Abstract:
A continuous process for spinning and drawing polyamide filaments with the steps of melting a polyamide and spinning the filaments from the molten polyamide through a spinnerette, quenching the filaments, applying a yarn finish to the filaments, applying steam and heat to the filaments by a steam and heating unit which consists of a steam box and at least one heated godet, drawing the filaments, and optionally texturing the filaments. The resulting filaments have low shrinkage, high crystallinity, and a high percentage of alpha crystals.

Description:
This is a continuation of application Ser. No. 07/860,658, filed Apr. 30, 1992, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     Polyamide yarns are commonly produced by melt spinning of one or of a plurality of filaments which are wound onto a container, stored for some time, sometimes referred to as lagging time, and subsequently in a second step drawn and textured. This two-step process produces a yarn with a high crystallinity and a low shrinkage. In addition, a high percentage of the crystals in the two-step yarn are the alpha-type which are more stable than the gamma-type crystals. 
     One step processes, often referred to as spin-draw-texture (SDT) processes, have been developed which are more efficient but which produce yarns with lower crystallinity and higher shrinkage during the heatsetting process. In addition, these yarns contain a lower percentage of the stable alpha crystals than two-step yarns. The disadvantages of these yarns are the differing deniers of comparable heatset products. 
     Another disadvantage is the very smooth surface of these yarns which leads to high yarn-to-guide friction in processing the yarns into fabrics which show undesirable non-uniformities such as streaks. 
     To overcome this latter problem, U.S. Pat. No. 3,414,646 describes a process for the production of polycarbonamide filaments using a treatment of the filaments with steam before the drawing step. 
     U.S. Pat. No. 3,761,556 discloses a process for the manufacture of a crimped polyamide yarn including a two-stage steaming process prior to drawing and crimping. 
     In order to improve ozone fading resistance of dyed nylon yarn, U.S. Pat. No. 4,396,570 describes a continuous process for spinning and drawing nylon 6 filaments by applying steam in a chamber to the filaments before the drawing step. 
     An object of the present invention was to provide a continuous process for spinning and drawing polyamide for the manufacture of polyamide yarns with a high crystallinity, a higher percentage of alpha crystals, and a low shrinkage. Another object was to provide an apparatus for such a process. 
     SUMMARY OF THE INVENTION 
     The objects of the present invention could be achieved with a continuous process for spinning and drawing polyamide filaments comprising: 
     (a) melting a polyamide and spinning the filaments from the molten polyamide through a spinnerette; 
     (b) quenching the filaments; 
     (c) applying a yarn finish to the filaments, 
     (d) applying steam and heat to the filaments by a steam and heating unit comprising a steam box and at least one heated godet; 
     (e) drawing the filaments; and optionally 
     (f) texturing the filaments. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Continuous processes for spinning and drawing polyamide filaments are known, for example, from U.S. Pat. Nos. 3,414,646; 3,761,556 and 4,396,570, hereby incorporated by reference. 
     Polyamides are well known under the generic term &#34;nylon&#34; and are long chain synthetic polymeric amides. Nylons are identified by the number of atoms in the diamine and dibasic acid, for example nylon 6/6, which stands for a polymer formed by the condensation of hexamethylene diamine and adipic acid. Other nylons are formed from only one reactive species such as an aminoacid or a lactam. Polyaminocaproic acid is produced by the polymerization of caprolactam and is known as &#34;nylon 6&#34;. Commercially available and useful for the purpose of this invention are all linear melt-spinnable polyamides. Preferred for the purpose of this invention are nylon 6, nylon 66, nylon 6/10, nylon 6/12, nylon 11, nylon 12, nylon 66T, nylon 6I6T, copolymers thereof, or mixtures thereof, and especially preferred is nylon 6. 
     In step (a) the polyamide is melted in an extruder and spun through a spinnerette to form filaments. These filaments are quenched in step (b) with a flowing quench medium such as air. 
     In step (c) a yarn finish is applied to the filament as 100% oil or as an aqueous emulsion containing from 5 to 30% finish solids. The finish could be metered onto the fiber or applied with a kiss roll. Suitable finishes could contain the following components: esters, vegetable oils, alkoxylated vegetables oils, alkoxylated acids, alkoxylated diacids, alkoxylated sorbitol esters, alkoxylated sorbitans, alkoxylated alkyl phenols, and phosphate esters. Preferred finishes contain vegetable oils, alkoxylated diacids, and phosphate esters or contain esters, vegetable oils, alkoxylated vegetable oils, alkoxylated alkyl phenols, and phosphate esters. 
