Heterofilament composite yarn, heterofilament and wire reinforced bundle

Abstract: A heterofilament of a PBT sheath, a multifilament composite yarn composed of a plurality of heterofilaments having PBT sheath, and a conductive bundle containing a wire wrapped with a plurality of the multifilament composite yarn.

Description: Field of Invention This invention is directed to heterofilament composite yarns and more particularly relates to such yarns composed of a plurality of heterofilaments, each having a polymeric core component and a sheath component of poly(butylene terephthalate). Background of the Invention Yarn in this invention is defined as a continuous strand of textile filament having a number of individual heterofilaments optionally laid together without twist. Multifilament composite yarns are disclosed in U.S. Patent 3,645,819. Such yarns are characterized as a unit composite having a core component and matrix or sheath component whose melting point is different from that of the core component, and assembling a plurality of the unit composites into a bundle and melting the sheath component forming a composite yarn. Polymeric material used include polyamide, polycaprolactam, poly-hexamethylene-adipamide, polyethylene terephthalate, polypropylene, polyethylene, polyacetal, polyvinyl chloride, polystyrene and copolymers of these polymers. The sheath component is a polyamide polymer. Also, the yarns are characterized as having a rough surface for the prevention of yarn slippage and has voids in the yarn. Such yarns are disclosed for use in tires, in particular, the chafer fabric of tires. U.S. Patent No. 5,162,153 discloses a sheath/core bicomponent fiber having a specific poly(butylene terephthalate) copolymer made from dimethyl terephthalate and a blended product of dimethyl adipate, dimethyl glutarate and dimethyl succinate, with butanediol and hexanediol. The yarns of the present invention are generally used either as monofilament replacements or for use as reinforcement in industrial materials, or in various components of tires. Such uses are predicated on properties of the yarn, in particular for heterofilaments, properties of the core component. Accordingly, there is a need to find a suitable heterofilament composite yarn having a wide variety of properties that may be used in monofilament applications as well as industrial uses and as components in tires. Summary of the Invention This invention is directed to a heterofilament, a multifilament composite yarn and a method to make the multifilament composite yarn. The heterofilament includes a polymeric core of polyester or polyamide and a sheath component of poly(butylene terephthalate). The multifilament composite yarn includes multiple thermally bonded sheath-core heterofilaments comprising a core component composed of a synthetic polymeric material with a melting point temperature and a sheath polymeric component surrounding the core component. The sheath component consists essentially of poly(butylene terephthalate) polymer having a melting point temperature lower than that of the core polymeric material. The heterofilaments are thermally bonded together to form the multifilament composite yarn. Detailed Description of the Invention Heterofilaments are known in the art (e.g., see U.S. Patent Nos. 3,616,183; 3,998,988 and 3,645,819 . Heterofilaments are known as "bi-component fibers", "conjugate fibers", "heterofils", or "composite fibers". The document EP-A 0 551 832 describes a first multifilament yarn which is composed of polyethylene terephthalate and is twisted together with a second multifilament yarn, which may be composed of polybutylene terephthalate. The first yarn is composed only of PET filaments and the second yarn is composed only of PBT filaments, whereby the first and second yarns are not thermally bonded heterofilaments of PET and PBT. US-A-4 518 658 discloses waterproof membranes consisting of a non-woven bitumen-coated reinforcement of heat-bonded continuous filaments containing polyethylene glycol terephthalate and polybutylene glycol terephthalate, whereby the two polymers are coaxial to each other, comprising the polyethylene glycol terephthalate in the core and the polybutylene glycol terephthatlate in the sheath. There is formed a web of individual filaments from an opened bundle of filaments and the resulting web is presumably heated at the intersecting points of the filaments to effect bonding of the filaments. JP-B-45 003 291 is related to a fibrous composite comprising a bundle of fibres in the state of paralleled yarn in which continuous fibres having low melting point temperature are surrounding a continuous fibre having high melting point temperature. None of the fibres is made from polybutylene terephthalate or any other polyester homopolymer. Only copolyesters are described as possible sheeth components. Heterofilament, as used herein, refers to a filament made from a thermoplastic, synthetic, organic polymer comprised of a relatively high melting polymer core component and