Patent GB-1240661-A (GB)
Title: Method of producing filaments, fibres or fibre networks
Inventor: RASMUSSEN OLE-BENDT
IPC: B29C48/08
Filed: 1967-08-09
Abstract: 1,240,661. Filamentary structures. O.-B. RASMUSSEN. 9 Aug., 1968 [9 Aug., 1967], No. 36531/67. Heading B5B. [Also in Division C1] A fibrous product comprises at least one fibre of a first material in the form of a strip having a micro-pleated cross-sectional configuration, the or each fibre being laminated with a filamentary strand of a second material. Fibrous products so made are shown in Fig. 1; internally pleated layers 1 of a first polymeric material are laminated with layers 2 of a second polymeric material. Fig. 2 (not shown) is similar, except that in processing, the sandwich-like product is divided in the fluid state to narrow ribbons before being compressed. Disruption of either product yields the bicomponent bulked fibre of Fig. 3. The first and second materials may be organic polymeric materials, or both may be glass. In the former case, the first material is suitably a split resistant polymeric material, e.g. a polyamide or polyester, a block copolymer of alternate crystalline and elastomer segments, or a graft polymer having an elastomer background and crystalline grafts. One of the materials may be a polyamide and the other a polyester, or the second material may be a polyolefin and the first material either a polyamide or a, polyester, the polyolefin being present in a higher proportion by weight than the polyamide or polyester.  Preferably, in the fibrous product, which may be in the form of a split fibre network or of individual filaments, each filamentary strand is a strip of micro-pleated cross-sectional configuration fitting into the configuration of an adjacent strip, or strips of said first material. Where the first and second materials are organic polymeric materials, the filamentary strands may be in a structurally disrupted state, desirably comprising micro-fibrillar crystal formations disrupted from one another. An adhesive layer may be present between each strip of first material and an adjacent strand of second material; in the case of organic polymeric materials, this may consist of a mixture of the first polymeric material and the second polymeric material or may be a graft polymer or block copolymer of said materials. The fibrous product may be made by forming a sandwich-like product consisting of alternating substantially parallel microscopically thin layers of at least two materials, subjecting said product to a simultaneous compression in one direction substantially in the plane of the layers and expansion perpendicularly thereto also in the plane of the layers under conditions at which the materials are in states of different fluidity. Preferably, this is followed by a step of disrupting the continuous connections between the layers of one of the materials formed by the layers of at least one other of the materials; where glass is used, waterglass is suitable as. layers in the sandwich-like product to effect the disruption.  The microscopically thin layers of the materials may be narrow strips, especially discontinuous narrow strips, and the direction of expansion may be substantially parallel to the longitudinal direction of the strips. After the compression and expansion steps, the product may be split into strips substantially parallel to the direction of expansion. The sandwich-like product may be formed by extruding a multitude of films and uniting the films in a common chamber; where both materials are maintained in a melted or semimelted state during the compression, compression and expansion may be effected by pressing the sandwich-like product through a chamber with gradually varying dimensions. Alternatively, the sandwich-like product may be made by forming films from solutions or dispersions of suitable polymers and uniting said films, or by successively melt-casting films on a roller or belt or by applying substances polymerizing in situ on to such roller or belt. Desirably, the sandwich-like product is made by feeding fluid first and second extrudable materials via ducts 4 and 5 (Fig. 6) to the interspersed circular rows of extrusion slots 6 and 7 and extruding into the chamber 8, parts 9 and 10 of which are rotated in opposite directions. The shearing action causes the radially arranged lamellµ (Fig. 7, not shown) to be drawn but to the form of Fig. 8 (not shown), and these layers may be divided into very narrow ribbons by means of a row of radial wires or blades to yield a product of the form shown in Fig. 9 (not shown). If material so formed is further sheared it acquires the form of Fig. 10 (not shown). Such further treatment improves the cohesion of the material when subsequently stretched. Fig. 12 (not shown) shows an alternative extrusion device, in which the alternating slots 6 and 7 are replaced by rectangular slots (11) alternating with rows of circular orifices (12), thus producing filaments of a polymeric material embedded in a matrix of a second polymeric material.  The sandwich-like product 3 is then fed to a stretching device (Fig. 4) comprising a first set of rubber-coated nip rollers; the nip zone of which is indicated by the line a-a, in a direction perpendicular to the axis of the rollers and is drawn off by the second set of rollers b-b in a direction almost perpendicular to the feeding direction. Simultaneously with the change of direction the ribbon is strongly stretched in its longitudinal direction, the peripheral speed of the rollers b-b being several times higher than that of the rollers a-a. Owing to the strong longitudinal drawing in combination with the extra narrowing resulting from the change of direction, tension is produced which imparts to the ribbon fine external longitudinal pleats, which are converted to internal pleating, when the ribbons subsequently pass the second set of rollers. The third set of nip-rollers is driven so as to produce a small further elongation and serves to maintain a high longitudinal tension in the ribbon during the passage between the second set of rollers. A hot-air oven may be located upstream of the first set of rollers, heating elements provided within said first set of rollers and a second hot-air oven located between the zones a-a and b-b; a cooling device may be located between b-b and c-c. Ribbon compressed and stretched in the device of Fig. 4 is preferably further treated in the device of Fig. 5, comprising first, second and third sets of rollers having nip zones indicated by the lines d-d, e-e and f-f respectively. The material to be compressed and expanded is fed into the zone between the first set of nip rollers under an angle to the nip zone and is drawn off by means of the second set of nip rollers. During its passage, a previously oriented sheet can become laterally compressed with only a small further longitudinal stretching, and the pleats produced become deeper. External pleating occurs between the first and second sets of rollers, and the external pleats are converted to internal pleats by passage through the rollers e-e. Micropleating may also be effected by passing the sandwich-like product obtained from the extruder of Fig. 6 by passage through two chambers in an extruder head which gradually changes the dimensions of the cross-section, as in Fig. 11, which, for clarity, shows only the shape of the melted material inside the chambers. One end of each chamber which is mounted in direct communication with the device of Fig. 6 is half-ring shaped except for a small grid of radial wires or blades for dividing the layers into narrow lamellµ. The width of each chamber gradually decreases and its thickness increases from one end of the chamber to the other so that the dimension of width becomes thickness and vice versa. In Example 1, a block copolymer of polypropylene with elastomeric segments of ethylene/propylene and an ethylene/vinyl acetate copolymer is extruded using the device of Fig. 6, provided with a row of twenty compression chambers, as shown in Fig. 11. The extruded product is oriented at 120 C. using a draw ratio of 5 : 1, swelled with chloroform and then expanded by passage through boiling water. Individual filaments are obtained therefrom by rubbing between rubber plates. In Example 2, a blend of polycaprolactam and polyethylene is extruded as in Example 1, and the product oriented at 165 C. using a draw ratio of 2À5 : 1. The structure is then disrupted by flexing and rubbing to yield a split fibre network.