High strength heat bondable fibre

Abstract: High strength melt spun fiber; preparation thereof utilizing selective, threadline oxidative, chain scission degradation of hot fiber spun from polymer component(s) with a delayed quench step, plus corresponding process and materials.

Description: Efficient, high speed spinning and processing of polyolefin fiber such as polypropylene requires careful control over the degree of chemical degradation and melt flow rate (MFR) of the spun melt, and a highly efficient quenching step for avoiding both over- or under-quench (i.e. melt fracture or ductile failure) during high speed commercial production. This invention improves control over polymer degradation, spin and quench steps and obtains fiber or filament for producing nonwoven fabrics with increased strength, toughness, integrity and heat-bonding properties. In one aspect, the present invention provides a melt spun polyolefin fiber or filament having a surface zone comprising a highly oxidative degraded polyolefin of low molecular weight, an inner zone of minimally oxidative degraded polyolefin of high molecular weight and an intermediate zone of intermediate oxidative degradation between said surface zone and said inner zone, said fiber or filament being made from a polyolefin having a broad molecular weight distribution, said fiber or filament containing at least one antioxidant/stabilizer. The expression "broad molecular weight distribution" herein denotes a molecular weight distribution (weight average/number average or M w /M n ) of at least 5.5. In another aspect, the present invention also provides a process for making a fiber or filament, comprising: A. providing a melt comprising polyolefin having a molecular weight distribution of at least 5.5 and further comprising at least one antioxidant/stabilizer; B. spinning the melt at a temperature and atmospheric environment favouring minimal oxidative chain scission degradation; C. taking up the resulting hot exudate or filament under an oxidising environment to obtain sufficient oxygen gas diffusion to effect threadline oxidative chain scission degradation; and D. fully quenching and finishing the resulting fiber or filament to obtain a highly degraded surface zone of low molecular weight, and a minimally degraded inner zone. The present invention will now be described with reference to various exemplary embodiments. Thus, a fiber or filament may be obtained by use of a process characterised by the steps of: A. admixing an effective amount of at least one antioxidant/stabilizer into a spun melt comprising olefin polymer or copolymer having a molecular weight distribution (wt. average/number average, or Mw/Mn) of at least 5.5, such as isotactic polypropylene, in the presence of a degrading agent. Typically, the polyolefin may have an M w of 195,000 to 359,000 and an M w /M n of 5.5 to 7.8. A suitable MFR (melt flow rate) for spinning being about 5-35, in the substantial absence of oxygen, oxygen-containing, or oxygen-evolving gases. Various other additives known to the polymeric fiber spinning art can also be incorporated and applied, as desired, such as pigments, colorants, pH-stabilizers, lubricants and antistatic agents in usual amounts (i.e. about 1%-10% by weight or less); B. spinning the spun melt at a temperature, preferably within a range of about 250°C.-325°C. for polypropylene, and atmospheric environment favoring little or no oxidative chain scission degradation of the polymeric component(s) within said spun melt during the spinning step; C. taking up the resulting hot extrudate (poorly quenched or essentially unquenched filament) under an oxygen-rich atmosphere to obtain sufficient oxygen gas diffusion to effect a threadline oxidative chain scission degradation of the hot extrudate or filament; and D. fully quenching and finishing the resulting filament to obtain a highly degraded surface zone of low molecular weight and low birefringence; and a minimally degraded, crystalline birefringent inner configuration, said two zones representing extreme configurations bounding and defining an intermediate zone (component (b) Figure 1) of intermediate polymeric oxidative degradation and crystallinity, the thickness of which depends essentially upon fiber