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Multiphase fiber materials and compositions, methods of manufacture and uses thereof

A technology of composition and gel composition, applied in the direction of final product manufacturing, sustainable manufacturing/processing, textile/flexible product manufacturing, etc.

Active Publication Date: 2011-04-20
ADVANSIX RESINS & CHEM LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The reduction of the concentration of low-melt continuous minor fibers can be difficult because the concentration is ultimately limited by the denier of the minor fibers

Method used

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  • Multiphase fiber materials and compositions, methods of manufacture and uses thereof
  • Multiphase fiber materials and compositions, methods of manufacture and uses thereof
  • Multiphase fiber materials and compositions, methods of manufacture and uses thereof

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0068] The preparation of embodiment 1-lactam

[0069] In a covered vessel, melt four liters of caprolactam overnight in a convection oven. The lactam was poured into a 5 liter 3-neck distillation flask with a magnetic stir bar and electric heating mantle (top and bottom mantle). The distillation column has a vacuum jacket and consists of a 29 / 42 column and 10 tray section, 5 tray section, split distillation head and condenser. The condenser was maintained at 50°C using a heated water circulator. The system reduces the pressure from 7 mmHg to 4 mmHg. Heat was applied to bring the column to reflux conditions and held for 30 minutes. After allowing the column to stabilize for 30 minutes, the distillation head sampler was started, 4 seconds off, and 10 seconds to reflux. Slightly less than 1 liter of lactam was distilled off. The heat was turned off, and the heating mantle was removed, the lactam in the 5-liter flask was allowed to drop to 90°C, and then the vacuum on the sy...

Embodiment 2

[0070] Example 2 - Preparation of contemplated pre-fiber gel compositions

[0071] Nylon-6 is ground into a fine powder and mixed with a lactam gelling agent, which in this case is caprolactam. A Braybender mixer was used to mix nylon and caprolactam at a speed of 60 RPM. The addition time was approximately 5 minutes and the gel was allowed to mix for 15 minutes after addition at the temperature indicated. Remove the sample while running the Braybender using a brass wiper. The samples were then ground in a Willey mill using a course screen. Weighed quantities of each ground gel mixture were extracted for 16+ hours using a jacketed Soxhlet extractor. The extract was filtered using folded #54 paper and rinsed into a 100 ml volumetric flask. The extract was brought up to volume with deionized water and then analyzed for % lactam by means of gas chromatography using a polyethylene glycol column.

[0072] gel

[0073] The resulting gel was gel-spun on a twin-screw ex...

Embodiment 3

[0074] Example 3 - Preparation of contemplated pre-fiber compositions

[0075] background

[0076] A conventional binder alloy sample (1-end of 22 denier / 12 monofilaments) was inserted into a 1202mp 2-plied yarn during cabling and performed heat set. exist After heat setting, the Plybond test of the yarns did not show any signs of bonding. Subsequently, the yarn is autoclave heat set before being processed into banded carpet. No significant aesthetic effect was observed in the carpet using any of the conventional binder alloy samples. However, at the lowest nylon / binder ratio, there was a slight impact on carpet hand (firmness), but no texture or surface changes were observed in the carpet.

[0077] This study tested compositionally altered low-melt alloy fibers (higher process "binder" and higher lactam concentration). The purpose of the study was to find an alloy composition which in Capable of melting and bonding the fibers together within the bundle during heat s...

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Abstract

A pre-fiber composition is disclosed herein that includes: a) a first fiber constituent having a first melting point; b) a second fiber constituent having a second melting point; and c) a gelling agent that solvates at least one of the first fiber constituent or the second fiber constituent, wherein the gelling agent significantly reduces co-polymerization of either of the constituents in the composition. A fiber is also disclosed herein that includes: a) at least two amide-based polymers, each having a melting point, wherein the melting point of one amide-based polymer is dissimilar to the melting point of a second amide-based polymer; and b) a gelling agent that is compatible with at least one of the amide-based polymers, wherein the fiber comprises two differentiatable melting points that are substantially similar to the melting points of each of the amide-based polymers. A method of producing a pre-fiber composition is disclosed herein that includes: a) providing a first fiber constituent having a first melting point; b) providing a second fiber constituent having a second melting point, wherein the first melting point and the second melting point are dissimilar; c) providing at least one gelling agent; and d) mixing the first constituent, the second constituent and the at least one gelling agent such that there is sufficient viscosity and sufficient melt strength in the composition so that it can be spun into a fiber and such that the first melting point and the second melting point in the fiber are substantially similar to their original values before mixing.

Description

technical field [0001] The technical field that is the subject of the present invention is multiphase pre-fibrous and fibrous materials and compositions, fibrous, yarn and carpet products, methods of their manufacture and uses. Background technique [0002] There is a constant interest in improving the aesthetics and performance of fibers for consumer use, especially for incorporation into yarns, carpet products and fabrics / textiles. These improvements may relate to appearance retention, texture and surface shape, softness and floor wear performance. Fibers and fiber products are also evaluated to determine if more efficient and cost-effective manufacturing processes and equipment exist. [0003] Fibers that can be used to produce carpet products such as room rugs, area rugs, and rugs are modified to provide a certain yarn texture when they are introduced into the carpet product and provide the desired "look" for the space in which the carpet product is used. Sex and in so...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): C08K5/34C08L77/00C08K5/3412D01F6/90
CPCC08K5/3412D01F6/90Y10T428/2913C08L77/00C08K5/00C08J5/06C08K5/34
Inventor J·B·博伊尔S·阿布达拉D·A·汉盖J·A·克维德尔
Owner ADVANSIX RESINS & CHEM LLC
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