Patent ID: 12195884

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the disclosed embodiments have broad utility and application. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Furthermore, an embodiment may incorporate only one or a plurality of the aspects disclosed herein; only one or a plurality of the features disclosed herein; or combination thereof. As such, many embodiments are implicitly disclosed herein and fall within the scope of this disclosure.

Accordingly, it is to be understood that this disclosure is illustrative and exemplary, and it is made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the invention. Accordingly, it is intended that the scope of patent protection afforded the invention is to be defined by the issued claim(s) rather than the description set forth herein.

Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term-differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.

With regard solely to construction of any claim with respect to the United States, no claim element is to be interpreted under 35 U.S.C. 112(f) unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to and should apply in the interpretation of such claim element.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers,” “a picnic basket having crackers without cheese,” and “a picnic basket having both cheese and crackers.” When used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.”

Referring now to the drawings, one or more preferred embodiments are next described. The following description of one or more preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its implementations, or uses.

FIG.1is a schematic cross-sectional view of an embodiment of a bi-component continuous filament10, in accordance with one or more aspects of the present disclosure, depicting the bi-component continuous filament10as having a circular cross-sectional shape with the polymer components in a concentrically-arranged sheath-core relationship, andFIG.2is a schematic cross-sectional view of an embodiment of a bi-component continuous filament110, in accordance with one or more aspects of the present disclosure, depicting the bi-component continuous filament110as having a circular cross-sectional shape with the polymer components in an eccentrically-arranged sheath-core relationship. In each ofFIGS.1and2, a first polymer component12,112entirely surrounds a second polymer component14,114(cross-sectionally) so that the first polymer component12,112forms a sheath around the second polymer component14,114, which forms a core. In a preferred embodiment, the first polymer component12,112is different from the second polymer component14,114, thereby imparting the bi-component continuous filament10,110with attributes of each filament individually as well as attributes that might arise by the pairing of the selected polymer components.

InFIG.1, the first and second polymer components12,14are generally concentrically arranged, with the core disposed at a generally central location within the sheath. It should be noted that, though each of the polymer components12,14of the bi-component continuous filament10ofFIG.1is depicted as having a generally circular cross-sectional shape, it is contemplated that either or both polymer components can be formed to have any of a variety of other non-circular cross-sectional shapes, including, but not limited to, elliptical, tri-lobal, polygonal (e.g., triangular, square, pentagonal, etc.), star, and like shapes.

InFIG.2, the first and second polymer components112,114are eccentrically arranged, with the core disposed at a generally non-central (i.e., off center) location within the sheath. As withFIG.1, it should be noted that, though each of the polymer components112,114of the bi-component filament110ofFIG.2is depicted as having a generally circular cross-sectional shape, it is contemplated that either or both polymer components can be formed to have any of a variety of other non-circular cross-sectional shapes, including, but not limited to, elliptical shapes, tri-lobal shapes, and the like.

FIGS.3and4are each schematic cross-sectional views of an embodiment of a bi-component filament210,310, in accordance with one or more aspects of the present disclosure, depicting the bi-component continuous filament210,310as having a tri-lobal cross-sectional shape with the polymer components in a sheath-core relationship. In each ofFIGS.3and4, a first polymer component212,312entirely surrounds a second polymer component214,314(cross-sectionally) so that the first polymer component212,312forms a sheath around the second polymer component214,314, which forms a core. In a preferred embodiment, the first polymer component212,312is different from the second polymer component214,314thereby imparting the bi-component continuous filament210,310with attributes of each filament individually as well as attributes that might arise by the pairing of the selected polymer components.

InFIG.3, each of the polymer components212,214of the bi-component continuous filament210ofFIG.3is depicted as having a tri-lobal cross-sectional shape. Although the arrangement of the tri-lobal cross-sectional shape of the core relative to the cross-sectional shape of the sheath is shown as being generally symmetric, an asymmetrical arrangement of the core relative to the sheath is likewise contemplated. A tri-lobal cross-sectional shape for each of the first and second polymer component212,214can provide increased surface-to-surface interface between the sheath and the core, thereby enhancing the opportunity for effective adhesion between the polymer components212,214.