cross-sectional structure and the rate of cooling of the hot extrudate or filament and oxygen concentration. A fiber or filament of this invention utilizes "broad molecular weight" polyolefin polymer or copolymer such as a polypropylene-containing spun melt having incorporated therein an effective amount of at least one antioxidant/stabilizer composition, the resulting fiber or filament, when quenched, comprising, in combination (ref. Figure 1), (a) an inner zone, shown schematically as a cross-section in Figure 1, is identified by minimal oxidative polymeric degradation, high birefringence, and a weight average molecular weight conveniently within a range of 100,000-450,000 and preferably within 100,000-250,000; (b) an intermediate zone generally externally concentric to the described inner zone and further identified by progressive (inside-to-outside progressive) oxidative chain scission degradation, the polymeric material within the intermediate zone having a molecular weight gradation less than the "a" zone of Figure 1 down to a minimum range of less than 20,000 and preferably 10,000-20,000; and (c) a surface zone generally externally concentric to the intermediate zone and defining the external surface of the spun fiber or filament, such surface zone being identified by low birefringence, a high concentration of oxidative chain scission-degraded polymeric material, and a weight average molecular weight of less than 10,000 and preferably 5,000-10,000. Figure 2 schematically represents cross-section of a corresponding bicomponent-type fiber or filament zones in which (a'), (b') and (c') are defined substantially as counterparts of elements a-c of Figure I, while element (d') represents a bicomponent core element of the same or different melt composition which is conveniently applied by use of a spin pack in a conventional manner, inner layer (a') being of a compatible (i.e. core-wettable) polymeric material. Core element, (d') is preferably formed and initially sheath-coated while in a substantially nonoxidative environment in order to avoid or minimize formation of a low-birefringent, low molecular weight interface between zones (d') and (a). The sheath and core elements of bicomponent fiber can be conventionally spun in accordance with equipment and techniques known to the bicomponent fiber art (ref. U.S. Patent 3,807,917, 4,251,200, 4,717,325 and "Bicomponent Fibers", R. Jeffries, Merrow Monograph Publ. Co., '71), except for the preferred use of nitrogen or other inert gas environment to displace and minimize oxygen diffusion into the hot spun melt or the hot core element prior to application of a sheath component around it. For present purposes the term "effective amount", as applied to the concentration of antioxidant/stabilizer compositions within the dry spun melt mixture, is defined as an amount, based on dry weight, which is capable of preventing or at least substantially limiting chain scission degradation of the hot polymeric component(s) within fiber or filament-spinning temperature range, assuming the substantialabsence of oxygen, an oxygen evolving, or an oxygen-containing atmosphere. In particular, it is the concentration of one or more antioxidant compositions sufficient to effectively limit chain scission degradation of polyolefin component of a heated spun melt composition within a temperature range of about 250°C. to about 325°C., in the substantial absence of an oxidizing environment such as oxygen, air or other oxygen/gas mixtures. The above definition, however, permits a substantial amount of oxygen diffusion and oxidative polymeric degradation commencing at or about the melt zone of the spun fiber threadline and extending downstream to a point where natural heat loss and/or an applied quenching environment lowers the fiber surface temperature to a point where oxygen diffusion into the spun fiber or filament is negligible (250°C or below for polypropylene polymer or copolymer). Generally speaking, the total combined antioxidant/stabilizer concentration usually falls within a range of about .002%-1% by weight, and preferably within a range of about .005%-0.5%, the exact amount depending on the particular rheological and molecular properties of the chosen broad molecular weight polymeric