     Steam and heat are applied to the filaments in step (d) by a steam and heating unit comprising a steam box and at least one heated godet. Steam is applied to the filaments by a steam box with a steam temperature of from about 60° C. to about 180° C., preferably from about 100° C. to about 150° C. and most preferably from about 120° C. to about 140° C. 
     In a preferred embodiment the filaments pass the steam box on the outside, where the steam box releases the steam out of individual steam applicator jets having a diameter of from about 0.1 to about 2.0 mm, preferably from about 0.5 to about 1.0 mm. 
     In a preferred embodiment, the number of applicator jets corresponds with the number of steps in the stepped-out godet used in step (d). 
     Preferably the steam box is located between two godets. 
     The jets releasing the steam are preferably on both sides of the steam box, where the steam is applied to the passing filaments. For a better alignment of the filaments in order to pass the jets, the jets of the steam box are Located in slots. The advantage of this steam box is that there arise no problems with condensing water because the steam is released in the air and evaporates. The water, condensed in the steam box is separated by an exhaust pipe. In embodiments where the filaments pass inside the steam box, problems always arise with the condensation of water on the filaments. 
     In step (d) preferably two godets are used, at least one of which could be heated. The godets may be heated electrically or with steam to a temperature of from about 60° C. to about 180° C., preferably from about 100° C. to about 160° C. and most preferably from about 120° C. to about 160° C. 
     The filaments wrap from about 1 to about 50 times around the two godets and the steam box, preferably from about 5 to about 30 times, most preferably from about 10 to about 20 times. 
     During this heat application the filaments elongate from about 10 to about 20%. In order to adjust this elongation to the size of the godets, a preferred embodiment of this invention uses at least one stepped-out godet. The stepped-out godet has preferably as many steps as wraps of the filaments which may be from about 1 to about 50, preferably from about 5 to about 30, most preferably from about 10 to about 20 steps. 
     In order to reduce any kind of friction, preferably two stepped-out godets are used with a difference in diameter from step to step from about 0.2 to about 10%, or double this value in the case that only one stepped-out godet is used. 
     More than two godets could be used but it is less desirable. More than one steam box could be be used but this is also less desirable. 
     Based on a speed of the filaments of from about 5 to 40 m/s, preferably from about 10 to about 20 m/s, the residence time in the steam and heating unit is from about 1 to about 9 s, preferably from about 2 to about 4 s. 
     The drawing step (e) is conducted with a drawing godet which could be heated, and a draw ratio of from about 1.1 to about 5.0, preferably from about 2.0 to about 4.0. 
     The optional texturing step (f) is known in the art and may utilize steam, air, hot air, solvent, water, crimping rolls, and the like. Preferred is the use of a texturing jet utilizing steam or hot air. 
     Determining the percentages of alpha and gamma crystals in the crystalline phase of a nylon 6 fiber is known in the art, and an excellent reference is R. F. Stepaniak, A. Garton, D. J. Carisson, and E. S. Clark, Journal of Applied Polymer Science, vol. 21, p. 2341 (1977). Determining the percent crystallinity in a nylon fiber is well known in art and is typically calculated from the measured fiber density and the intrinsic density values for the amorphous and crystalline phases. 
     The filaments produced by this process show a Superba shrinkage, measured in a 129° C. tunnel, of from about 18 to 20% in comparison to about 25 to 28% for filaments without this steam and heating treatment. With emulsion finish and this treatment the shrinkage was reduced below 18%. Superba shrinkage measured in a 117° C. tunnel dropped from about 17-19% for the untreated filaments to about 9 to 12% for the filaments produced by the process of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic drawing of the apparatus used for the process of the present invention. 
     FIG. 2 is a partial schematic drawing of the steam and heating unit comprising two godets, at least one of which is heatable, and a steam box. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     In FIG. 1 the filaments 1, which have been spun by a spinnerette, pass the quenching unit 2, followed by a finish application unit 3. The filaments continue to run over a guide 4 to the steam and heating unit comprising godet 5, which could be heated, steam box 6 and the godet 7 which could be heated. The filaments may pass several wraps (18 in FIG. 2) around the two godets 5,7 and the steam box 6, before continuing to run over the guide 8 to the spinning godet 9, which could be heated and the accompanying idler roll 9a and further to the drawing godet 10, which could be heated, with the accompanying idler roll 10a. 