In at least some embodiments, it may be preferred to use a polymer material in the same polymer family for the core and sheath. (e.g., a core made from recycled polyester and a sheath made from virgin polyester). In embodiments where the core and sheath share similar properties, a binding agent may not be required. In some such embodiments, however, a binding agent may still be desirable. In some embodiments where a binding agent is not used, the surface area of contact between the core and the sheath may be engineered to increase adhesion between the core and sheath. For example, a tri-lobal cross-sectional shape may be used for the core to increase surface area and improve adhesion properties. Any of the other cross-sectional shapes disclosed herein may be used to increase the surface area of contact between the core and the sheath.

InFIG.4, the first polymer component312is depicted as having a tri-lobal cross-sectional shape, and the second polymer component314is depicted as having a generally circular shape. As should be clear, it is contemplated that the cross-sectional shape of the sheath and the core of bi-component continuous filaments in accordance with one or more aspects of the present disclosure are not required to embody the same cross-sectional shape. It is contemplated that cross-sectional shapes of the sheath and the core can be selected to provide resulting bi-component filaments with physical attributes that might be well-suited to a particular end-use application.

With regard to each of the bi-component continuous filaments10,110,210,310shown and described in connection with each ofFIGS.1-4, a wide variety of different polymers can be selected for implementation as the polymer components. Polymers can be selected to impart the resulting bi-component with desired physical attributes, such as resiliency, durability and/or strength, which may be advantageous for a particular end-use application.

In at least some embodiments, the first polymer component12,112,212,312, which component is ultimately implemented as the sheath in the resultant bi-component continuous filaments10,110,210,310, includes a polyamide, a polyolefin, or polyester. Other classes of polymers commonly used in the manufacture of woven textile materials and products are likewise contemplated. A polyamide that can be selected as the first polymer component12,112,212,312includes any of a variety of chained polymers having amide linkages, including (but not limited to): nylon 6, nylon 6,6, nylon 7, nylon 6,10, nylon 6,12, nylon 12, nylon 46 or nylon 1212. A polyolefin that can be selected as the first polymer component12,112,212,312includes, but is not limited to, polyethylene (PE), ethylene-vinyl acetate (EVA), or polypropylene (PP). A polyester that can be selected as the first polymer component12,112,212,312includes, but is not limited to, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). In a preferred embodiment, the first polymer component12,112,212,312includes nylon 6. In another preferred embodiment, the first polymer component12,112,212,312includes polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

In at least some embodiments, the second polymer component14,114,214,314, which component is ultimately implemented as the core in the resultant bi-component continuous filaments10,110,210,310, includes a polyamide, a polyolefin, or a polyester. Other classes of polymers commonly used in the manufacture of woven textile materials and products are likewise contemplated. A polyamide that can be selected as the second polymer component14,114,214,314includes any of a variety of chained polymers having amide linkages, but is not limited to, nylon 6, nylon 6,6, nylon 7, nylon 6,10, nylon 6,12, nylon 12, nylon 46 or nylon 1212. A polyolefin that can be selected as the second polymer component14,114,214,314includes, but is not limited to, polyethylene (PE), ethylene-vinyl acetate (EVA), or polypropylene (PP). A polyester that can be selected as the second polymer component14,114,214,314includes, but is not limited to, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). In a preferred embodiment, the second polymer component14,114,214,314includes polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

In at least some embodiments, bi-component continuous filaments10,110,210,310include one or more binding agents to facilitate effective adhesion between the first and second polymer components along their respective lengths. It is contemplated that a binding agent can be added to either or both of the first and/or second polymer components when in chip form, prior to heating and extrusion. In a preferred embodiment, the binding agent is mixed with the chip form of the second polymer component14,114,214,314, which ultimately is used to form the core of the resulting bi-component continuous filaments10,110,210,310. Once thoroughly mixed, the binding agent is spun (i.e., extruded) with either or both of the and second polymer components so that the first and second polymer components can be bound together in such a way that the resulting bi-component continuous filaments10,110,210,310are less likely to undergo delamination (i.e., separation of the first and second polymer components) during preparation and/or use of a textile product utilizing the filament.

It is contemplated that a wide variety of different materials can be used as a binding agent in connection with generation of bi-component continuous filaments10,110,210,310in accordance with one or more aspects of the present disclosure. In one contemplated embodiment, the binding agent includes a polyolefin modified by an organic acid anhydride. Polyolefins capable of modification by an organic acid anhydride to function as a binding agent include, but are not limited to, polyethylene (PE), ethylene-vinyl acetate (EVA), and polypropylene (PP). An organic acid anhydride for modifying a polyolefin to function as a binding agent includes, but is not limited to, maleic anhydride.