component(s) and the temperature of the spun melt; additional parameters are represented by temperature and pressure within the spinnerette itself, and the amount of prior exposure to residual amounts of oxidant such as air while in a heated state upstream of the spinnerette. Below or downstream of the spinnerette an oxygen/nitrogen gas flow ratio of 100-10:0-90 by volumeat an ambient temperature up to 200°C. plus a delayed quench step are preferred to assure adequate chain scission degradation of the polymer component and to provide improved thermal bonding characteristics, leading to increased strength, elongation and toughness of nonwovens formed from the corresponding continuous fiber or staple. The amount of degrading composition used can extend from 0% up to a concentration, by weight, sufficient to supplement the application of heat and pressure to the spun melt mix and obtain a spinnable MFR (melt flow rate) value. Assuming the use of a broad molecular weight distribution of polypropylene-containing spun melt, this constitutes an amount which, at a melt temperature range of 275°C.-320°C. and in the substantial absence of oxygen or oxygen-containing or oxygen-evolving gas, is capable of obtaining a spun melt within a 5-35 MFR range. Suitable antioxidant/stabilizer compositions, comprise one or more art-recognized antioxidant compositions inclusive of phenylphosphites such as Irgafos® 168, Ultranox® 626 (Ciba Geigy) Sandostab® PEP-Q (Sandos Chemical Co.) ; N,N'bis-piperidinyl-diamine-containing compositions such as Chimassorb® 119 or 944 (American Cyanamid Co.) ; hindered phenolics such as Cyanox® 1790 (American Cyanamid) or Irganox® 1076 or 1425 (Ciba Geigy) . The term "quenching and finishing", as here used, is defined as a process step generic to one or more of the steps of gas quench, fiber draw (primary and secondary if desired) and texturing, (optionally inclusive of one or more of the routine steps of bulking, crimping, cutting and carding), as desired. Typical spun fiber or filament obtained in accordance with the present invention can be continuous and/or staple fiber, such fiber being shown schematically in cross-section in the accompanying Figures as a monocomponent-(Figure 1) or bicomponent- (Figure 2) type, the inner zone in the former, having a relatively high crystallinity and birefringence with negligible or very small polymeric oxidative chain scission degradation. In the bicomponent-type fiber or filament, the corresponding inner layer of the sheath element is comparable in physical condition to the center cross sectional area of a monocomponent fiber, however, the bicomponent core element is not necessarily treated in accordance with the instant process or even consist of the same polymeric material as the sheath component, although preferably compatible with and wettable by the polymer forming inner zone of the sheath component. The above-described zones within Figures 1 and 2 are representative of the effect of the instant process on monocomponent and bicomponent fibers but the described zones are usually not visually ascertainable in test samples, nor can an even depth of oxygen diffusion throughout the treated fiber be assumed. As above noted, the instant invention does not necessarily require the addition of a conventional polymer degrading agent in the spun melt mix, although such use is not precluded by this invention in cases where a low spinning temperature and/or pressure is preferred, or if, for other reasons, the MFR value of the heated polymer melt is otherwise too high for efficient spinning. In general, however, a suitable MFR (melt flow rate) for initial spinning purposes is best obtained by careful choice of a broad molecular weight polyolefin-containing polymer to provide the needed rheological and morphological properties when operating within a spun melt temperature range of about 275°C.