a relatively low melting sheath component. Generally, the heterofilaments are either a sheath/core type or a side-by-side type. In either embodiment, both components of the heterofilament will be present in a continuous phase. The sheaths comprise 30 % or less of the cross-sectional area of the heterofilaments. Preferably, a sheath/core heterofilament is used, with the core comprising of about 80 % by volume of the heterofilament. The high-melting point polymer core component may have a melting point about 30 °C greater than that of the lower melting point polymer component. In any way the second polymeric component, e.g. the lower melting point temperature component has a melting point which is at least 15°C lower than the melting point temperature of the first component. The high-melting point polymer core component may be a polyester or a polyamide. The polyester may be polyethylene terephthalate (PET). The polyamide may be nylon-6 or nylon-6,6. Preferred high melting point core components do possess the properties disclosed in the Davis et al. U.S. Patent No. 4,101,525. Thus a preferred core component possesses a stability index value of 6 to 45 obtained by taking the reciprocal of the product resulting from multiplying the shrinkage at 175 °C in air measured in percent times the work loss at 150 °C when cycled between a stress of 0.6 gram per denier and 0.05 gram per denier measured at a constant strain rate of 1,27cm (0.5 inch) per minute in cm-1.75N (inch-pounds) on a 25,4cm (10 inch) length of yarn normalized to that of a multifilament yarn of 1000 total denier, and a tensile index value greater than 825 measured at 25 °C obtained by multiplying the tenacity expressed in grams per denier times the inital modulus expressed in grams per denier and preferably a birefringence value of + 0.160 to + 0.189. The low-melting point polymer sheath component is polybutylene terephthalate (PBT). Heterofilaments of the present invention may be spun using the method and apparatus described in U.S. Patent No. 5,256,050. In producing heterofilaments having a high-melting point polymer core component of PET and a low-melting point polymer sheath component of PBT, the PET has a typical melting point temperature of 250 °C unless modified to lower the temperature. The melting point of highly crystalline PET is about 270 °C. The melting point of PBT depends on its degree of crystallization, ranging from 225 to about 235 °C. The composite yarns are formed from a bundle of heterofilaments which are drawn and heated. The yarn number is at least about 50 filaments. Typically, the bundle of heterofilaments is drawn in the range from about 2x to about 6x. Then the yarn is relaxed 2% before winding up. Then the yarn is passed through a heated zone under tension. The temperature in the zone is from about 220 °C to about 320 °C; time is from about 4 sec to about 30 sec; and the amount of tension is about 1 to 2 gpd (grams per denier). Actual conditions are determined by the apparatus and needs of the product. If for example the yarn is passed continuously through an oven the temperature is held high enough to cause the sheath material to fuse and flow. The operating temperature is found by a combination of expertise and trial and error and is dependent on such factors as the denier of the yarn, the velocity of the yarn, the length of the heated zone, and the rate of heat transfer. Several methods have been used to compress the multifilaments into bonded cords (linear composites). Method 1: The multifilament yarn is twisted to 0.39 to 0.79 turns per cm (1 to 2 turns per inch) prior to passing it through the heated zone. In this case no compression device other than tension on the yarn is needed. Method 2: The yarn (if the yarn denier is not sufficient several yarn bundles can be plied together) is passed through a heated zone as described above. At the exit of the zone the yarn is passed around a set of three free wheeling rolls with grooves cut about 4 cm in diameter and positioned relative to each other about 6 cm apart at the apexes of an equilateral triangle. A typical groove is U shaped and conforms to the dimensions of the bonded cord. However any practical shape is possible depending on the desired cross section of the composite. Method 3: This method is like method 2 except that the compression device consists of a converging nozzle into which the yarn is fed. The exit hole of the nozzle is the same shape as the desired cross section of the composite and is sized so that the yarn fully fills it and produces a composite with no voids. Note that practical methods of providing a heating zone have been found to be hot air ovens or hot rolls in the case of methods 2 and 3. The thickness of the heterofilaments of the present invention ranges from about 1.11 to about 27.75 dtex (about 1 to about 25 denier), and more preferably between 2.22 and 16.65 dtex (2 and 15 denier). The number of heterofilaments contained within a multifilament yarn is determined according to the requirement of the end