To illustrate effectiveness of the inclusion of a binding agent in the generation of bi-component filaments in accordance with one or more aspects of the present disclosure,FIGS.5A-5Dare images depicting a plurality of bi-component continuous filaments, arranged in a sheath-core relationship, having parameters similar to that of the bi-component continuous filaments210ofFIG.3.

FIG.5Adepicts a cross-sectional view of bi-component continuous filaments, with a tri-lobal cross-sectional shape, having a sheath formed of a polyamide that includes nylon 6 and a core formed of a polyester that includes polyethylene terephthalate (PET). The bi-component continuous filament depicted inFIG.5Adoes not include a binding agent.

Each ofFIGS.5B-5Dlikewise depicts a cross-sectional view of bi-component continuous filament, with a tri-lobal cross-sectional shape, having a sheath formed of a polyamide that includes nylon 6 and a core formed of a polyester that includes polyethylene terephthalate (PET). The percentage of each polymer component relative to the whole varies across the three samples, as presented in the second column of Table 1. Each of the samples ofFIGS.5B-5Dwas prepared using a binding agent as described above.

The test data associated with the images ofFIGS.5A-5Dare summarized below in Table 1. Industry standard ASTM D-2256 was used to identify the elongation and tenacity, ASTM D-2259 was to measure boiling water shrinkage, and ASTM D-6774 was used to measure crimp contraction.

TABLE 1CrimpBi-componentDenier/ElongationTenacityBoiling WaterContractionImagefilamentFilament(%)(gpd)Shrinkage (%)(%)FIG. 5ANylon 6/PET (no1200/6037.8832.520.41Binding Agent)FIG. 5BNylon 6/PET1200/6037.643.851.2520.58(50/50)(with BindingAgent)FIG. 5CNylon 6/PET1200/6035.393.390.9219.27(33/67)(with BindingAgent)FIG. 5DNylon 6/PET1200/6033.613.551.8121.64(67/33)(with BindingAgent)

As summarized in Table 1, the bi-component continuous filament samples ofFIGS.5B-5Dexhibit higher tenacity levels (i.e., strength) than the bi-component continuous filament sample ofFIG.5A, which was prepared without a binding agent. As further shown in Table 1, the bi-component continuous filament samples ofFIGS.5B-5Dmaintain relatively high elongation percent in conjunction with increased tenacity. Accordingly, the bi-component continuous filament samples ofFIGS.5B-5Dsupport an increase in overall strength with the use of a binding agent as described above. It is noted that ASTM D-2256, an industry standard for measuring tensile of yarn by the single-strand method, was used to identify the tenacity and elongation.

Furthermore, with reference toFIG.5A(and by comparison ofFIG.5AwithFIGS.5B-5D), some bi-component continuous filaments ofFIG.5Aexhibit delamination between the sheath512and the core514. In particular,FIG.5Aillustrates that gaps518have already formed between the sheath512and the core514, where the polymer components are no longer adhered to one another. InFIG.5B(as well asFIGS.5C and5D), by comparison, the bi-component continuous filaments exhibit a high degree of lamination, with little to no gaps, where the binding agent has effectively bound the sheath612and the core614together along their respective lengths.

In addition to the test data corresponding toFIGS.5A-5D, additional samples with tri-lobal cross-sections were tested to explore compositions to further increase performance. More specifically, a study was conducted to explore compositions and the effects of composition on the elongation and tenacity of the bi-component continuous filaments. In this experiment, the ratio of the materials used in the bi-component continuous filament's core and sheath was examined. ASTM D-2256, an industry standard for measuring tensile of yarn by the single-strand method, was used to identify the tenacity and elongation. ASTM D-2259 was to measure boiling water shrinkage. ASTM D-6774 was used to measure crimp contraction. The test data associated with the additional study are summarized below in Table 2.

