Process of making textured multicomponent fibers

Abstract

A process for texturing a multicomponent fiber having a shaped cross section is provided. The process comprises: (A) providing a multicomponent fiber having a shaped cross section and at least one water dispersible polymer; and a plurality of domains comprising one or more water non-dispersible polymers, wherein said domains are substantially isolated from each other by said water dispersible polymer intervening between said domains; and (B) passing the multicomponent fiber through a first zone comprising a first heating device and a twisting unit, wherein the first heating device has a heating temperature that is at least 10% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions.

What is claimed is: 
     
         1 . A process for texturing a multicomponent fiber having a shaped cross section, the steps comprising:
 (A) providing a multicomponent fiber having a shaped cross section and at least one water dispersible polymer; and a plurality of domains comprising one or more water non-dispersible polymers, wherein said domains are substantially isolated from each other by said water dispersible polymer intervening between said domains; and   (B) passing the multicomponent fiber through a first zone comprising a first heating device and a twisting unit, wherein the first heating device has a heating temperature that is at least 10% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions.   
     
     
         2 . The process of  claim 1 , wherein the first zone comprises a cooling zone, and the step of passing the multicomponent fiber through a first zone further comprises providing a twist to the multicomponent fiber and cooling the multicomponent fiber. 
     
     
         3 . The process of  claim 1 , further comprising a step (C) passing the fiber through a second zone, wherein the second zone comprises a second heating device. 
     
     
         4 . The process of  claim 3 , wherein the second heating device comprises at least one godet roller. 
     
     
         5 . The process of  claim 3 , wherein the heating temperature of the second heating device is at least 10% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions. 
     
     
         6 . The process of  claim 1 , further comprising providing at least one additional fiber different from the multicomponent fiber having a shaped cross section and at least one water dispersible polymer, and texturing the additional fiber with the multicomponent fiber having a shaped cross section and at least one water dispersible polymer to form a textured yarn comprising at least two different fibers; optionally, the additional fiber is a multicomponent fiber. 
     
     
         7 . The process of  claim 1 , wherein the heating temperature of the first heating device is at least 15% less than the temperature used fora fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions. 
     
     
         8 . A process for texturing a multicomponent fiber having a shaped cross section, the steps comprising:
 (A) providing a multicomponent fiber having a shaped cross section and at least one water dispersible polymer; and a plurality of domains comprising one or more water non-dispersible polymers, wherein said domains are substantially isolated from each other by said water dispersible polymer intervening between said domains;   (B) passing the multicomponent fiber through a first zone comprising a heating device, a twisting unit and a cooling zone, wherein the step of passing the multicomponent fiber through a first zone comprises heating the multicomponent fiber, providing a twist to the multicomponent fiber and cooling the multicomponent fiber, and wherein the first heating device has a heating temperature that is at least 10% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions; and   (C) optionally, passing the fiber through a second zone, wherein the second zone comprises a second heating device.   
     
     
         9 . The process of  claim 8 , wherein the second heating device comprises at least one godet roller. 
     
     
         10 . The process of  claim 8 , further comprising providing at least one additional fiber different from the multicomponent fiber having a shaped cross section and at least one water dispersible polymer, and texturing the additional fiber with the multicomponent fiber having a shaped cross section and at least one water dispersible polymer to form a textured yarn comprising at least two different fibers; optionally, the additional fiber is a multicomponent fiber. 
     
     
         11 . The process of  claim 8 , wherein the heating temperature of the first heating device is at least 15% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions. 
     
     
         12 . A process for texturing a fiber, the steps comprising:
 (A) providing a first fiber, wherein the first fiber is a multicomponent fiber having a shaped cross section and at least one water dispersible polymer; and a plurality of domains comprising one or more water non-dispersible polymers, wherein said domains are substantially isolated from each other by said water dispersible polymer intervening between said domains;   (B) providing a second fiber;   (C) passing the first fiber through a first processing zone, wherein the first processing zone comprises a heating device and a twisting zone, wherein the first fiber is heated, wherein the heating temperature of the first heating device is at least 10% less than the temperature used for a fiber without the water dispersible component having the same water non-dispersible polymer, same number of total filaments in the fiber, and the same total denier for a given type of equipment and process conditions, wherein the twisting zone comprises at least one friction disk;   (D) passing the second fiber through a second processing zone, wherein the second processing zone comprises a heating device and a twisting zone wherein the second fiber is heated; and   (E) combining the first fiber and the second fiber to make a yarn comprising the multicomponent fiber having a shaped cross section and at least one water dispersible polymer and the second fiber.   
     
     
         13 . The process of  claim 12 , wherein the second fiber comprises a multicomponent fiber having a shaped cross section and at least one water dispersible polymer; and a plurality of domains comprising one or more water non-dispersible polymers, wherein said domains are substantially isolated from each other by said water dispersible polymer intervening between said domains. 
     
     
         14 . The process of  claim 12 , wherein the second fiber is selected from the group consisting of cotton, linen, silk, sisal/grass, leather, acetate, acrylic, modacrylic, polylactide, saran, cellulosic fiber pulp, inorganic fibers, polyester fibers, nylon fibers, polyolefin fibers, rayon fibers, lyocell fibers, cellulose ester fibers, post-consumer recycled fibers, elastomeric fibers and combinations thereof. 
     
     
         15 . The process of  claim 12 , wherein the first processing zone further comprises a cooling zone, and the step of passing the multicomponent fiber through the first processing zone further comprises cooling the multicomponent fiber. 
     
     
         16 . The process of  claim 12 , wherein the second processing zone further comprises a cooling zone, and the step of passing the multicomponent fiber through the second processing zone further comprises cooling the multicomponent fiber. 
     
     
         17 . The process of  claim 1 , further comprising a third fiber.