CA1108813A - Eva yarn compositions - Google Patents
Eva yarn compositionsInfo
- Publication number
- CA1108813A CA1108813A CA314,071A CA314071A CA1108813A CA 1108813 A CA1108813 A CA 1108813A CA 314071 A CA314071 A CA 314071A CA 1108813 A CA1108813 A CA 1108813A
- Authority
- CA
- Canada
- Prior art keywords
- vinyl acetate
- yarn
- component
- binding material
- polymeric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
- D02G3/408—Flocked yarns
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Multicomponent Fibers (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The invention is a method of preparing a yarn product wherein fibers adhere to a central portion of a polymeric material which comprises a polymeric alloy having as a first component a thermoplastic material and as a second component an ethylene vinyl acetate copolymer. The use of an ethylene vinyl acetate copolymer improves the manufacturing conditions of the yarn and imparts desirable characteristics to the final product.
The invention is a method of preparing a yarn product wherein fibers adhere to a central portion of a polymeric material which comprises a polymeric alloy having as a first component a thermoplastic material and as a second component an ethylene vinyl acetate copolymer. The use of an ethylene vinyl acetate copolymer improves the manufacturing conditions of the yarn and imparts desirable characteristics to the final product.
Description
~ 83~1L3 The present invention relates to ~arns and more partic-ularly, relates to yarn compositions and a method o~ manufactu-ring said yarns.
Recent technology in the field of textiles and partic-ularly yarns has included the development of what have become known as "composite" yarns; ~hese composite yarns are manufac-tured by several different processes which have been described in the art and in this respect, reference may be had, for example, to Canadian Patents 833,443; 880,988 and 983,6941 among others.
These patents describe various processes and apparatuses for manufacturing composite yarns.
A first method for manufacturiny a composite yarn, as taught in the art, comprises extruding a filament of a tacky material such as a molten polymeric material and subsequently juxtaposing fibers thereto such that ~he fibers adhere to and are embedded in the polymeric material which acts as a binder. In a second method of manufacturing composite yarns, a carrier material, which may be any suitable material, either single or multi-filament, is coated with a tacky binder substance such as a molten polymeric material by passing the same through an extrusion die whereby a sheath of molten polymeric material is extruded thereabout, and subsequently fibers are jux-taposed to the coated carrier to form the final yarn product which has the fibers adhering to and embedded in the polymeric sheath about the carrier.
The advantages of composite yarn manufactured accor-ding to the above~described processes have been multifold. Thus, the methods and apparatuses permit manufacture of yarn at sub-stantially greater speeds than were previously o~tainable by con- , ventional techniques such as rotor spinning or ring sp:inning.
Furthermore~ the multi-component yarns permit one to "engineer"
the desired properties into the final ~Yarn product and in some instances, have permitted the us-e of certain ma~erial previously not suitable for yarn products.
~ ith the manufacture of the yarn occurring at high speeds, certain problem~ are encountered. Thus, the use of certain polymeric material as the binding material for the fibers introduces a limitation to the speed at which the process can be run. Furthermore, the use of certain materials, in certain re-quired percentages, has been found to impart some undesirablecharacteristics to the final yarn products such as stiffness, limited dyeability, etc.
It is an object of the present invention to provide a method Eo~ the manu:Eacture o:E a composite yarn, which method provides better processahility of the yarn and furthermore pro-~des a yarn having an increased fiber loading.
Accordin~ to one aspect of the present invention, in a yarn product wherein an outer yarn component adheres to a center core of the yarn product by means o~ a binding material, there is provided the improvement wherein said binding material comprises an alloy having as a first component thereof a polymeric material and a second component thereof a vinyl acetate.
In a further aspect of the present invention, in a ..
method of manufacturing a yarn product wherein an outer yarn com-ponent is placed in contact with a center core having a tacky surface, there is provided the improvement comprising the step of contacting said outer yarn component with a binding material com-prising an alloy having as a first component thereof a polymeric ~ ..
material and as a second component thereof a vinyl acetate.
In greater deta~l, the present inYentiOn provides a :' ,. , ~ ' ,:
polymeric "alloy" ~hich is suitahle ~or use in the manufacture of composite ~axn as a bind~n~ material. The polymeric alloy com-prises a first polymeric material to wh~ch is added a vinyl ace-tate preferably in ~he form of an ethylene vinyl acetate copoly-mer.
