Fibers including an alkylene oxide-containing non ionic surfactant, articles, and methods

Abstract

A fiber comprising: a base polymer comprising an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the base polymer; wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25° C. and an HLB of greater than 10. An article comprising a plurality of said fibers, wherein a dye is present in a greater amount in a first portion of the fibers than in other portions of the fibers of the article.

1 . A fiber comprising:
 a base polymer comprising an aromatic polyester or nylon-6; and   an alkylene oxide-containing nonionic surfactant mixed within the base polymer;   wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25° C. and an HLB of greater than 10.   
     
     
         2 . The fiber of  claim 1  wherein the alkylene oxide-containing nonionic surfactant has a melting point of at least 30° C. 
     
     
         3 . The fiber of  claim 1  wherein the alkylene oxide-containing nonionic surfactant has an HLB of 11 to 20. 
     
     
         4 . The fiber of  claim 1 , wherein the alkylene oxide-containing nonionic surfactant comprises an ethylene oxide-containing nonionic surfactant, an ethylene oxide/propylene oxide-containing nonionic surfactant, or a combination thereof. 
     
     
         5 . The fiber of  claim 1 , comprising 0.5 wt-% to 5.0 wt-% of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber. 
     
     
         6 . The fiber of  claim 1 , further comprising talc. 
     
     
         7 . The fiber of  claim 6  comprising 0.5 wt-% to 3.0 wt-% talc, based on the total weight of the fiber. 
     
     
         8 . The fiber of  claim 1 , wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test. 
     
     
         9 . The fiber  claim 8  wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test to a distance of at least 5 cm. 
     
     
         10 . The fiber of  claim 1 , wherein a meltblown web of a plurality of the fibers demonstrates absorption of a water drop within 5 minutes according to the Water Drop Test. 
     
     
         11 . The fiber of  claim 1 , having a median fiber diameter or an effective fiber diameter of 5 to 125 microns. 
     
     
         12 . The fiber of  claim 1 , which is a continuous or staple fiber. 
     
     
         13 . The fiber of  claim 1 , wherein the aromatic polyester is polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), or mixtures thereof. 
     
     
         14 . A plurality of fibers of  claim 1 . 
     
     
         15 . An article comprising a plurality of fibers of  claim 14  wherein a first portion of the plurality of fibers comprise:
 a base polymer comprising an aromatic polyester or nylon-6; 
 an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25° C. and an HLB of greater than 10; and 
 a dye; 
 wherein the dye is present in a greater amount in the first portion of the fibers than in other portions of the fibers of the article. 
 
     
     
         16 . A method of making a plurality of fibers of  claim 14 , the method comprising:
 providing a base polymer comprising an aromatic polyester or nylon-6;   providing an alkylene oxide-containing nonionic surfactant, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25° C. and an HLB of greater than 10;   melt mixing the alkylene oxide-containing nonionic surfactant with the base polymer; and   forming a plurality of fibers, each of which comprised the alkylene oxide-containing nonionic surfactant mixed within the base polymer.   
     
     
         17 . The method of  claim 16  wherein a meltblown web of a plurality of the fibers demonstrates absorption of a water drop within 5 minutes according to the Water Drop Test. 
     
     
         18 . The method of  claim 16  wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test. 
     
     
         19 . The method of  claim 18  wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test to a distance of at least 5 cm. 
     
     
         20 . A method of differentially dyeing a fibrous substrate, the method comprising:
 providing a fibrous substrate comprising:
 a first portion of fibers comprising:
 a base polymer comprising an aromatic polyester or nylon-6; and 
 an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25° C. and an HLB of greater than 10; and 
 
 a second portion of fibers comprising:
 a base polymer that is the same as in the first portion; and 
 optionally, an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the amount and/or type of the alkylene oxide-containing nonionic surfactant is different than that in the first portion; 
 
   applying the same type and amount of dye under the same conditions to the first and second portions of the fibrous substrate;   wherein the first and second portions of the fibrous substrate differentially absorb the dye.