TABLE 2BoilingWaterPoly-CrimpShrink-NipsmerRealElong-TenacityContrac-age(perOil PickDenier/(core/Denieration (%)(gpd)tion(%)(%)meter)Up (%)Filamentsheath)±1.5%±5±0.2±2±0.2±2±0.21200/60% PP +120254.02.013.24.3271.06040% PA61200/70% PET +121352.72.914.61.3260.96030% PA61550/70% PET +155545.42.514.21.2261.06030% PA61200/50% PA6 +120352.72.99.83.7260.96050% PET1200/70% PET +120353.02.89.63.9250.96030% PA61200/70% PET +120550.02.812.11.8270.96030% PA61200/70% PET +120052.72.813.01.6290.96030% PA61200/70% PET +120356.83.315.93.4280.96030% PA61550/70% PET +155450.43.218.11.6260.06030% PA61550/70% PET +155045.63.118.61.7261.16030% PA61200/70% PET +120346.13.215.63.7261.16030% PA61550/70% PET +155445.73.218.71.7261.06030% PA61200/70% PET +120443.53.116.51.7251.26030% PA61200/70% PET +120442.92.714.42.8251.36030% PA61200/70% PET +120444.52.814.33.1261.16030% PA61200/70% PET +120441.62.715.02.8281.16030% PA61200/70% PET +120441.12.614.82.6281.16030% PA61200/50% PP +120460.42.29.25.2271.16050% PA61200/50% PP +120459.52.39.15.0271.06050% PA61200/50% PP +120457.12.18.94.9270.96050% PA61200/50% PP +120455.52.58.94.9270.86050% PA61200/50% PP +120452.22.19.14.2280.96050% PA61200/50% PET +120452.63.214.02.8281.06050% PA61200/50% PET +121056.63.114.62.7281.16050% PA61900/50% PET +190849.22.919.22.6281.06050% PA61900/50% PET +189851.02.918.63.0281.26050% PA61200/50% PET +120654.63.214.92.9291.36050% PA61200/50% PET +120456.73.014.52.3291.16050% PA61900/50% PET +189952.02.918.52.7271.16050% PA61900/50% PET +189548.42.819.32.7281.16050% PA61200/50% PET +123051.33.114.62.8271.16050% PA61200/50% PBT +120452.63.214.02.8281.06050% PA61200/60% PBT +121056.03.114.62.7280.96040% PA61900/50% PBT +190848.02.919.22.6281.16050% PA61900/50% PBT +189851.02.918.63.0281.06050% PA61200/50% PET +120654.63.214.92.9291.26050% PBT1200/50% PET +120456.73.014.52.7291.36050% PBT1900/60% PET +189952.02.918.53.1271.16040% PBT1900/70% PET +189548.42.819.32.7281.16030% PBT1200/50% PET +123051.33.114.63.0271.16050% PA61200/50%120452.63.215.72.8281.160RecyclePET +50% PA61200/50%121056.63.116.92.7281.060RecyclePET +50% PA61900/50%190849.22.919.22.6271.060RecyclePET +50% PA61900/50%189852.22.918.63.0251.060RecyclePET +50% PA61200/50% PET +120453.43.214.02.7270.96050%RecyclePA61200/50% PET +121056.63.314.62.7280.96050%RecyclePA61900/50% PET +190848.22.918.42.5291.06050%RecyclePA61900/50% PET +189851.02.918.63.3280.96050%RecyclePA61200/50% PA6 +120452.63.215.02.8281.16050% PBT1200/50% PA6 +121056.03.116.92.7281.06050% PBT1900/50% PA6 +190848.02.919.22.6281.26050% PBT1900/50% PA6 +189851.02.817.53.0281.16050% PBT1200/50% PP +120460.42.39.25.2261.16050% PBT1200/50% PP +120459.52.311.05.0271.06050% PBT1200/50% PP +120457.12.18.94.9280.96050% PBT1200/50% PP +120455.51.99.64.9270.86050% PBT1200/70% PET +120353.03.29.63.9250.99330% PA61200/70% PET +120550.03.512.11.8270.99330% PA61200/70% PET +120052.72.813.01.6290.99330% PA61200/70% PET +120356.83.315.93.4280.99330% PA6

In at least some embodiments, either or both of the first and second polymer components of bi-component continuous filaments10,110,210,310is solution dyed (i.e., dope-dyed) or hank dyed to enhance certain physical attributes of the resulting bi-component continuous filaments. Because many polymers are initially color-free (i.e., raw white), polymers can be treated using a solution dyeing process prior to spinning a bi-component continuous filament or using a hank dyeing process after spinning a bi-component continuous filament. With solution dyeing, the polymer components themselves can be permeated with a desired pigment via solution dyeing so that the color exists in the extruded polymer mix. Filaments prepared using a solution dyeing process have demonstrated enhanced ability to retain color (i.e., color fastness). With hank dyeing, the polymer filaments are permeated with a dye and then finished (e.g., steamed) to fix the dye. Filaments prepared with a hank dyeing process allow manufactures to maintain an inventory of undyed yarns and decrease lead times for special color orders. Filaments prepared using a hank dyeing process have demonstrated richer color vibrancy than other methods.