In this speci~icat~on, the term "composite yarn" refers to a yarn whic~ is manufactured of two or more components. This includes yarns having a central core, a polymeric sheath or binder t~ereabout, ~ith fi~ers adhered to or em~edded in the polymeric sheath. In this embodiment, thxee "different" compo-nents are employed although thay may all be of the same material.
The cente~ core component may comprise, in one aspect, one or more single or multi-filament bundles or a "yarn" or like carrier material. The outer yarn component "fibers" may be either in the form of individual discrete fibers such as staple fibers or in the form of "filaments"; still further, the term fibers includes the use of material in the form of a yarn which may then be further treated to achieve the desired effect.
Still further, the centër core of the yarn may comprise an extruded filament of the polymeric alloy discussed herein.
An outer yarn component comprising fibers or filaments as dis-cussed above will then be adhered to the filament, at least the outer surface of which is in a tacky condition when contacted with the outer yarn component.
The polymexic "alloy" used as a binding material com-prises a first polymeric material, which material may be any of the conventional resins employed for use in the formation of com-posite yarns. For example, resins such as polypropylene, poly-ethylene, polyurethane, nylon, polyester, "SARAN" etc., may be employed. The polymeric alloy further includes a vinyl acetate , . , .
' ' , ' ' ' ~ ' ' ; '' ' ,, _ 4 ~ 8~3 compound prefera~l~ in the form of an ethylene vinyl acetate ~EVA) copolymer, It has ~een found that the use of an EVA copolymer imparts substant~al advantages bot~ to the f;nal product and to a method o~ manufacturing a compo`s~te yarn The term "EVA" i.s in this specification used to designate a yroup of EVA copolymers, which copolymers are commercially available in various grades with different ratios in the copolymer itself. Such E~A mate-rials are known, for example, under the trade mark "ULTRATHENE"
designating the et~ylene vinyl acetate family of polyolefin co-polymers developed ~y U. S~ Industrial Chemicals Co. The co-polymers are availa~le ranging from a few percent by weight of vinyl acetate or up to and in excess of 50~ vinyl acetate.
Previously, problems of adhesion of the mo].ten polymer to the carrier, when the carrier is passed through the extruder, have been present due to the high speed at which such cornposite yarns are formed. However, it has been found that the inclusion of an EVA copolymer in the melt significantly improves the pro-cessing and permits higher production speeds without breaks in the polymeric sheath about the carrier. Naturally, this leads to improved proper-ties for the yarn itself such as increased fi.ber coverage and a more uniform fiber coverage.
It has further been found that the use of a polyme.ric alloy having thereln an EVA copolymer reduces the stiffness of the yarn and as a consequence, fabrics made therefrom. Still further, the hand of a fabric knitted from the yarn has been ~ound to be improved. Other ad~-antages include an improvement of colour uniformity as the amount of EVA copolymer (i.e. the amount of vinyl acetate) present in the alloy increases. Util-izing this, slightly darker shades of the yarn can be achieved utilizing the same-dyeing-conditions or, in other words, less dye ~ 5 --is needed for the same shade. Also, ~enerally, the dyeability of the ~abrlc is improved with increasin~ amounts of EVA until a maximum effect ;s achieved - further increase in the EVA copoly-mer content has a d minis~ing e~fect on uniformity or dye pick-up.
The use o~ an EVA copolymer in a polymeric alloy also results in a more relia~le spinning. Stabilit~ in the spinning zone has generally been ~ound to improve and the number of poly-mer breaks reduced. In addition, EVA copolymer blend alloys can in general be run a~out 40C lower in temperature than, for example, a straight polypropylene resin. The bonding of the resin to a fiber as well as to the carrier is improved~
As aforementioned, the particular resin to which the EVA copo]ymer is added may vary. However, it is a condition r as will be understood by those skilled in the art, that the resin which is employed must be one with which the EVA copolymer is compati~le or, in other words, is "soluble" in.
The ratio of resin to EVA copolymer will vary depending on the specific properties of the yarn desired and as well, the particular resin or resins employed in the polymeric a].loy. In certain instances, the EVA copolymer is only soluble in the resin to a certain extent as is the case, for example, with condensa~
tion polymers. Thus, with certain resins, a maximum of 10~ of the EVA copolymer with respect to the remaining resin or resins may be employed before the polymers separate and the melt will appear as a two-phase system. On the otherhand~ with resins such as ethylene and vinyl polymers, any ratio o~ EVA to resin may be employed without separation problems. Naturally, as will be understood by those skilled in the art, a single phase alloy system is employed with the present invention.
