Patent GB-1181249-A (GB)
Title: A method for the production of Crimped Fibres from Thermoplastic Macromolecular Materials
Inventor: SCHUUR GERRIT
IPC: B29C48/08
Filed: 1967-08-29
Abstract: 1,181,249. Crimped fibres. SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ N.V. 29 Aug., 1967 [31 Aug., 1966], No. 39468/67. Heading B5B. [Also in Division D1] In a method for the production of crimped fibres or yarns from thermoplastic macromolecular materials, a laminate composed of materials of this type comprising at least two layers which at the same temperature display stress-strain curves which do not coincide, is stretched and mechanically fibrillated or divided into narrow strips parallel to the direction of stretch. Suitable combinations of materials for the laminates which adhere well together are: nylon 6 with nylon 66; the polyester of glycol and terephthalic acid and the polyester of glycol and isophthalic acid; polypropylene with copolymers of propylene and ethylene; polypropylene with block copolymers of propylene and ethylene; polypropylene with a block copolymer, containing blocks of polypropylene and blocks of a copolymer of propylene and ethylene in which propylene and ethylene are present; polymethyl acrylate with polymethyl methacrylate; polyvinyl acetate with polyvinyl propionate; polyvinyl chloride with polyvinylidene chloride; cyclized rubber with polyolefins; cyclized rubber with the polymer from pivalolactone; and cyclized rubber with polyvinyl chloride. The laminates are produced either directly, e.g. by joint extrusion of two molten, or at least plastified thermoplasts through one and the same slit-shaped extrusion orifice, or by separate extrusion of the two layers and subsequent uniting of the layers in the plasticized state, generally under pressure. The laminate can be extruded in the form of a tube which is later cut open, preferably in the longitudinal direction. If the laminate has been formed by uniting two separately extruded films which already display some degree of orientation it is desirable for effective and easy fibrillation that the directions of orientation in the two layers coincide. Stretching may precede or follow fibrillation or division. Thus the laminate may be cut into strips having a width of from 2-30 mm., which strips are subsequently stretched, or alternatively the laminate may be first stretched and subsequently fibrillated by a rubbing, beating, or tearing mechanical treatment, a preferred apparatus for the fibrillation operation, particularly if staple fibre is required, being a carding machine. Stretching is suitably carried out at temperatures 10-100 C. below the temperature at which the highest softening layer of the laminate softens. Stretching ratios are chosen on the basis of the effects desired and the composition of the laminate; suitable stretching ratios are between 1: 3 and 1: 20, especially between 1: 5 and 1: 15. If desired, the stretching operation can be effected in a number of stages. Fibrillation of the laminate is suitably carried out at temperatures between 0 C. and 40 C. Where it is desired to produce staple fibre, the laminate is preferably cut prior to the fibrillation, in view of the desired fibre length, into suitable dimensions, transversely to the direction of stretch. After the aforesaid treatments the crimping effect may be reinforced by heating, moistening, swelling and/or extraction of additives. Suitable temperatures for such heat treatment are generally between 5 C. and 80 C. below the softening point of the layer in the laminate with the lowest softening point, the required period of heating depending on the composition of the laminate, the orientation in the layers, the temperature and the effect desired; the duration of heating can be determined experimentally and usually lies between several seconds and several minutes. Reduction of crimping by reduction of the orientation by means of heating or other treatments described above, can also if desired be effected by means of this heating or other treatment prior to the fibrillation or the division into narrow strips. If desired, crimping may be induced, reinforced or reduced after the narrow strips or fibres have been worked up into yarns, fabrics, knitted articles or non-woven fabrics. Preferably the laminate consists of layers which are chemically identical, but which have (a) different average molecular weights; (b) dissimilar molecular weight distribution; (c) dissimilar stereo-configuration; (d) dissimilar crystallinity; or the laminate may consist of layers which are chemically identical in respect of the thermoplastic macromolecular material, but which are dissimilar in respect of the distribution of substances which influence crystallization, in particular crystallization nucleating agents. Alternatively, the laminate may consist of layers which are chemically identical but which differ as regards porosity. Thus one layer may be solid, and the other foamed, or both layers may be foamed but have different bulk densities. Again, the laminate may consist of layers which are chemically identical in respect of the thermoplastic macromolecular material, but which are dissimilar in respect of the presence of (a) fillers, plasticizers and/or flow promoting agents; (b) stabilizers, whereby a difference in average molecular weight between the layers is brought about, if necessary by means of heating, illumination and/or irradiation. The laminate may also consist of layers which are either chemically identical or not identical in respect of the thermoplastic macromolecular material, but which are dissimilar in respect of the presence of dyes, pigments and/or substances which affect the dyeability. By chemical identity is understood identity in respect of at least 90% of the molecule fragments repeating in the chain molecules which molecule fragments correspond in their carbon skeleton with the polymerized monomer molecules, or, in the case of polycondensation products of two different functional compounds, with a condensation product formed from one molecule of one functional compound with one molecule of the other functional compound. The chemical identity is thus not impaired by dissimilarity in molecular weight. Also chemically identical, according to this definition, are copolymers which only differ by a few per cent in respect of the ratio in which they have been built up from the monomers. Thus, the combination of the copolymer built up from propylene and ethylene in the molar ratio 50: 50 and a copolymer built up from the same monomers in the ratio 60: 40 is just on the edge of chemical identity. Preferred thermoplastic macromolecular materials are polyolefins, especially polyolefins which are at least 50% crystalline, and desirably the polyolefin in at least one of the layers of the laminate is polypropylene, or a copolymer based for more than 50% on propylene. Examples are given.