-320°C. for polypropylene. For present purposes a quenching of the bicomponent fiber is preferably delayed at the threadline, by partially blocking the quench gas, and then providing air, ozone, oxygen, or other conventional oxidizing environment (heated or ambient temperature) further downstream to assure sufficient oxygen diffusion into the sheath element and oxidative chain scission within at least surface zone (c') and preferably both (c') and (b') zones of the sheath element (ref. Figure 2). Yarns as well as webs for nonwoven material are conveniently formed from fibers or filaments obtained in accordance with the present invention by jet bulking, cutting to staple, crimping and laying down the fiber or filament in conventional ways and as demonstrated, for instance, in U.S. Patents 2,985,995, 3,364,537, 3,693,341, 4,500,384, 4,511,615, 4,259,399, 4,480,000, and 4,592,943. While Figures 1 and 2 show generally circular fiber cross sections, the present invention is not so limited. Conventional diamond-, delta-, oval-, "Y-", "X-" and dog bone-shaped cross sections are equally treatable within the instant invention. The present invention is further demonstrated, but not limited to the following Examples: EXAMPLE I Dry melt spun compositions identified hereafter as SC-1 through SC-12 are individually prepared by tumble mixing linear isotactic polypropylene flake identified as "A"-"D" in Table I (Himont Incorporated) and having Mw/Mn values of 5.35 to 7.75 and a Mw range of 229,000-359,000, which are admixed respectively with about 0.1% by weight of conventional stabilizer(s) (see above). The mix is then heated and spun as circular cross section fiber at a temperature of about 300°C. under a nitrogen atmosphere, using a standard 782 hole spinnerette at a speed of 750-1200 M/m. The fiber thread lines in the quench box are exposed to a normal ambient air quench (cross blow) with up to about 5.4% of the upstream jets in the quench box blocked off to delay the quenching step. The resulting continuous filaments, having spin denier within a range of 2.0-2.6 dpf (2.2-2.9 dtex), are then drawn (1.0 to 2.5X), crimped (stuffer box steam), cut to 1.5 inches (38 mm), and carded to obtain conventional fiber webs. Three ply webs of each staple are identically oriented and stacked (machine direction), and bonded, using a diamond design calender at respective temperatures of about 157°C. or 165°C., and 240 PLI (pounds/linear inch) (420 N/linear cm) to obtain test nonwovens weighing 17.4-22.8 gm/yd 2 (20.8-27.3 g/m 2 ). Test strips of each nonwoven (1" x 7") (25.4 mm x 177.8 mm) are then identically conventionally tested for CD strength (tensile tester from Instron Incorporated) elongation and toughness based on stress/strain curve values. The fiber parameters and fabric strength are reported in Tables II-IV, below, using the polymers described in Table I, the "A" polymers being used as controls. EXAMPLE 2 (Controls) Example I is repeated, utilizing polymer A and/or other polymers with a low Mw/Mn of 5.35 and/or full (nondelayed) quench. The corresponding webs and test nonwovens are otherwise identically prepared and identically tested as in Example 1. Test results of the controls, identified as C-1 through C-9 are reported in Tables II-IV. Spun Mix Polymer Identification M w (g/mol) Sec Mn (g/mol) M w/ M n Intrinsic Visc. IV (decileters/g) MFR (gm/10 min) A 229,000 42,900 5.35 1.85 13 B 359,000 46,500 7.75 2.6 5.5 C 290,000 44,000 6.59 2.3 8 D 300,000 42,000 7.14 2.3 8 Melt Sample Polymer MWD Spin Temp °C. Area % Quench Box Blocked Off Comments C-1 A 5.35 298 3.74 Control SC-1 C 6.59 305 3.74 > 5.5 MWD SC-2 D 7.14 309 3.74 > 5.5 MWD SC-3 B 7.75 299 3.74 > 5.5 MWD C-2 A 5.35 298 3.74 Control < 5.5 MWD C-3 A 5.35 300 3.74 Control < 5.5 MWD C-4 A 5.35 298 3.74 Control < 5.5 MWD SC-4 D 7.14 309 3.74 No stabilizer SC-5 D 7.14 312 3.74 --- SC-6 D 7.14 314 3.74 --- SC-7 D 7.14 309 3.74 --- SC-8 C 6.59 305 5.38 SC-9 C 6.59 305 3.74 C-5 C 6.59 305 0 Control/Full Quench C-6 A 5.35 290 5.38 Control < 5.5 MWD C-7 A 5.35 290 3.74 Control < 5.5 MWD C-8 A 5.35 290 0 Control < 5.5 MWD SC-10 D 7.14 312 3.74 C-9 D 7.14 312 0 Control/Full Quench SC-11 B 7.75 278 4.03 --- SC-12 B 7.75 299 3.74 --- SC-13 B 7.75 300 3.74 --- Melt Sample FIBER PROPERTIES Tenacity (g/den) Elongation % Comments MFR (dg/min) MWD dpf C-1 25 4.2 2.50 1.90 343 Effect of MWD SC-1 25 5.3 2.33 1.65 326 SC-2 26 5.2 2.19 1.63 341 SC-3 15 5.3 2.14 2.22 398 C-2 17 4.6 2.28 1.77 310 Additives C-3 14 4.6 2.25 1.74 317 Effect C-4 21 4.5 2.48 1.92 380 Low MWD SC-4 35 5.4 2.28 1.59 407 High MWD SC-5 22 5.1 2.33 1.64 377 Additives SC-6 14 5.6 2.10 1.89 357 Effect SC-7 17 5.6 2.48 1.54 415 SC-8 23+ 5.3 2.64 1.50 327 Quench SC-9 25 5.3 2.33 1.65 326 Delay C-5 23 5.3 2.26 1.93 345 C-6 19 4.5 2.28 1.81 360 Quench C-7 17 4.5 2.26 1.87 367 Delay C-8 18 4.5 2.28 1.75 345 SC-10 22 5.1 2.33 1.64 377 Quench C-9 15 5.2 2.18 1.82 430 Delay SC-11 11 5.4 2.40 2.00 356 --- SC-12 15 5.3 2.14 2.22 398 --- SC-13 24 5.1 2.59 1.65 418 ---