As will be appreciated, for each resin or resins :' '~: , .
~ 6 ~ 8~3 emplo~ed, thexe is a range ~ithin ~hich the bene~its and the ad-vantages outl~ned a~ove are maxl}nized. Thus, for resins such as polypropylene and polyeth~lene, a 20 to 70% EVA content has been found to be generally most suitahle ~ith a 40 to 60~ range being preferred~ Naturally, the amount of EVA can be varied, as prev~ously mentioned, depending on the specific properties desired and on the amount of-vinyl acetate in the EV~.
It will be understood, in the above context, that the term "ethylene vinyl acetate" includes copolymers wherein the percentage of vinyl acetate may vary. Thus, in commercially availa~le EVA copolymers, the vinyl acetate percentage generally varies between 9 and 55%. For the practice of the present in-vention, a 20 to 28~ vinyl acetate content has been found to be suita~le.
The present invention also includes the embodiment, as discussed previously, ~erein the centre core of the composite yarn comprises an extruded filament of the binding material per se. It has been found that not only doesthe binding material act as in the above-mentioned yarns ~better adhesion and fiber coverage)~ but also provides increased processability. In this ernbodiment, the polymer alloy is as defined above.
Having thus generally described the invention, refer-ence will be made to the accompanying E~amples illustrating embodiments thereof.
EXAM~LES 1 TO 7 Seven different composite yarns were manufactured with varying compositions as shown in Table I. Th~e yarns were pro-duced on a Bobtex Mark I ICS Machine produced for the manufacture of composite yarns b~ The Bobtex Corporation. In each instance, the carrier was fed through an extruder die wherein it was coated 8~3 with the binder. The ~ibers ~ere then juxtaposed to the coated carrier.
TABLE I
_A ALLO~ BASED ICS YAR~S
SAMP~E NO. 1 2 3 4 5 6 7 Count (tex) 190 215 75 115 115 140 100 Compositionl Fibers % V60 A~W 64 W55 A50 A50 W/~A 27V40 Carrier % PET 26 PET 22 PET 22 PET 29 PET 29 24 PET 33 -10 Binder % 14 13 23 21 21 49 27 ~Binder Composition Resin Name PP PP PP PP PP SARAN PP
Resin % 33 33 25 50 75 97 100 EVA3 % 66 66 75 50 25 3 0 (Ft/min) 2040 2000 1450 2010 2010 2040 2000 Break Strength(g)10501550 633 1400 1400 2500 1320 Elongation (%) 46 22 30 35 35 3 32 Adhesion Index2 5 5 4 4 4 5 wool V - viscose PP - Polypropylene MA - modacrylic PPA - PP alloy PET - polyester EVA - EVA/PP copolymer A - acr~lic SA - SARAN alloy 2Adhes~on Index - measure oE ability to strip fiber/polymer sheath from the carrier core filament, scale 1 to 5; 1 - easy sliding off, 5 - no stripping, force to strip exceeds strength of yarn.
"ULTRATHENE" - 28% vinyl acetate content.
As will be evident from Table I, the use of EVA in the b~nder composition substantially improved the adhesion of the fibers to the carrier. AS little as 25% EV~, ~hich translates to a 7% vinyl acetate content, substantially improved the adhesion of - the ~-ibers to the blnder andcarrier. ~ith certain resins, such as ,. :
',, ;
is the case ~ith S~RAN, as l~ttle as 3% EYA content provides not only perfect adhesion but greatly improved processability.
Thus, t~e use of t~e EYA provid,es an extremely high adhesion characteristic ~hile it has been found that the same polyester filaments with pure polypropylene ~as in Examples 1 to 5 and 7) has res~n yield adhesion îndices in the range of 1 and 2.
~it~in t~e operating EVA range, there does not appear to be high sensitivity to the level of EVA content versus the adhesion index.
In these Examples, a yarn was manufactured as described above with reference to Examples 1 to 7. In each instance, the -carrier was a polyester with fibers being of an acrylic material.
The resin was polypropylene with the percentage of EVA being varied as set forth in Table II.
TABLE II
EVA ALLOYING CHARACTERISTICS
EVA % Process Draw DownSoftnessFiber Loading Temp. F Ratio Index Index Index _ 0% 550 60 .35 48%
20 25% 525 90 .45 53%
50% 475 95 .70 57%
75% 450 95 .70 60%
00% 450 10 O70 60~
The Softness Index is an arbitrary dimensionless subjective index with 1.0 representing maximum softness and .1 representing a very stiff yarn.
