Multicomponent latent-crimping staple fiber and method therefor

Abstract

A multicomponent latent-crimping staple fiber, or a non-mechanically-crimped staple fiber contains a first component and a second component which each have their own differing lengths and a shrinkage differential therebetween and eccentric cross-sectional centers of mass. The staple fibers herein have a tenacity after crimping of at least 90% as compared to the tenacity prior to crimping. Processes for making such a fiber are also described.

1 . A multicomponent latent-crimping staple fiber comprising:
 A. a first component comprising:
 i. a first length; and 
 ii. a first cross-sectional center of mass; and 
   B. a second component comprising:
 i. a second length; and 
 ii. a second cross-sectional center of mass, 
   wherein the shrinkage differential between the first length and the second length is at least 0.01%, and wherein the first cross-sectional center of mass and the second cross-sectional center of mass are eccentric, wherein the first component and the second component are extruded and combined to form a multicomponent latent-crimping fiber, wherein the multicomponent latent-crimping fiber is cut to form a multicomponent latent-crimping staple fiber, wherein the multicomponent latent-crimping staple fiber is crimped either before, during, or after cutting, and wherein the multicomponent latent-crimping staple fiber has a tenacity of at least about 90% as compared to the tenacity of the multicomponent latent-crimping fiber prior to crimping.   
     
     
         2 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the first component comprises a polymer selected from the group consisting of a polyamide, a sulfur-containing polymer, an aromatic polyester, an aliphatic polyester, a polyolefin, and a combination thereof. 
     
     
         3 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the second component comprises a polymer selected from the group consisting of a polyamide, a sulfur-containing polymer, an aromatic polyester, an aliphatic polyester, a polyolefin, and a combination thereof. 
     
     
         4 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the multicomponent latent-crimping staple fiber is selected from a heat-crimped fiber, a humidity-crimped fiber, a water-crimped fiber, a light-crimped fiber, and a combination thereof. 
     
     
         5 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the multicomponent latent-crimping fiber is extruded and drawn to optimize tenacity 
     
     
         6 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the tenacity is the tenacity at break. 
     
     
         7 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the tenacity is the tenacity at 7% elongation. 
     
     
         8 . (canceled) 
     
     
         9 . The multicomponent latent-crimping staple fiber according to  claim 1 , wherein the first component comprises nylon, wherein the second component comprises nylon, wherein the tenacity at break prior to crimping is at least 5.5 g/denier, wherein the tenacity at 7% elongation prior to crimping is at least 1.3 g/denier, wherein the tenacity at break after crimping is at least 90% of the tenacity at break prior to crimping, and wherein the tenacity at 7% elongation after crimping is at least 90% of the tenacity at 7% elongation prior to crimping. 
     
     
         10 . A fabric comprising the multicomponent latent-crimping staple fiber according to  claim 1 . 
     
     
         11 .- 14 . (canceled) 
     
     
         15 . A non-mechanically-crimped staple fiber comprising:
 A. a first component comprising:
 i. a first length; and 
 ii. a first cross-sectional center of mass; and 
   B. a second component comprising:
 i. a second length; and 
 ii. a second cross-sectional center of mass, 
   wherein the shrinkage differential between the first length and the second length is at least 0.01%, and wherein the first cross-sectional center of mass and the second cross-sectional center of mass are eccentric, wherein the first component and the second component are extruded to form a non-mechanically-crimped fiber, wherein the non-mechanically-crimped fiber is cut to form a non-mechanically-crimped staple fiber, wherein the non-mechanically-crimped fiber is crimped either before, during, or after cutting, and wherein the non-mechanically-crimped staple fiber has a tenacity of at least about 90% as compared to the tenacity of the non-mechanically-crimped fiber prior to crimping.   
     
     
         16 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the first component comprises a polymer selected from the group consisting of a polyamide, a sulfur-containing polymer, an aromatic polyester, an aliphatic polyester, a polyolefin, and a combination thereof. 
     
     
         17 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the second component comprises a polymer selected from the group consisting of a polyamide, a sulfur-containing polymer, an aromatic polyester, an aliphatic polyester, a polyolefin, and a combination thereof. 
     
     
         18 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the multicomponent latent-crimping staple fiber is selected from a heat-crimped fiber, a humidity-crimped fiber, a water-crimped fiber, a light-crimped fiber, and a combination thereof. 
     
     
         19 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the multicomponent latent-crimping fiber is extruded and drawn to optimize tenacity 
     
     
         20 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the tenacity is the tenacity at break. 
     
     
         21 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the tenacity is the tenacity at 7% elongation. 
     
     
         22 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the first component is nylon 6, 6, with a relative viscosity of from about 30 to about 60, wherein the second component is nylon 6, 6, with a relative viscosity of from about 50 to about 130, and wherein the relative viscosity of the second component is at least 20 higher than the relative viscosity of the first component. 
     
     
         23 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the tenacity at 7% elongation is at least 1.3 g/denier prior to non-mechanically crimping, and wherein the tenacity at 7% elongation after non-mechanically-crimping is at least 70% of the tenacity at 7% elongation prior to non-mechanically crimping. 
     
     
         24 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the tenacity at break is at least 5.5 prior to non-mechanically crimping, and wherein the tenacity at break after non-mechanically-crimping is at least 70% of the tenacity at break prior to non-mechanically crimping. 
     
     
         25 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the first component, the second component, or both the first component and the second component comprises a polyphenylene sulfide. 
     
     
         26 . The non-mechanically-crimped staple fiber according to  claim 15 , wherein the first component comprises nylon, wherein the second component comprises nylon, wherein the tenacity at break prior to crimping is at least 5.5 g/denier, wherein the tenacity at 7% elongation prior to crimping is at least 1.3 g/denier, wherein the tenacity at break after crimping is at least 90% of the tenacity at break prior to crimping, and wherein the tenacity at 7% elongation after crimping is at least 90% of the tenacity at 7% elongation prior to crimping. 
     
     
         27 . A fabric comprising the non-mechanically-crimped staple fiber according to  claim 15 . 
     
     
         28 . A garment comprising the non-mechanically-crimped staple fiber according to  claim 15 .