Claims: A melt spun polyolefin fiber or filament having a surface zone comprising a highly oxidative degraded polyolefin of low molecular weight, an inner zone of minimally oxidative degraded polyolefin of high molecular weight and an intermediate zone of intermediate oxidative degradation between said surface zone and said inner zone, said fiber or filament being made from a polyolefin having a molecular weight distribution of at least 5.5, said fiber or filament containing at least one antioxidant/stabilizer. A fiber or filament according to claim 1 wherein the polyolefin is propylene homopolymer or copolymer. A fiber or filament according to claim 1 wherein the polyolefin is propylene homopolymer. A fiber or filament according to claim 1, 2 or 3 wherein said polyolefin has a molecular weight distribution of at least 6.59. A fiber or filament according to claim 4 wherein said polyolefin has a molecular weight distribution of at least 7.14. A fiber according to. any of the preceding claims which is a staple fiber. A fiber or filament according to any of the preceding claims wherein the inner zone polyolefin has a weight average molecular weight of from 100,000 to 450,000 grams/mole. A fiber or filament according to claim 7 wherein the inner zone polyolefin has a weight average. molecular weight of from 100,000 to. 250,000 grams/mole. A fiber or filament according to any of the preceding claims wherein the polyolefin has a melt flow rate of from. 5 to 35 dg/min. A fiber or filament according to any of the preceding claims wherein the surface zone. polyolefin has a weight average molecular weight of less than 10,000 grams/mole. A fiber or filament according to claim 10 wherein the surface zone polyolefin has a weight average molecular weight of from 5,000 to 10,000 grams/mole. A fiber or filament according to any of the preceding claims wherein the inner zone has a high birefringence, and the surface zone has a low birefringence. A fiber or filament according to any of claims 1-12 wherein the intermediate zone is. generally externally concentric to the inner zone and has progressive oxidative chain scission degradation with a molecular weight range of slightly less than the inner zone to 10,000-20,000. A fiber or filament according to any of the preceding claims wherein the polyolefin having a molecular weight distribution of at least 5.5 contains 0.002 to 1 % by weight of an antioxidant/stabilizer composition. A fiber or filament as claimed in claim 14 wherein the polyolefin contains 0.005 to 0.5% by weight of the antioxidant/stabilizer composition. A fiber or filament according to any of the preceding claims containing at least one antioxidant/stabilizer composition selected from the group consisting of phenylphosphites, N,N' bis-piperidinyl-diamine-containing compositions, and hindered phenolics, and mixtures thereof. A fiber or filament according to any of the preceding claims containing a degrading agent. A fiber or filament according to any of claims 1-16 that does not contain a degrading agent. A fiber or filament according to any of the preceding claims which is a monocomponent fiber or filament. A fiber or filament according to any of claims 1-19 which is a sheath-core bicomponent fiber or filament and the inner zone is part of the sheath that is internally contiguous with and generally externally concentric to a core element. A process for making a fiber or filament, comprising: A. providing a melt comprising polyolefin having a molecular weight distribution of at least 5.5 and containing at least one antioxidant/stabilizer; B. spinning the melt at a temperature and atmospheric environment favouring minimal oxidative chain scission degradation of the polymeric component(s) within the melt during the spinning step; C. taking up the resulting hot extrudate or filament under an oxidising environment to obtain sufficient oxygen gas diffusion to effect