2Vinyl acetate content - 28%.
As will be seen from Table II, the increase in EVA con-tent permitsian increased number of fibers to be adhered to the ~30 core of the yarn~ An increased number of adhered fibers is naturally desira~le to give any desired surface effect iII a tex-tile product.
As w~ll Be seen fro~ Example 8, and as ~las ~een estab-lished, 48%~represents the approximate maximum, in a practical sense, o~ the fiber loading with pure polypropylene~ I-t will also be noted that the maximum fiber loading was achieved with a 21% vinyl acetate content - fur-ther increase in the vinyl acetate content did not further improve the fiber loading index. The maximum softness was achieved with a 14~ vinyl ace-tate content.
As will be further noted, the process temperature can 10 be substantially reduced with the increase in the vinyl acetate -;
content.
EXAM LES 13 TO_14 Yarns were rnanufactured according to Table III with the me-thod of previous Examples ~Ising a carrler o~ glass material and fi.bers of viscose/modacrylic ma-terial.
- TABLE III
ALLOYING EFFECT ON PROCESSABILITY
Example Resin Process Draw Do~n Process-Allo~ TOmp. Ratio ability %~% F Index Index _ _______ lon a scale of 1 to 5 with 5 indicating maximurn processability -i.e. the most desirable.
As will be seen, the use of even a srnall percentage of EVA results in a dramatic increase in the processability of the yarn. The EVA yarn provides twice the draw down and at a lower temperature, the processability increased dramatically.
As will be seen from the above Examples, the use ~ an EVA copolymer in the binder material leads to substantial advan-tages. With the processability, the high strains placed upon the li~uid extrudate in the process for manufacturin~ composite yarns makes the yarn path h~ghl~ sensitive to breaka~e, Use of the EVA alloying ~as permitted greater line sta~ility, reduction or eliminat~on of melt resonance, processing reliability t and the attainment of eff~ciency levels not other~ise attainable, It ~ill be understood that the a~ove-described embodi-men~s are Eor purposes of exemplificat~on only and are not limiting.
Recent technology in the field of textiles and partic-ularly yarns has included the development of what have become known as "composite" yarns; ~hese composite yarns are manufac-tured by several different processes which have been described in the art and in this respect, reference may be had, for example, to Canadian Patents 833,443; 880,988 and 983,6941 among others.
These patents describe various processes and apparatuses for manufacturing composite yarns.
A first method for manufacturiny a composite yarn, as taught in the art, comprises extruding a filament of a tacky material such as a molten polymeric material and subsequently juxtaposing fibers thereto such that ~he fibers adhere to and are embedded in the polymeric material which acts as a binder. In a second method of manufacturing composite yarns, a carrier material, which may be any suitable material, either single or multi-filament, is coated with a tacky binder substance such as a molten polymeric material by passing the same through an extrusion die whereby a sheath of molten polymeric material is extruded thereabout, and subsequently fibers are jux-taposed to the coated carrier to form the final yarn product which has the fibers adhering to and embedded in the polymeric sheath about the carrier.
The advantages of composite yarn manufactured accor-ding to the above~described processes have been multifold. Thus, the methods and apparatuses permit manufacture of yarn at sub-stantially greater speeds than were previously o~tainable by con- , ventional techniques such as rotor spinning or ring sp:inning.
Furthermore~ the multi-component yarns permit one to "engineer"
the desired properties into the final ~Yarn product and in some instances, have permitted the us-e of certain ma~erial previously not suitable for yarn products.
~ ith the manufacture of the yarn occurring at high speeds, certain problem~ are encountered. Thus, the use of certain polymeric material as the binding material for the fibers introduces a limitation to the speed at which the process can be run. Furthermore, the use of certain materials, in certain re-quired percentages, has been found to impart some undesirablecharacteristics to the final yarn products such as stiffness, limited dyeability, etc.
It is an object of the present invention to provide a method Eo~ the manu:Eacture o:E a composite yarn, which method provides better processahility of the yarn and furthermore pro-~des a yarn having an increased fiber loading.
Accordin~ to one aspect of the present invention, in a yarn product wherein an outer yarn component adheres to a center core of the yarn product by means o~ a binding material, there is provided the improvement wherein said binding material comprises an alloy having as a first component thereof a polymeric material and a second component thereof a vinyl acetate.