     From the drawing godet 10, the filaments continue to run to the texturing unit 11 followed by a cooling unit 12 over the take-off godet 13 to the take-up unit 14, where the filaments are taken up on a winder. 
     FIG. 2 illustrates the steam and heating application unit comprising the stepped-out godets 5 and 7, which could be heated and the steam box 6, all connected to the plate 15. The stepped-out godets 5 and 7 comprise the steps 5a and 7a. The steam box 6 comprises the steam applicator jets 6a which are located inside the slots 6b. The steam is fed into the steam box through pipe 6(c) and is exhausted through exhaust pipe 6(d). Preferably the steam box has the same arrangement on the other side. 
     EXAMPLE 1 
     Using the Apparatus shown in FIGS. 1 and 2, nylon 6, with relative viscosity of 2.7 (Ultramid BS-700™ from BASF) chips were melted, extruded and processed under the following conditions: 
     
         ______________________________________Polymer Temp., °C.                270Mass Throughput, grams per minute                256Polymer Pressure, psig               2000Finish Type         formulation of vegetable               oils, alkoxylated diacids,               and phosphate estersFinish Level, %       1.5Entry (first step) Speed of Godets 5                800and 7 in FIGS. 1 and 2, meters perminuteExit (last step) Speed of Godets 5 and                9367 in FIGS. 1 and 2, meters per minuteTemperature of Godets 5 and 7 in               varied during testing:FIGS. 1 and 2, °C.               ambient, 90, 125, 140,               and 150Steam Pressure in steam box 6 in               varied during testing:FIGS. 1, and 2, psig               off, 53Steam Temperature in steam box 6 in               varied during testing:FIGS. 1 and 2, °C.               off, 140Spinning Godet Speed, MPM               varied: 800 for control               and 960 with steam boxSpinning Godet Temperature, °C.               varied: 50 for control               and 80 with steam boxDrawing Godet Speed, MPM               2400Drawing Godet Temperature, °C.                185Text. Jet Steam Temp., °C.                190Text. Jet Steam Pres., psig                85Take Off Godet Speed, MPM               2130Take Off Godet Temp., °C.               ambientWinding Speed, MPM  2020Winding Tension, grams                100______________________________________ 
    
     EXAMPLE 2 
     Like example 1 except that the finish type was an aqueous emulsion of esters, vegetable oils, alkoxylated vegetable oils, alkoxylated alkyl phenols, and phosphate esters. 
     EXAMPLE 3 CONTROL 
     Like example 1 without any steam and heat treatment. 
     EXAMPLE 4 CONTROL 
     Like example 2 without any steam and heat treatment. 
     EXAMPLE 5 CONTROL 
     Nylon 6 chips are processed in a conventional two-step spinning and drawing process. 
     
                                           TABLE__________________________________________________________________________PROPERTIES OF STEAM BOX TREATED SDT YARN vs. CONTROLSSTEAM/HEAT UNIT__________________________________________________________________________       GODET STEAM  STEAM  FINISH       5 &amp; 7 PRESSURE                    TEMP.      %    TENACITYEXAMPLE  TYPE TEMP °C.             (psi)  °C.                         DENIER                               ELONG                                    (gpd)__________________________________________________________________________1      Neat 150   53     140   1272*                               34.6 2.422      Emul-       150   53     140  1097  30.3 2.36  sion3      Neat --    --     --   1111  40.0 3.36Control4      Emul-       --    --     --   1084  36.7 2.88Control  sion5      Emul-       --    --     --   1111  44.0 2.05Control  sion__________________________________________________________________________                      TYPE OF  129° C.         117° C.               DEN-   CRYS-  TYPE OF                                    TOTAL %  SUPER- SUPER-               SITY   TALS % CRYSTALS                                    CRYSTAL-EXAMPLE  BA %   BA %  (g/cc) ALPHA  % GAMMA                                    LINITY__________________________________________________________________________1      18     --    1.128  85     15     432      17     10    1.133  95      5     473      25     17    1.127  63     37     42Control4      28     19    1.127  64     36     42Control5      15      6    1.141  96      4     53Control__________________________________________________________________________ *1300 denier target