Patent EA-005282-B1 (EA)
Title: Multilobal polymer filaments and articles produced therefrom
Inventor: JOHNSON STEPHEN B
IPC: D03D15/00
Filed: 2001-05-24
Abstract: 1. A synthetic filament having a multilobal cross-section, a filament factor of about 2 or greater, wherein the filament factor is determined according to the following formula: FF=K1x(MR)<A>(N)<B>x(1/(DPF)<C>x[K2(N)<D>x(MR)Ex1/(LAF)+K3x(AF)], wherein K1 is 0.0013158; K2 is 2.1; K3 is 0.45; A is 1.5; B is 2.7; C is 0.35; D is 1.4; E is 1.3; MR is R/r1, wherein R is the radius of a circle centered in the middle of the cross-section and circumscribed about the tips of the lobes, and r1 is the radius of a circle centered in the middle of the cross-section and inscribed within the cross-section about the connecting points of the lobes; N is the number of lobes in the cross-section; DPF is the denier per filament; LAF = (TR)x(DPF)x(MR)<2>, wherein TR is r2/R, wherein r2 is the average radius of a circle inscribed about the lobes, and R is as set forth above, and DPF and MR are as set forth above; and AF is 15 minus the lobe angle, wherein the lobe angle is the average angle of two tangent lines laid at the point of inflection of curvature on each side of the lobes of the filament cross-section, and an average tip ratio of >= about 0.2. 2. The filament of claim 1, wherein the tip ratio is >= about 0.3. 3. The filament of claim 2, wherein the tip ratio is >= about 0.4. 4. The filament of claim 1, wherein the lobe angle is <= about 15 degree . 5. The filament of claim 1, wherein said lobe angle is <= about 0 degree . 6. The filament of claim 4, wherein said lobe angle is <= about -30 degree . 7. The filament of claim 1, wherein said filament is comprised of at least one melt-spinnable polymer selected from the group consisting of polyesters, polyamides, polyolefins, and combinations thereof. 8. The filament of claim 7, wherein said polymer is a polyester selected from the group consisting of polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate, polyethylene naphthalate, and combinations thereof. 9. The filament of claim 7, wherein said filament is a bicomponent filament. 10. The filament of claim 9, wherein the bicomponent filament comprises a first component selected from the group consisting of poly (ethylene terephthalate) and copolymers thereof and a second component selected from the group consisting of poly (trimethylene terephthalate) and copolymers thereof, the two components being present in a weight ratio of about 95:5 to about 5: 95. 11. The filament of claim 1, wherein said filament has a filament factor of greater than or equal to about 3.0. 12. The filament of claim 11, wherein said filament has a filament factor of greater than or equal to 4.0. 13. The filament of claim 1, wherein said filament has 3 to 8 lobes. 14. The filament of claim 1, wherein the filament has a denier in the range of between about 0.2 to about 5.0 denier per filament. 15. A multifilament yarn formed at least in part from a filament of claim 1. 16. A multifilament yarn formed at least in part from a filament of claim 4. 17. The yarn of claim 15, wherein the filaments of the yarn have a denier in the range of between about 0.2 to about 5.0 denier per filament. 18. The yarn of claim 16, wherein the filaments of the yarn have a denier in the range of between about 0.2 to about 1.0 denier per filament. 19. The yarn of claim 17, wherein the yarn is falsetwist textured. 20. The yarn of claim 18, wherein the yarn is falsetwist textured. 21. An article formed at least in part from a filament of claim 1. 22. A garment formed at least in part from a filament of claim 1. 23. A fabric formed at least in part from a filament of claim 1.