In one contemplated form of solution dyeing usable to generate bi-component continuous filaments10,110,210,310in accordance with one or more aspects of the present disclosure, the solution is prepared using a pigment dyestuff to add a desired color to the polymer mix. Here, the pigment is typically a pure color pigment that is added during the melt stage and extruded with either or both polymer components to deliver a spun filament exhibiting the selected color. It is contemplated that the pigment can be in an organic or an inorganic form, as might be desired. In many cases, use of a pure color pigment in connection with solution dyeing results in filaments with strong, vivid color, although a range of color variability (i.e., subtle changes of hues) can sometimes be difficult to achieve.

In another contemplated form of solution dyeing usable to generate bi-component continuous filaments10,110,210,310in accordance with one or more aspects of the present disclosure, the solution is prepared using each of a pigment dyestuff and a solvent. A solvent added to the solution dyeing process can introduce added strength to an extruded polymer. In addition, inclusion of a solvent can facilitate enhanced color variability. In other words, the solvent can often the effect of the pure color pigment, standing alone, so that a wider range of color shades and hues can be obtained in an extruded polymer.

It is contemplated that either the first component, the second component or both the first and second components can be treated via a solution dyeing process. Furthermore, it is contemplated that, to the extent that a natural white color is preferred, neither the first polymer component nor the second polymer component is solution dyed so as to preserve the raw white characteristic of color-free polymer. In a preferred embodiment, each of the first and second polymer components is solution dyed prior to extrusion-either using a pigment alone or using a pigment in combination with a solvent. In this regard, it is contemplated that each of the first and second polymer components can be treated using the same solution dyeing process (i.e., using the same solvent and/or pigment) or using a different solution dyeing processes (i.e., using different solvents and/or pigments for each polymer component). In this latter regard, a resultant bi-component continuous filament10,110,210,310can exhibit a sheath of one color and a core of a different color.

In one contemplated form of hank dyeing usable to generate bi-component continuous filaments10,110,210,310in accordance with one or more aspects of the present disclosure, the bi-component continuous filaments are spun into yarns and submerged in a dye bath to add a desired color to the polymer mix. Here, the dye bath is formulated based on the polymer material that is being used. For example, if the sheath of the bi-component continuous filament is polyester (PET), the dye bath may be prepared with a disperse dye. In another example, if the sheath of the bi-component continuous filament is polyamide, the dye bath may be prepared with an acid dye.

It is contemplated that many polymer materials may be used to create the bi-component continuous filament described herein and that the hank dyeing process should be determined based on the polymer material and the appropriate dyestuff for that polymer.

In at least some embodiments, it is contemplated that in either or both of the first and second polymer components of bi-component continuous filaments10,110,210,310, functional additives may be added to the first and/or second polymer component to achieve desirable properties, including (but not limited to): fire retardancy, fire resistance, antimicrobial, antibacterial, antifungal, and anti-staining properties. As used herein, the term “functional additive” includes materials added to the polymer itself and materials added to a finish used to coat or otherwise treat the bi-component continuous filaments. It is contemplated that the functional additives may be incorporated into the bi-component continuous filament as a copolymer during the polymerization process, during extrusion, or as a finish after fiber or yarn formation. It is contemplated that any known, commercially available functional additive that is suitable for use with the polymer materials implemented may be used to achieve the desirable properties. For example, reactive and additive fire retardants may be used; including: minerals, organohalogen compounds, organophosphorus compounds, and organic compounds. For example, to achieve antimicrobial, antibacterial, or antifungal properties, additives such as isothiazolinone treatments, zinc pyrithione, thiabendazole and silver may be implemented. For example, to achieve anti-staining properties, additives known to alter polymers to increase (or decrease) the polymer's hydrophobic and/or olephobic properties, or to lower the surface energy of the polymer may be implemented.

