Patent ID: 6251322
Filing Date: 2001-06-26
Classification: A61F,A61L,D01D

Abstract:
A process for making a distorted, bulky synthetic polymeric fiber comprising the steps of:(a) extruding a molten polymer from an aperture of a spinnerette to form an extruded polymer, the aperture having a non-round shape;(b) cooling the extruded polymer to form a fiber having an as spun cross-section shape;(c) lubricating the fiber;(d) transporting the fiber at a speed of between 500 and 3500 meters per minute;(e) forming the fiber into a tow;(f) shrinking the fiber by disposing the tow in an environment having a sufficient temperature to effect shrinking of the fiber to form a shrunk fiber having a shrunk denier at least five percent greater than a pre-shrunk denier, wherein the tow is delivered to the environment at a first speed and removed from the environment at a second speed which is slower than the first speed; and(g) cutting the shrunk fiber to form a shrink-cut fiber, wherein the shrink-cut fiber has a length of between 2 and about 37 millimeters, a single fiber bulk factor between 0.5 and 10.0, a short range distortion factor greater than 5, and a long range distortion factor between 0.05 and 0.9.