In a further aspect of the present invention, in a ..
method of manufacturing a yarn product wherein an outer yarn com-ponent is placed in contact with a center core having a tacky surface, there is provided the improvement comprising the step of contacting said outer yarn component with a binding material com-prising an alloy having as a first component thereof a polymeric ~ ..
material and as a second component thereof a vinyl acetate.
In greater deta~l, the present inYentiOn provides a :' ,. , ~ ' ,:
polymeric "alloy" ~hich is suitahle ~or use in the manufacture of composite ~axn as a bind~n~ material. The polymeric alloy com-prises a first polymeric material to wh~ch is added a vinyl ace-tate preferably in ~he form of an ethylene vinyl acetate copoly-mer.
In this speci~icat~on, the term "composite yarn" refers to a yarn whic~ is manufactured of two or more components. This includes yarns having a central core, a polymeric sheath or binder t~ereabout, ~ith fi~ers adhered to or em~edded in the polymeric sheath. In this embodiment, thxee "different" compo-nents are employed although thay may all be of the same material.
The cente~ core component may comprise, in one aspect, one or more single or multi-filament bundles or a "yarn" or like carrier material. The outer yarn component "fibers" may be either in the form of individual discrete fibers such as staple fibers or in the form of "filaments"; still further, the term fibers includes the use of material in the form of a yarn which may then be further treated to achieve the desired effect.
Still further, the centër core of the yarn may comprise an extruded filament of the polymeric alloy discussed herein.
An outer yarn component comprising fibers or filaments as dis-cussed above will then be adhered to the filament, at least the outer surface of which is in a tacky condition when contacted with the outer yarn component.
The polymexic "alloy" used as a binding material com-prises a first polymeric material, which material may be any of the conventional resins employed for use in the formation of com-posite yarns. For example, resins such as polypropylene, poly-ethylene, polyurethane, nylon, polyester, "SARAN" etc., may be employed. The polymeric alloy further includes a vinyl acetate , . , .
' ' , ' ' ' ~ ' ' ; '' ' ,, _ 4 ~ 8~3 compound prefera~l~ in the form of an ethylene vinyl acetate ~EVA) copolymer, It has ~een found that the use of an EVA copolymer imparts substant~al advantages bot~ to the f;nal product and to a method o~ manufacturing a compo`s~te yarn The term "EVA" i.s in this specification used to designate a yroup of EVA copolymers, which copolymers are commercially available in various grades with different ratios in the copolymer itself. Such E~A mate-rials are known, for example, under the trade mark "ULTRATHENE"
designating the et~ylene vinyl acetate family of polyolefin co-polymers developed ~y U. S~ Industrial Chemicals Co. The co-polymers are availa~le ranging from a few percent by weight of vinyl acetate or up to and in excess of 50~ vinyl acetate.
Previously, problems of adhesion of the mo].ten polymer to the carrier, when the carrier is passed through the extruder, have been present due to the high speed at which such cornposite yarns are formed. However, it has been found that the inclusion of an EVA copolymer in the melt significantly improves the pro-cessing and permits higher production speeds without breaks in the polymeric sheath about the carrier. Naturally, this leads to improved proper-ties for the yarn itself such as increased fi.ber coverage and a more uniform fiber coverage.
It has further been found that the use of a polyme.ric alloy having thereln an EVA copolymer reduces the stiffness of the yarn and as a consequence, fabrics made therefrom. Still further, the hand of a fabric knitted from the yarn has been ~ound to be improved. Other ad~-antages include an improvement of colour uniformity as the amount of EVA copolymer (i.e. the amount of vinyl acetate) present in the alloy increases. Util-izing this, slightly darker shades of the yarn can be achieved utilizing the same-dyeing-conditions or, in other words, less dye ~ 5 --is needed for the same shade. Also, ~enerally, the dyeability of the ~abrlc is improved with increasin~ amounts of EVA until a maximum effect ;s achieved - further increase in the EVA copoly-mer content has a d minis~ing e~fect on uniformity or dye pick-up.
The use o~ an EVA copolymer in a polymeric alloy also results in a more relia~le spinning. Stabilit~ in the spinning zone has generally been ~ound to improve and the number of poly-mer breaks reduced. In addition, EVA copolymer blend alloys can in general be run a~out 40C lower in temperature than, for example, a straight polypropylene resin. The bonding of the resin to a fiber as well as to the carrier is improved~
As aforementioned, the particular resin to which the EVA copo]ymer is added may vary. However, it is a condition r as will be understood by those skilled in the art, that the resin which is employed must be one with which the EVA copolymer is compati~le or, in other words, is "soluble" in.