use. Typically the thickness of the composite yarn is from about 55.5 to about 88,800 dtex (about 50 to about 80,000 denier), containing from about 6 to about 26,000 heterofilaments. General physical properties of the yarn are similar to that of a typical homofil PET yarn. Thus yarns can be produced by those skilled in the art to approximate to any property that can be achieved with PET using an appropriate process. Thus a typical yarn produced by a process route disclosed in U.S. Patents 4,101,525 and 4,414,169 would have a tenacity of 7.2 g/dtex (8.0 gpd) and elongation of 10 % and a hot air shrinkage at 175 °C of 8 %. Such composite yarns have many uses such as in power transmission belts, chafer fabric for tires, tire cord, and monofilamental applications. Also, the composite yarn may be used in combination with a conductive means such as a wire. In particular, a plurality of composite yarns, 3 for example, may be wrapped around or twisted around a copper wire to create a composite yarn/wire bundle. The bundle is then passed through a heated oven with 1 - 7 % stretch to fuse the yarn into a reinforced sheath encapsulating the wire. This makes a conductive yarn for electrostatic dissipation or for abrasion resistance. Examples Example 1: A heterofilament consisting of polyethylene terephthalate (PET) in the core and polybutylene terephthalate (PBT) in the sheath is spun using the heterofil spinning process disclosed in the U.S. Patent No. 5,256,050. Spinning conditions were set to simulate those that would produce high modulus polyester fibers as described by Davies et al (U.S. Patent No. 4,101,525) and McClary (U.S. Patent No. 4,414,169). Thus a 3110 dtex/330 filament yarn was spun at a speed of 1370 m/min with a core composed of 0.92 IV (intrinsic viscosity; measured in dichloro acetic acid at 25 °C) PET and a sheath of 1.00 IV (intrinsic viscosity; measured in dichloro acetic acid at 25 °C) PBT in the ratio of 8 : 2. The spinning temperature was 300 °C. Quench air was applied between 5 cm/sec. These conditions typically give a spun yarn orientation of about 0.03 birefringence. This yarn was drawn in two stages to a total draw ratio of 2.2. The yarn was then passed around a roll at 220 °C and relaxed 2 % before winding up to give a final denier of 1280 1421 dtex. At this stage the yarn, which still has the appearance of a multifilament, was plied three times and then passed through a heated zone at 238 °C (460 °F) for 60 seconds under tension. In that zone a compression device was used to compact the filaments into a monofilament. The device consisted of three free wheeling rolls with grooves cut into them to control the monofil shape. These small diameter rolls (4 cm) were positioned at the apex of a equilateral triangle with a side length of 6 cm. The following properties were obtained. DTex. 4577 Tenacity 6.32 g/dtex Elongation 10.9 % Initial modulus 79.5 g/dtex Hot air shrinkage 1.48% @ 177°C (350 °F) Testrite shrinkage 0.74% @ 0.055 g/dtex Aspect ratio 3 : 1 By comparison the properties of the PET monofil obtained under the conditions found to optimize its properties were: DTex. 4024 Tenacity 5.69 g/dtex Elongation 20.2 % Initial modulus 52.7 g/dtex Hot air shrinkage 3.96 % @ 177°C (350 °F) Testrite shrinkage 1.26 % @ 0.055 g/dtex Aspect ratio 1.5 : 1 Thus the yarn had 11 % better strength, 50 % higher modulus, 40 % of the shrinkage than the conventional monofil. All these properties directions are desirable for rubber reinforcement. The lateral integrity of the yarn was tested by conducting a rubber peel adhesion test. The yarn was treated by applying a standard tire cord epoxy adhesive followed by an RFL latex at a condition standard for tire cord. The yarn was then vulcanized into a rubber pad and the peels carried out. The peels indicated that the tear failure was all in the rubber and none within the monofil. This indicates very good lateral strength. If the lateral bonding had been poor, the filaments within the yarn would have separated. This is a condition which is sometimes seen in filaments and monofils prone to fibrillation. Example 2: A heterofil yarn was prepared under the same conditions as given in example 1 except that the PET : PBT ratio was 7 : 3. The 1100 dtex (1000 denier) yarn was plied 4 times and fed to a pair of hot rolls set at a temperature of 240 °C at 100 m/min. The rolls were 20.3 cm (8") diameter and 8 turns (wraps) of yarn were put on the rolls. The yarn coming off the rolls was fed into a converging nozzle with an exit hole shape like an oval with an L : S ratio of 1.5 : 1. The yarn was fed from this device to a second pair of cold rolls under a slight tension. From these rolls it was wound up on a bobbin. The resulting composite cord had a smooth appearance similar to a conventional monofil. The tensile properties were tenacity 5.35 g/dtex (5.94 gpd), elongation 11.0 % and initial modulus 76.6 g/dtex (85 gpd). Cross-section of the composite showed an oval shaped cross-section with an L : S ratio of 1 : 5 and no voids in the structure.