Turning now toFIG.6, a schematic cross-sectional view of an embodiment of a bi-component filament410, in accordance with one or more aspects of the present disclosure, is shown. Here, the bi-component continuous filament410has a generally circular cross-sectional shape with the polymer components arranged in a side-by-side relationship. As shown inFIG.6, bi-component filaments in accordance with one or more aspects of the present disclosure are not limited to the polymer components being arranged in a sheath-core relationship. InFIG.6, two different polymer components416,418are shown side-by-side, and adhered together, to form a single bi-component continuous filament410having a generally circular cross-sectional shape. It should be noted that, though the bi-component continuous filament410ofFIG.6is depicted as having a generally circular cross-sectional shape, filaments with non-circular cross-sectional shapes (e.g., elliptical, tri-lobal, and the like) are likewise contemplated. Furthermore, in at least some contemplated embodiments, a bi-component continuous filament with polymer components arranged in a side-by-side relationship, as inFIG.6, can be symmetrically arranged. In other contemplated embodiments, a bi-component continuous filament with polymer components arranged in a side-by-side relationship can be asymmetrically arranged.

Although not specifically depicted here, it is further contemplated that the polymer components of bi-component continuous filaments in accordance with one or more aspects of the present disclosure may exhibit matrix-fibril type structure, whereby filaments of one polymer component are dispersed in a matrix made using another polymer component, or the polymer components of bi-component continuous filaments in accordance with one or more aspects of the present disclosure may be arranged in a segmented pie-chart (or citrus) type structure. It is contemplated that these other types of bi-component continuous filament arrangements can have circular or non-circular arrangements, as might be preferred. It is further contemplated that these other types of bi-component filament arrangements can have symmetrical or asymmetrical arrangements, as might be preferred.

In a contemplated method of generating bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present disclosure, the first and second polymer components, are selected for inclusion in a bi-component continuous filament. Though the polymer components often exist in a chip or pellet form, other forms of polymer components are contemplated. In a contemplated method, the first and second polymer components are mixed independently of one another. A binding agent, as described hereinabove, can be included in the polymer mix of one or both of the first and/or second polymer components. In a contemplated embodiment, the binding agent is mixed with the second polymer component, which, inFIGS.1-4, forms the core of the resulting bi-component continuous filament.

Either or both of the and second polymer components can be solution dyed prior to spinning or hank dyed after spinning. In contemplated embodiments, the solution dyeing process includes a pigment or each of a pigment and a solvent. It is contemplated that solution dyeing the polymer components prior to spinning enables coloration of the polymer components (across a wide spectrum of colors, particularly when a solvent is included in the solution dyeing process). The solution-dyeing process can also enhance strength and durability in the polymer components so as to impart the resulting bi-component continuous filament with desirable attributes for various end-use applications.

Each polymer mix is heated and stirred so that each of the first and second polymer components forms a melt that is ready for extrusion via a spinneret. The first and second polymer melts are fed through a spinneret selected to yield a bi-component continuous filament10,110,210,310,410of a particular cross-sectional shape. After spinning, the resulting bi-component filament10,110,210,310,410can be further treated and/or texturized for implementation across a wide range of different end-use applications. The resulting filament further can be heat set, including, but not limited to, dry heat setting, steam heat setting, or a combination of both.

It is further contemplated that the resulting bi-component continuous filament10,110,210,310,410can be texturized to form bulk continuous filament suitable for tufting and weaving into floor coverings, such as carpets, or other textile products where durability, strength and/or color-fastness may be advantageous. In further preparation for end-use applications, bulk continuous filament bundles of the bi-component continuous filaments10,110,210,310,410can be intermingled with two or three bundles of the same color or a different color.

Additionally, or alternatively, the resulting bi-component continuous filament10,110,210,310,410can be cable formed, whereby the filaments exhibit a pile construction with chunky tufts and longer pile height, or twist and heat set formed, whereby the filaments are twisted together and then heat set to help the twisted bundle stay intact and increase resistance to pile crush. Where bi-component continuous filaments are twisted, it is contemplated that single or multiple bundles of bulk continuous filaments (e.g., one, two or three bundles) of the same or different color can be twisted to satisfy the demands of various end-use applications. In this regard, it is contemplated that twisting can range from zero turns per meter up to approximately 300 turns per meter. Likewise, where bi-component continuous filaments are heat set, it is contemplated that single or multiple bundles of bulk continuous filaments (e.g., one, two or three bundles) of the same or different color can be heat set to satisfy the demands of various end-use applications. Heat setting can afford the filaments with enhanced dimensional stability as well as other desirable attributes, such as wrinkle resistance and/or temperature resistance. It is contemplated that heat setting can be accomplished by steam heating, by dry heating or by a combination of steam and dry heating.

