Ribbon like filaments and systems and methods for producing the same

Abstract

Various implementations include a melt-spun filament that has a radial cross section that has two substantially parallel linear perimetrical sections and first and second curved perimetrical sections. The first curved perimetrical section extends between first ends of the linear perimetrical sections, and the second curved perimetrical section extends between second ends of the linear perimetrical sections. The curved perimetrical sections are convex. According to some embodiments, the curved perimetrical sections are semi-circular or semi-elliptical. A plurality of melt-spun filaments may be included in a bundle of filaments and/or a yarn made with the melt-spun filaments. In addition, a spinneret plate for spinning the melt-spun filaments and a method of making the melt-spun filaments is also provided.

1 .- 72 . (canceled) 
     
     
         73 . A spinneret plate for producing a self-bulking melt-spun filament comprising:
 at least one capillary comprising:   a first section comprising a counterbore with vertical sides;
 wherein the counterbore comprises a depth of between about 0.010 inches and about 0.025 inches; 
   a second section comprising angled sides of a first angle;   a third section comprising vertical sides;   a fourth section comprising angled sides of a second angle;   wherein a cross-section of the at least one capillary comprises a rectangle; and   wherein a rectangular cross-section comprises a width and a height, and wherein a spin slot aspect ratio is the ratio of the width to the height in the counterbore of the capillary.   
     
     
         74 . The spinneret plate according to  claim 73 , wherein the spin slot aspect ratio is selected from the group consisting of about 4:1 or about 6:1. 
     
     
         75 . The spinneret plate according to  claim 73 , wherein the first angle is between 45° and 80°. 
     
     
         76 . The spinneret plate according to  claim 73 , wherein the second angle is between 45° and 80°. 
     
     
         77 . The spinneret plate according to  claim 73 , wherein the first angle is equal to the second angle. 
     
     
         78 . A method for producing a melt-spun filament from the capillary according to  claim 73  comprising:
 pumping a polymer melt into the capillary at a first speed to produce a filament having a first filament aspect ratio at the spinneret plate; 
 drawing the filament at a first draw rate from the spinneret plate such that the filament has a second filament aspect ratio at a point further away from the spinneret plate. 
 
     
     
         79 . The melt-spun filament produced from the capillary according to  claim 78 , wherein the radial cross section is capsule shaped. 
     
     
         80 . The melt-spun filament produced from the capillary according to  claim 78 , wherein the radial cross section is rice shaped. 
     
     
         81 . The melt-spun filament produced from the capillary according to  claim 78 , wherein a plane extending axially through the melt-spun filament intersects the curved perimetrical ends and includes a central axis of the filament, and a line that is tangential to one of the ends of the linear perimetrical sections intersects the plane at an angle of between 0° and 10°. 
     
     
         82 . The melt-spun filament produced from the capillary according  claim 78 , further comprising a core and a sheath disposed around the core, the core being formed from a first material, and the sheath being formed from a second material. 
     
     
         83 . The melt-spun filament produced from the capillary according to  claim 82 , wherein the first material and the second material are selected from the group consisting of polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), polyamides (PA), Polybutylene terephthalate (PBT), other polyesters and polyolefins, or combinations thereof. 
     
     
         84 . A method for producing a self-bulking melt-spun filament comprising:
 providing a spinneret plate comprising at least one capillary, wherein the capillary comprises:
 a rectangular opening with a first section comprising a counterbore having substantially vertical sides that are perpendicular to a face of the spinneret plate; 
 a second section adjoining the first section, wherein the second section comprises sides that are angled away from the vertical sides of the first section at a first angle; 
 a third section adjoining the second section, wherein the third section comprises sides that are substantially vertical; 
 a fourth section adjoining the third section, wherein the fourth section comprises sides that are angled away from the vertical sides of the third section at a second angle; 
   pumping a polymer melt into the fourth section of the capillary at a first speed to extrude a filament from the counterbore, wherein the filament has a first filament aspect ratio at the spinneret plate;   drawing the filament at a first draw rate from the spinneret plate such that the filament has a second filament aspect ratio at a point further away from the spinneret plate.   
     
     
         85 . The melt-spun filament according to  claim 84 , wherein the radial cross section is capsule shaped. 
     
     
         86 . The melt-spun filament according to  claim 84 , wherein the radial cross section is rice shaped. 
     
     
         87 . The melt-spun filament according to  claim 84 , wherein a plane extending axially through the melt-spun filament intersects the curved perimetrical ends and includes a central axis of the filament; and
 wherein a line that is tangential to one of the ends of the linear perimetrical sections intersects the plane at an angle of between 0° and 10°.   
     
     
         88 . The capillary according to  claim 84 , wherein the counterbore comprises a depth of between about 0.010 inches and about 0.025 inches. 
     
     
         89 . The capillary according to  claim 84 , wherein the first angle is between 45° and 80°. 
     
     
         90 . The capillary according to  claim 84 , wherein the second angle is between 45° and 80°. 
     
     
         91 . The capillary according to  claim 84 , wherein the first angle is equal to the second angle. 
     
     
         92 . The melt-spun filament produced from the capillary according to  claim 82 , wherein the first material and the second material are selected from the group consisting of polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), polyamides (PA), Polybutylene terephthalate (PBT), other polyesters and polyolefins, or combinations thereof.