The ratio of resin to EVA copolymer will vary depending on the specific properties of the yarn desired and as well, the particular resin or resins employed in the polymeric a].loy. In certain instances, the EVA copolymer is only soluble in the resin to a certain extent as is the case, for example, with condensa~
tion polymers. Thus, with certain resins, a maximum of 10~ of the EVA copolymer with respect to the remaining resin or resins may be employed before the polymers separate and the melt will appear as a two-phase system. On the otherhand~ with resins such as ethylene and vinyl polymers, any ratio o~ EVA to resin may be employed without separation problems. Naturally, as will be understood by those skilled in the art, a single phase alloy system is employed with the present invention.
As will be appreciated, for each resin or resins :' '~: , .
~ 6 ~ 8~3 emplo~ed, thexe is a range ~ithin ~hich the bene~its and the ad-vantages outl~ned a~ove are maxl}nized. Thus, for resins such as polypropylene and polyeth~lene, a 20 to 70% EVA content has been found to be generally most suitahle ~ith a 40 to 60~ range being preferred~ Naturally, the amount of EVA can be varied, as prev~ously mentioned, depending on the specific properties desired and on the amount of-vinyl acetate in the EV~.
It will be understood, in the above context, that the term "ethylene vinyl acetate" includes copolymers wherein the percentage of vinyl acetate may vary. Thus, in commercially availa~le EVA copolymers, the vinyl acetate percentage generally varies between 9 and 55%. For the practice of the present in-vention, a 20 to 28~ vinyl acetate content has been found to be suita~le.
The present invention also includes the embodiment, as discussed previously, ~erein the centre core of the composite yarn comprises an extruded filament of the binding material per se. It has been found that not only doesthe binding material act as in the above-mentioned yarns ~better adhesion and fiber coverage)~ but also provides increased processability. In this ernbodiment, the polymer alloy is as defined above.
Having thus generally described the invention, refer-ence will be made to the accompanying E~amples illustrating embodiments thereof.
EXAM~LES 1 TO 7 Seven different composite yarns were manufactured with varying compositions as shown in Table I. Th~e yarns were pro-duced on a Bobtex Mark I ICS Machine produced for the manufacture of composite yarns b~ The Bobtex Corporation. In each instance, the carrier was fed through an extruder die wherein it was coated 8~3 with the binder. The ~ibers ~ere then juxtaposed to the coated carrier.
TABLE I
_A ALLO~ BASED ICS YAR~S
SAMP~E NO. 1 2 3 4 5 6 7 Count (tex) 190 215 75 115 115 140 100 Compositionl Fibers % V60 A~W 64 W55 A50 A50 W/~A 27V40 Carrier % PET 26 PET 22 PET 22 PET 29 PET 29 24 PET 33 -10 Binder % 14 13 23 21 21 49 27 ~Binder Composition Resin Name PP PP PP PP PP SARAN PP
Resin % 33 33 25 50 75 97 100 EVA3 % 66 66 75 50 25 3 0 (Ft/min) 2040 2000 1450 2010 2010 2040 2000 Break Strength(g)10501550 633 1400 1400 2500 1320 Elongation (%) 46 22 30 35 35 3 32 Adhesion Index2 5 5 4 4 4 5 wool V - viscose PP - Polypropylene MA - modacrylic PPA - PP alloy PET - polyester EVA - EVA/PP copolymer A - acr~lic SA - SARAN alloy 2Adhes~on Index - measure oE ability to strip fiber/polymer sheath from the carrier core filament, scale 1 to 5; 1 - easy sliding off, 5 - no stripping, force to strip exceeds strength of yarn.
"ULTRATHENE" - 28% vinyl acetate content.
As will be evident from Table I, the use of EVA in the b~nder composition substantially improved the adhesion of the fibers to the carrier. AS little as 25% EV~, ~hich translates to a 7% vinyl acetate content, substantially improved the adhesion of - the ~-ibers to the blnder andcarrier. ~ith certain resins, such as ,. :
',, ;
is the case ~ith S~RAN, as l~ttle as 3% EYA content provides not only perfect adhesion but greatly improved processability.
