting of DT/DI, DT/6I, DI/6T and 6T/6I, and copolymers and blends thereof. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . The synthetic fiber of  claim 21 , wherein the spin assist additive does not substantially copolymerize with the first fiber forming polymer. 
     
     
         25 . The synthetic fiber of  claim 17 , wherein the first fiber forming polymer is selected from the group consisting of a polyamide, polyester, polyolefin and combinations thereof. 
     
     
         26 . The synthetic fiber of  claim 25 , wherein the first fiber forming polymer is selected from polyethylene terephthalate and nylon-6,6. 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . An article of manufacture comprising the synthetic fiber of  claim 26 . 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . (canceled)