It is further contemplated that bulk continuous filaments yarn may be generated using bi-component filaments10,110,210,310,410in accordance with one or more aspects of the present disclosure exhibits a denier per filament (DPF) ratio measuring from approximately 2 DPF to approximately 50 DPF. Furthermore, it is contemplated that bulk continuous filament yarns generated using bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present disclosure exhibits a weight measuring between approximately 500 denier to approximately 3500 denier.

Bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present disclosure have broad utility across a range of end-use textile applications. In at least some embodiments, a polyamide sheath can provide a good visual appeal to pile change and, as such, the bi-component continuous filament is well-suited for use in floor covering products. Furthermore, in at least some embodiments, a polyester or a polyolefin (e.g., polypropylene) core can provide enhanced moisture-repelling properties so that textile products incorporating such filaments are more durable and are quick-drying.

It is contemplated that, bi-component continuous filaments10,110,210,310,410and bi-component continuous filament yarns in accordance with one or more aspects of the present disclosure can be woven for production of any of a wide range of floor and surface coverings, including, but not limited to, door mats, bath rugs, area rugs, accent rugs, carpet tile rugs, broadloom carpet, automotive floor mats, automotive covering, automotive internal floor covering. It is further contemplated that bi-component continuous filaments10,110,210,310,410and bi-component continuous filament yarns in accordance with one or more aspects of the present disclosure may likewise be implemented in textile products such as sheeting, towels and other bed and bathroom textile needs.

EXAMPLES

It is contemplated that the examples discussed below may be implemented with respect to any of the bi-component continuous filament shapes and/or arrangements discussed above.

Example 1

In one contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component continuous filament are arranged in a sheath-core relationship. In this example, each of the first polymer component (i.e., the sheath) and the second polymer component (i.e., the core) is solution dyed during or prior to the extrusion process. The solution-dyeing process in this example includes: (a) solution dyeing with a pigment (using a pigment in either an organic or an inorganic form); or (b) solution dyeing with a combination of a pigment and a solvent.

In Example 1, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Furthermore, in Example 1, it is contemplated that the second polymer component (i.e., the core) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Example 2

In another contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component filament are arranged in a sheath-core relationship. Although not required, one or both of the first polymer component (i.e., the sheath) and the second polymer component (i.e., the core) are solution dyed during or prior to the extrusion process. The solution-dyeing process in this example includes: (a) solution dyeing with a pigment (using a pigment in either an organic or an inorganic form); or (b) solution dyeing with a combination of a pigment and a solvent. Alternatively, it is contemplated that each of the first polymer component and the second polymer can be color-free (i.e., raw white). It is further contemplated that the first polymer component (i.e. the sheath) can be solution dyed in accordance with one of the above-described processes, while the second polymer component (i.e., the core) is color-free, or that the second polymer component (i.e., the core) can be solution dyed in accordance with one of the above-described processes, while the first polymer component (i.e., the sheath) is color-free.

In Example 2, a binding agent is mixed with one or both of the and second polymer components. As the polymers are extruded into the bi-component continuous filament, the binding agent facilitates strong adhesion qualities between the first and second polymer components. The binding agent includes, for example, a polyolefin modified by maleic anhydride.

Furthermore, in Example 2, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Furthermore, in Example 2, it is contemplated that the second polymer component (i.e., the core) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Example 3

In another contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component filament are arranged in a sheath-core relationship. In this example, each of the first polymer component (i.e., the sheath) and the second polymer component (i.e., the core) is solution dyed during or prior to the extrusion process. The solution-dyeing process in this example includes: (a) solution dyeing with a pigment (using a pigment in either an organic or an inorganic form); or (b) solution dyeing with a combination of a pigment and a solvent.

In Example 3, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide in cationic form, a polyolefin in cationic form, or a polyester in cationic form The polyamide includes, for example, a cationic form of nylon 6. The polyolefin includes, for example, a cationic form of polypropylene (PP). The polyester includes, for example, a cationic form of polyethylene terephthalate (PET), a cationic form of polybutylene terephthalate (PBT), or a cationic form of polytrimethylene terephthalate (PTT).

