Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/04—Pigments
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/06—Dyes
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides

Definitions

• the present invention is generally directed to pigmented polyamide fibers and processes for making them. More particularly, the present invention is directed to a nylon 6,6 fiber containing carbon black.
• Nylon fiber is widely used in the manufacture of textile materials, carpet yarn, and apparel products.
• nylon fiber may be colored using a variety of techniques.
• One method is to include a pigment in the polymer melt from which the nylon fiber is spun. Molten polymer is extruded through capillaries in a spinneret. As the molten polymer solidifies, fibers are formed. If black fibers are desired, carbon black may be used in the color concentrate. As the amount of carbon black is increased in the polyamide fibers, the physical properties can significantly change such as the breaking strength. This may also cause the spinning characteristics of the yarn to change. One skilled in the art may conclude that this is caused by the color concentrate lowering the RV of the yarn and causing nucleation in the yarn. Inadequate carbon black particle distribution may be the source of the problems especially when the polyamide is nylon 6,6.
• the present invention is generally directed to a fiber containing nylon 6,6, carbon black, and copper phthalocyanine colorant.
• the carbon black concentration may be up to about 2% of the fiber by weight, and the concentration of copper phthalocyanine colorant may be up to 4% of the fiber by weight.
• This fiber exhibits improved spinning characteristics when making yam such as an increase in drawforce, an increase in tenacity, and a decrease in filament breaks.
• the yam also has improved physical properties over other yams with high carbon black concentrations.
• the present invention may additionally contain a copolymer.
• the copolymer is selected from the group including nylon 6,6 with 2% nylon 6, nylon 6,1, nylon 6, sulfonated IA, nylon 6,9, nylon 6,10, nylon 6,T, nylon 6/12, nylon 11, nylon 12 and mixtures thereof.
• nylon 6,6 with 2% nylon 6, nylon 6,1, nylon 6, sulfonated IA, nylon 6,9, nylon 6,10, nylon 6,T, nylon 6/12, nylon 11, nylon 12 and mixtures thereof.
• the present invention is also directed to the processes of forming the fibers described above. DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
• Fiber is any continuous filament or staple form of a polyamide polymer which may be spun, knitted, woven, pressed, tufted and otherwise formed in the manufacturing of carpets or other textile materials;
• “yam” is any spun material made from natural or synthetic fibers or mixtures or blend thereof.
• copper phthalocyanine colorant is any of the polymorphic crystalline forms of copper phthalocyanine and blends of such forms. A complete description of copper phthalocyanine colorants may be found in Analytical Chemistry of Synthetic Dyes, editor K. Van Kataraman, J. Wiley & Sons (1977), the entire contents of which are incorporated herein by reference.
• One aspect of the present invention is generally directed to a nylon 6,6 fiber with carbon black, and copper phthalocyanine colorant.
• copper phthalocyanine colorant When copper phthalocyanine colorant is added to the nylon 6,6 with a high carbon black concentration of up to 2% by weight, no appreciable nucleation occurs. There is also excellent carbon black dispersion, lower elongation, and higher breaking strength when the fiber is spun into a yam.
• the amount of copper phthalocyanine colorant in the final fiber composition may be between 0.0001% and 4 % by weight.
• the preferred amount of copper phthalocyanine colorant is such that the fiber composition has a final weight, percent of 0.005 to 0.2 of copper phthalocyanine colorant.
• a copolymer is formed by adding nylon 6 to the nylon 6,6 in addition to the carbon black and copper phthalocyanine colorant to form a pigmented polymer.
• the copolymer may comprise nylon 6,6 in an amount of about 95.0 to about 99.5 wt %, preferrably about 96 to about 99 wt %, and more preferably about 97 to about 98 wt % by weight of the copolymer.
• the remainder of copolymer may contain nylon 6 in an amount of about 0.5 to about 5.0 wt %, preferably about 1 to about 4 wt %, and more preferably about 2 to about 3 wt % by weight of the copolymer.