Thus, t~e use of t~e EYA provid,es an extremely high adhesion characteristic ~hile it has been found that the same polyester filaments with pure polypropylene ~as in Examples 1 to 5 and 7) has res~n yield adhesion îndices in the range of 1 and 2.
~it~in t~e operating EVA range, there does not appear to be high sensitivity to the level of EVA content versus the adhesion index.
In these Examples, a yarn was manufactured as described above with reference to Examples 1 to 7. In each instance, the -carrier was a polyester with fibers being of an acrylic material.
The resin was polypropylene with the percentage of EVA being varied as set forth in Table II.
TABLE II
EVA ALLOYING CHARACTERISTICS
EVA % Process Draw DownSoftnessFiber Loading Temp. F Ratio Index Index Index _ 0% 550 60 .35 48%
20 25% 525 90 .45 53%
50% 475 95 .70 57%
75% 450 95 .70 60%
00% 450 10 O70 60~
The Softness Index is an arbitrary dimensionless subjective index with 1.0 representing maximum softness and .1 representing a very stiff yarn.
2Vinyl acetate content - 28%.
As will be seen from Table II, the increase in EVA con-tent permitsian increased number of fibers to be adhered to the ~30 core of the yarn~ An increased number of adhered fibers is naturally desira~le to give any desired surface effect iII a tex-tile product.
As w~ll Be seen fro~ Example 8, and as ~las ~een estab-lished, 48%~represents the approximate maximum, in a practical sense, o~ the fiber loading with pure polypropylene~ I-t will also be noted that the maximum fiber loading was achieved with a 21% vinyl acetate content - fur-ther increase in the vinyl acetate content did not further improve the fiber loading index. The maximum softness was achieved with a 14~ vinyl ace-tate content.
As will be further noted, the process temperature can 10 be substantially reduced with the increase in the vinyl acetate -;
content.
EXAM LES 13 TO_14 Yarns were rnanufactured according to Table III with the me-thod of previous Examples ~Ising a carrler o~ glass material and fi.bers of viscose/modacrylic ma-terial.
- TABLE III
ALLOYING EFFECT ON PROCESSABILITY
Example Resin Process Draw Do~n Process-Allo~ TOmp. Ratio ability %~% F Index Index _ _______ lon a scale of 1 to 5 with 5 indicating maximurn processability -i.e. the most desirable.
As will be seen, the use of even a srnall percentage of EVA results in a dramatic increase in the processability of the yarn. The EVA yarn provides twice the draw down and at a lower temperature, the processability increased dramatically.
As will be seen from the above Examples, the use ~ an EVA copolymer in the binder material leads to substantial advan-tages. With the processability, the high strains placed upon the li~uid extrudate in the process for manufacturin~ composite yarns makes the yarn path h~ghl~ sensitive to breaka~e, Use of the EVA alloying ~as permitted greater line sta~ility, reduction or eliminat~on of melt resonance, processing reliability t and the attainment of eff~ciency levels not other~ise attainable, It ~ill be understood that the a~ove-described embodi-men~s are Eor purposes of exemplificat~on only and are not limiting.
Claims (16)
1. In a composite yarn product wherein an outer yarn component adheres to a centre core of the yarn product by means of a binding material, the improvement wherein said binding material comprises an alloy having as a first component thereof a polymeric material and as a second component thereof a vinyl acetate polymeric material.
2. The yarn product of claim 1 wherein said centre core comprises a carrier material formed of one or more filaments.
3. The yarn product of claim 2 wherein said outer yarn component comprises fiber partially embedded in said binding material.
4. The yarn product of claim 3 wherein said fibers are staple fibers.
5. The yarn product of claim 2 wherein said centre core comprises a carrier of a polyester or glass material.
6. The yarn product of claim 1 wherein said first polymeric material is polypropylene.
7. A yarn product of claim 1 wherein said vinyl acetate polymeric material is an ethylene vinyl acetate copolymer, said copolymer comprising between 20% to 70% of said binding material, said copolymer having between 20% to 28% vinyl acetate content.
8. In a method of manufacturing a composite yarn product wherein an outer yarn component is placed in contact with a centre core having a tacky surface, the improvement comprising the step of contacting said outer yarn component with a binding material comprising an alloy having as a first component thereof a polymeric material and as a second com-ponent thereof a vinyl acetate polymeric material.
9. The method of claim 8 wherein said centre core comprises a carrier coated with said binding material.
10. The method of claim 8 wherein said centre core comprises an extruded filament of said binding material.
11. The method of claim 8 wherein said outer yarn component comprises fibers.
12. The method of claim 8 wherein the step of contacting said outer yarn component with a binding material comprises the step of contacting the same with a binding material comprising polypropylene and vinyl acetate.
