Hot melt size and yarn sized therewith and packages and fabrics of sized yarn

Abstract

A non-aqueous,water-soluble, quick-setting sizing composition suitable for application in the molten state to textile yarns of both continuous-filament and staple types, and for later removal by aqueous means, comprising a combination of a film-forming thermoplastic polymer with a melt-miscible viscosity reducer and solification promoter, and yarns so sized. The polymer protects and consolidates the yarn, while its companion component promotes the even application and particularly the quick set-up of the molten size. Optionally, if desired, water-soluble lubricants may also be added to increase the lubricity and flexibility of the sized yarn.

We claim: 
     
       1. A quick-setting non-aqueous water-extractable textile melt size composition comprising an intimate admixture of a water-soluble film-forming meltable thermoplastic polymer and a melt-miscible, solid modifier .Iadd.having a melting point of at least about 90° C. and .Iaddend.selected from the class consisting of aliphatic .Iadd.polycarboxylic acids .Iaddend.and .Iadd.partial esters thereof, .Iaddend.aromatic .[.carboxylic.]. .Iadd.monocarboxylic .Iaddend.acids, .[.partial esters thereof,.]. .Iadd.partial esters of aromatic polycarboxylic acids, .Iaddend.non-polymeric polyhydric alcohols, phenolic acids, and polyhydric phenols, wherein the proportion of polymer to modifier is about 90:10 to about 50:50 on a weight basis, said size capable of being applied as a melt to textile yarns, with quick setting when exposed to ambient conditions, and capable of being removed from the yarns by aqueous or alkali extraction. 
     
     
       2. The size of claim 1 wherein the film-forming polymer is selected from the class of water- or aqueous alkali-soluble thermoplastic polymers consisting of sulfonated and phosphonated copolymers and their ammonium and metal salts, vinyl acetate copolymers, and acrylic and methacrylic acid copolymers. 
     
     
       3. The size of claim 2 further including a melt-miscible and aqueous-extractable yarn lubricant. 
     
     
       4. The size of claim 2 wherein the polymer is a water-soluble thermoplastic copolymer of isophthalic acid, 5-sulfoisophthalic acid or a salt thereof, and diethylene glycol, and the modifier is adipic acid, the polymer and acid being melt blended. 
     
     
       5. Yarn sized with the size of claim 1. 
     
     
       6. Yarn sized with the size of claim 2. 
     
     
       7. Yarn suitable for weaving sized with the size of claim 1. 
     
     
       8. A woven fabric made with the yarn of claim 7. 
     
     
       9. A yarn supply package containing the yarn of claim 7. 
     
     
       10. Yarn suitable for knitting sized with the size of claim 1. 
     
     
       11. A knitted fabric made with the yarn of claim 9. 
     
     
       12. A continuous filament yarn sized with the size of claim 1. 
     
     
       13. A spun yarn sized with the size of claim 1. 
     
     
       14. The spun yarn of claim 13 wherein the yarn contains polyester. 
     
     
       15. The spun yarn of claim 13 wherein the yarn contains rayon. 
     
     
       16. The spun yarn of claim 13 wherein the yarn is polyester and rayon. 
     
     
       17. The spun yarn of claim 13 wherein the yarn contains cotton. 
     
     
       18. The spun yarn of claim 13 wherein the yarn contains polyester and cotton. 
     
     
       19. The yarn of claim 5 wherein the yarn contains polypropylene. 
     
     
       20. The yarn of claim 5 wherein the yarn contains wool. 
     
     
       21. The yarn of claim 5 wherein the yarn contains glass. 
     
     
       22. A textured yarn sized with the size of claim 1. 
     
     
       23. In a process for sizing textile yarns by applying a size composition to textile yarn, the improvement comprising using, as said size composition, A quick-setting non-aqueous melt size composition comprising an intimate admixture of a film-forming water-soluble meltable thermoplastic polymer and a melt-miscible, solid modifier .Iadd.having a melting point of at least about 90° C. and .Iaddend.selected from the class consisting of aliphatic .Iadd.polycarboxylic acids .Iaddend.and .Iadd.partial esters thereof, .Iaddend.aromatic .[.carboxylic.]. .Iadd.monocarboxylic .Iaddend.acids, .[.partial esters thereof,.]. .Iadd.partial esters of aromatic polycarboxylic acids, .Iaddend.non-polymeric polyhydric alcohols, phenolic acids, and polyhydric phenols, wherein the proportion of polymer to modifier is about 90:10 to about 50:50 on a weight basis, and applying the size composition to the textile yarn as a melt, wherein the size composition is characterized by a rapid setup and absence of tackiness when the sized yarn is led away from the point of application of the size composition to the yarn, the size composition being capable of removal from the textile yarn by aqueous extraction media. 
     
     
       24. The process of claim 23 wherein the polymer is selected from the class consisting of sulfonated and phosphonated copolymers and their ammonium and metal salts, vinyl acetate copolymers, and acrylic and methacrylic acid copolymers.