Claims: A multifilament composite yarn comprising multiple thermally bonded heterofilaments, each heterofilament comprising a first component composed of a synthetic polymeric material having a given melting point temperature and a second polymeric component consisting essentially of poly(butylene terephthalate) polymer having a melting point temperature lower than said given melting point of said synthetic polymeric material said second polymeric component being combined with said first component; wherein said heterofilaments are thermally bonded together to form a multifilament composite yarn. The multifilament composite yarn of claim 1, wherein said heterofilaments are of the side-by-side type or, preferably of the sheath/core type. The multifilament composite yarn of claim 1, wherein the heterofilaments are sheath/core heterofilaments. The multifilament composite yarn of claim 3, wherein the first component comprises the core and the second polymeric component comprises the sheath. The multifilament composite yarn of claim 1, wherein the first component is polyester or polyamide. The multifilament composite yarn of claim 1, wherein the first component is polyethylene terephthalate. The multifilament composite yarn of claim 1, wherein said second polymeric component has a melting point at least 15 °C lower than said given melting point temperature of said first component. The multifilament composite yarn of claim 2, wherein the sheaths comprise 30 % or less of the cross sectional area of said heterofilaments. The multifilament composite yarn of claim 1, wherein the yarn number is at least about 50 filaments. The multifilament composite yarn of claim 4, wherein the first component is polyester and wherein the core has a tenacity of at least 5.35 g/dtex [5.94 g/denier]. A method of manufacturing a multiflament composite yarn comprising: providing a plurality of individual heterofilaments each comprising a first component composed of synthetic polymeric material having a given melting point temperature and a second polymeric component consisting essentially of poly(butylene terephthalate) polymer having a lower melting point temperature than said synthetic polymeric material, said first component being combined with said second component; bundling together said plurality of individual hetereofilaments to form a multifilament composite; and melting the second component of the heterofilaments at a temperature between the melting point temperatures of said first and second components into a multifilament composite yarn. The method of claim 11, wherein said heterofilaments are of the side-by-side type or preferably of the sheath core type. The method of claim 11 wherein said first component is selected from a group consisting of polyester and polyamide. The method of claim 11, wherein said synthetic polymeric material is polyethylene terephthalate. The method of claim 11, wherein said melting point temperature of said first component is higher than that of said second component by at least 15 °C. The method of claim 12, wherein the heterofilaments are sheath/core filaments and the first component, forming the core, is polyester and the second polymeric component is forming the sheath, and wherein the core has a tenacity of at least 5.35 g/dtex [5.94 g/denier]. A sheath/core heterofilament comprising a high melting point temperature first component of polyester and a low melting point temperature second component consisting essentially of poly(butylene terephthalate) polymer having a melting point temperature lower than said high melting point temperature first component, the first component comprising the core and the second component comprising the sheath and the core having a tenacity of at least 5.35 g/dtex [5.94 g/denier]. The sheath/core heterofilament of claim 17, wherein the first component is polyethylene terephthalate. A wire reinforced bundle comprising a plurality of multifilament composite yarn twisted around a metallic wire, wherein said multifilament composite yarn comprises thermally bonded heterofilaments comprising a first component composed of a synthetic polymeric material having a given melting point temperature and a second polymeric component consisting essentially of poly(butylene terephthalate) polymer having a melting point temperature lower than said given melting point temperature of said synthetic polymeric material said first component being combined with said second component, wherein said heterofilaments are thermally bonded together to form a multifilament composite yarn. The wire reinforced bundle of claim 19, wherein said heterofilaments are of the side-by-side type or, preferably of the sheath/core type. The wire reinforced bundle of claim 20, wherein the heterofilaments are sheath/core heterofilaments wherein the first component is polyethylene terephthalate and forms the core and the second polymeric component forms the sheath.

Inventors: GIBBON JOHN D, SHERRIFF STEPHAN F, GIBBON, JOHN D., SHERRIFF, STEPHAN F.
Applicants: ARTEVA TECH SARL, ARTEVA TECHNOLOGIES S.A.R.L.
Application year: 1995
Main classification: D01F8
IPC codes: D01F8, D01D5, D02G3