13. The method of claim 8 wherein said vinyl acetate polymeric material is an ethylene vinyl acetate copolymer, said copolymer comprising between 20% to 70% of said binding material, said copolymer having between 20% to 28% vinyl acetate content.
14. The method of claim 9 including the step of passing said carrier through an extruder to coat the carrier with said binding material.
15. In a method of manufacturing a composite yarn product wherein a central core is passed through an extruder to coat the core with a polymeric sheath prior to contacting the sheath with fibers, the improvement wherein said polymeric sheath consists essentially of an alloy of a first polymeric material with a second ethylene vinyl acetate copolymer, the vinyl acetate content of the polymeric sheath being between about 2% and about 35%.
16. A composite yarn product having a centre core com-prised of a carrier material formed of one or more filaments selected from the group consisting of polyester or glass material, a binding material, and an outer yarn component adhered to said centre core through said binding material, said yarn component being comprised of staple fibers, the improve-ment wherein said binding material comprises an alloy having as a first component thereof a polymeric material and as a second component thereof an ethylene vinyl acetate copolymer constituting between 20% to 70% of said binding material, said copolymer having between 20% to 28% vinyl acetate content.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB45726/77 | 1977-11-03 | ||
| GB4572677 | 1977-11-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1108813A true CA1108813A (en) | 1981-09-15 |
Family
ID=10438331
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA314,071A Expired CA1108813A (en) | 1977-11-03 | 1978-10-24 | Eva yarn compositions |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPS5477717A (en) |
| BE (1) | BE871758A (en) |
| CA (1) | CA1108813A (en) |
| DE (1) | DE2847242A1 (en) |
| FR (1) | FR2407996A1 (en) |
| IN (1) | IN150891B (en) |
| IT (1) | IT1203215B (en) |
| ZA (1) | ZA786037B (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1983003434A1 (en) * | 1982-03-31 | 1983-10-13 | Barnes, Alan | Flame resistant yarns and fabrics, and furnishings incorporating such fabrics |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA833443A (en) * | 1970-02-03 | J. Bobkowicz Andrew | Method and apparatus for ringless spinning of fiber-polymer yarns | |
| BE551544A (en) * | ||||
| CA880988A (en) * | 1969-09-15 | 1971-09-14 | J. Bobkowicz Andrew | Composite fibrid yarns and method of manufacture |
| US3849929A (en) * | 1972-01-27 | 1974-11-26 | Scient Anglers Inc | Buoyant fishing line |
| GB1454503A (en) * | 1972-12-29 | 1976-11-03 | Tba Industrial Products Ltd | Asbestos reinforced plastics materials |
| GB1484667A (en) * | 1973-09-19 | 1977-09-01 | Bobtex Corp Ltd | Method and apparatus for manufacture of spun yarns |
| CA983694A (en) * | 1973-10-24 | 1976-02-17 | Emilian Bobkowicz | Apparatus and method for forming composite yarns |
| US3968283A (en) * | 1974-05-21 | 1976-07-06 | Scott Paper Company | Flocked filamentary element and structures made therefrom |
-
1978
- 1978-10-24 CA CA314,071A patent/CA1108813A/en not_active Expired
- 1978-10-26 ZA ZA00786037A patent/ZA786037B/en unknown
- 1978-10-31 DE DE19782847242 patent/DE2847242A1/en not_active Ceased
- 1978-11-01 IN IN1182/CAL/78A patent/IN150891B/en unknown
- 1978-11-02 JP JP13467378A patent/JPS5477717A/en active Pending
- 1978-11-02 FR FR7831043A patent/FR2407996A1/en active Granted
- 1978-11-03 IT IT83497/78A patent/IT1203215B/en active
- 1978-11-03 BE BE191531A patent/BE871758A/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| IT7883497A0 (en) | 1978-11-03 |
| DE2847242A1 (en) | 1979-05-10 |
| BE871758A (en) | 1979-03-01 |
| IT1203215B (en) | 1989-02-15 |
| JPS5477717A (en) | 1979-06-21 |
| ZA786037B (en) | 1979-10-31 |
| FR2407996A1 (en) | 1979-06-01 |
| FR2407996B1 (en) | 1984-01-20 |
| IN150891B (en) | 1983-01-08 |
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