threadline oxidative chain scission degradation; and D. fully quenching and finishing the resulting fiber or filament to obtain a highly degraded surface zone of low molecular weight, and a minimally degraded inner zone. A process according to claim 21 wherein the polyolefin is propylene homopolymer or copolymer. A process according to claim 21 wherein the polyolefin is propylene homopolymer. A process according to claim 21, 22 or 23 wherein said polyolefin has a molecular weight distribution of at least 6.59. A process according to claim 24 wherein said polyolefin has a molecular weight distribution of at least 7.14. A process according to any of claims 21-25 wherein step D comprises cutting to form a staple fiber. A process according to any of claims 21-26 wherein step D comprises crimping. A process according to any of claims 21-27 comprising controlling quenching of the hot extrudate in the oxidising environment so as to effect the oxidative chain scission degradation of the surface. A process according to any of claims 21-28 comprising delaying quenching of the hot extrudate. A process according to claim 28 or 29, wherein the oxidising environment comprises a cross-blow quench. A process according to claim 30 wherein the fiber or filament is passed through a quench box in which it is exposed to the cross-blow quench with. up to 5.4% of the upstream jets in the quench box blocked off to delay the quenching step. A process according to any of claims 21-31 wherein in step B. the spinning the melt comprises passing the melt through a spinnerette and in steps C and D below or downstream of the spinnerette an oxygen/nitrogen gas flow ratio of 100-10:0-90 by volume at ambient temperature up to 200°C plus a delayed quench step are used to obtain chain scission degradation of the polymer. A process according to any of claims 21-32 further comprising maintaining temperature conditions. of the hot extrudate so as to effect gas diffusion into the. hot extrudate to effect oxidative chain scission degradation. A process according to any of claims 21-33 wherein the oxidising environment is air. A process according to any one of claims 21-34 wherein the polyolefin is polypropylene, wherein the melt is spun in step B at a temperature of from 250 to 325°C and wherein the temperature of the spun fiber or filament is brought to below 250°C in step D. A process according to any of claims 21-35 wherein the inner zone has a high birefringence, and the outer zone has a low birefringence. A process according to any of claims 21-36 wherein the surface zone and the inner zone define an intermediate zone of intermediate polymeric oxidative degradation and crystallinity. A process according to any of claims 21-37 wherein the melt also comprises an effective amount of at least one antioxidant/stabilizer. A process according to claim 38 wherein the melt consists essentially of the polypropylene and the antioxidant/stabilizer composition. A process according to claim 38 or 39 wherein the antioxidant/stabilizer composition is selected from the group consisting of phenylphosphites, N,N' bis-piperidinyl diamine-containing compositions, and hindered phenolics, and mixtures thereof. A process according to claim 38, 39 or 40 wherein said antioxidant/stabilizer is present in an amount of from 0.002 to 1 % by weight. A process according to claim 41 wherein said antioxidant/stabilizer is present in an amount of from 0.005 to 0.5% by weight. A process according to any of claims 21-42 wherein the fiber or filament is a monocomponent fiber or filament. A process according to any of claims 21-43 wherein the polyolefin consists essentially. of isotactic propylene homopolymer. A non-woven fabric or material obtainable by bonding. fibers and/or filaments according to any of claims 1-20 or by a process according to any of claims 21-44. A non-woven fabric or material according to claim 45 obtainable by thermally bonding the fibers and/or filaments. A non-woven fabric or material according to claim 45 obtainable by carding and thermally bonding the fibers and/or filaments.

Inventors: KOZULLA RANDALL EARL, KOZULLA, RANDALL EARL
Applicants: FIBERVISIONS L P, FIBERVISIONS, L.P.
Application year: 1991
Main classification: D01F6
IPC codes: D04H1, D01F8, D01F6, D01F1