• the pigmented polymer may contain up about 2 wt % of carbon black (preferably about 0.5 to about 2.0 wt %) and up to 4 wt % copper phthalocyanine colorant (preferably about 0.005 to about 0.3 wt %) by weight of the pigmented polymer. If the colorant and pigment are added in the form of a concentrate, then the concentrate is present in an amount of about 1 to about 10 wt %, preferably about 2 to about 7 wt %, and more preferably about 3 to about 5 wt %, by weight of the pigmented polymer, with the remainder being made of the copolymer.
• the concentrate may contain the desired amounts of pigment and colorant in order to achieve the amounts specified herein with regard to the resulting pigmented polymer.
• the polymer in the concentrate is nylon 6.
• the yam also has a softer, slicker feel.
• drawforce Dense Fil
• Typical partially oriented ya s have a drawforce of 85 to 90 cN, elongation percent of approximately 70% and a tenacity of approximately 4.5 grams/denier.
• the yams of the present invention may be made by using the pigmented polymer and then producing the yams by standard techniques.
• the pigment and colorant may be added in neat form directly to the copolymer, or by forming one or more pigmented concentrates containing the pigment and/or colorant compounded with a polymer, preferably nylon 6, and then letting the concentrate down into the copolymer.
• a pigmented concentrate may be formed by mixing the carbon black with the copper phthalocyanine blue in a desired ratio and then compounding the mixture with nylon 6.
• the pigmented concentrate(s) may then be blended with a suitable copolymer, such as nylon 6,6 polymerized with nylon 6, and subsequently melt spinning the blended pigmented polymer into fibers and/or yams.
• MODSTF modulus stiffness at 1.0% elongation
• EXAMPLE 1 is elongation at 110.0 gram load All tests were performed on a Perkin Elmer DSC and an Instron Tensile Tester. EXAMPLE 1
• a nonpigmented yam is compared to three black pigmented yarns.
• Tables 1 and 2 contain the physical property test results of the three mass pigmented black nylon 6,6 yams and the nonpigmented nylon 6,6 control.
• Each of the samples is a 95 denier / 34 filament partially oriented ya .
• Samples 1-3 are spun at 4,500 meters per minute and Sample 4 is spun at 4,800 meters per minute.
• Sample 1 is 97.975% nylon 6,6, 2% nylon 6 and 0.0125% TiO 2 for brightness and has a RV of 41, 47.5 amine end groups and 9 parts per million Mn.
• Sample 2 is pigmented by adding about 4% PAF-50, a commercial carbon black concentrate from Magenta Master Fibers to the yam used in Sample 1.
• Samples 3 and 4 are formed by adding a concentrate to the yam used in Sample 1.
• the concentrate is formed by compounding 20 % carbon black with 0.4 % copper phthalocyanine blue and 79.6% of nylon 6.
• the carbon black and copper phthalocyanine are compounded to form a concentrate before they are blended with the copolymer.
• About 4% of this concentrate is added to the copolymer used in Sample 1 to form Samples 3 and 4.
• Samples 3 and 4 which are made according to the present invention, have improved breaking strength, elongation and tenacity as compared to the black pigmented yarn without copper phthalocyanine blue.
• compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Textile Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Artificial Filaments (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Publications (2)

Family

ID=23093915

Family Applications (1)

Country Status (8)

Cited By (1)

Families Citing this family (3)

Family Cites Families (4)

• 2002
  • 2002-04-22 CN CNA028084861A patent/CN1735656A/zh active Pending
  • 2002-04-22 AU AU2002307471A patent/AU2002307471A1/en not_active Abandoned
  • 2002-04-22 KR KR10-2003-7013608A patent/KR20040010625A/ko not_active Withdrawn
  • 2002-04-22 BR BR0208954-8A patent/BR0208954A/pt not_active IP Right Cessation
  • 2002-04-22 IL IL15844702A patent/IL158447A0/xx unknown
  • 2002-04-22 JP JP2002583714A patent/JP2004525276A/ja not_active Withdrawn
  • 2002-04-22 EP EP02764291A patent/EP1397426A4/en not_active Withdrawn
  • 2002-04-22 WO PCT/US2002/012657 patent/WO2002086204A2/en not_active Application Discontinuation

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