Furthermore, in Example 3, it is contemplated that the second polymer component (i.e., the core) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Example 4

In still another contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component filament are arranged in a sheath-core relationship. Although not required, one or both of the first polymer component (i.e., the sheath) and the second polymer component (i.e., the core) can be solution dyed during or prior to the extrusion process. The solution-dyeing process in this example includes: (a) solution dyeing with a pigment (using a pigment in either an organic or an inorganic form); or (b) solution dyeing with a combination of a pigment and a solvent. Alternatively, it is contemplated that each of the first polymer component and the second polymer can be color-free (i.e., raw white). It is further contemplated that the first polymer component (i.e. the sheath) can be solution dyed in accordance with one of the above-described processes, while the second polymer component (i.e., the core) is color-free, or that the second polymer component (i.e., the core) can be solution dyed in accordance with one of the above-described processes, while the first polymer component (i.e., the sheath) is color-free.

In Example 4, a binding agent is mixed with one or both of the and second polymer components. As the bi-component continuous filament is extruded, the binding agent facilitates strong adhesion qualities between the first and second polymer components. The binding agent includes, for example, a polyolefin modified by maleic anhydride.

Furthermore, in Example 4, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Furthermore, in Example 4, it is contemplated that the second polymer component (i.e., the core) includes a recycled polyamide or a recycled polyester. The polyamide includes, for example, a recycled form of nylon 6. The polyester includes, for example, a recycled form of polyethylene terephthalate (PET).

Example 5

In another contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component filament are arranged in a sheath-core relationship. Although not required, one or both of the first polymer component (i.e., the sheath) and the second polymer component (i.e., the core) are hank dyed after the extrusion process. Alternatively, it is contemplated that each of the first polymer component and the second polymer can be color-free (i.e., raw white).

In Example 5, a binding agent is mixed with one or both of the and second polymer components. As the polymers are extruded into the bi-component continuous filament, the binding agent facilitates strong adhesion qualities between the first and second polymer components. The binding agent includes, for example, a polyolefin modified by maleic anhydride.

Furthermore, in Example 5, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). Furthermore, in Example 5, it is contemplated that the second polymer component (i.e., the core) includes a polyamide, a polyolefin, or a polyester. The polyamide includes, for example, nylon 6. The polyolefin includes, for example, polypropylene (PP). The polyester includes, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT).

Example 6

In another contemplated bi-component continuous filament in accordance with one or more aspects of the present disclosure, first and second polymer components of the bi-component continuous filament are arranged in a sheath-core relationship. It is contemplated that either or both of the polymers may be dyed or have a functional additive added.

In Example 6, it is contemplated that the first polymer component (i.e., the sheath) includes a polyamide, a polyolefin, or a polyester. Furthermore, in Example 6, it is contemplated that the second polymer component (i.e., the core) includes a polyamide, a polyolefin, or a polyester. It is further contemplated that the ratio of the sheath material to the core material (calculated by weight) may be manipulated to lower the costs of producing an enhanced bi-component continuous filament by maintaining the desired denier while decreasing the percentage of the sheath or core material that contains a dye or functional additive. For example, it is contemplated that the core of the enhanced bi-component continuous filament could comprise polyester core that accounts for 70% of the filament's volume and a sheath that has a functional additive that accounts for 30%. By decreasing the volume of the sheath material, it is possible to optimize the desired properties and cost.

Turning now toFIG.6, a schematic cross-sectional view of an embodiment of a bi-component filament410, in accordance with one or more aspects of the present disclosure, is shown. Here, the bi-component continuous filament410has a generally circular cross-sectional shape with the polymer components arranged in a side-by-side relationship. As shown inFIG.6, bi-component filaments in accordance with one or more aspects of the present disclosure are not limited to the polymer components being arranged in a sheath-core relationship. InFIG.6, two different polymer components416,418are shown side-by-side, and adhered together, to form a single bi-component continuous filament410having a generally circular cross-sectional shape. It should be noted that, though the bi-component continuous filament410ofFIG.6is depicted as having a generally circular cross-sectional shape, filaments with non-circular cross-sectional shapes (e.g., elliptical, tri-lobal, and the like) are likewise contemplated. Furthermore, in at least some contemplated embodiments, a bi-component continuous filament with polymer components arranged in a side-by-side relationship, as inFIG.6, can be symmetrically arranged. In other contemplated embodiments, a bi-component continuous filament with polymer components arranged in a side-by-side relationship can be asymmetrically arranged.

Although not specifically depicted here, it is further contemplated that the polymer components of bi-component continuous filaments in accordance with one or more aspects of the present disclosure may exhibit matrix-fibril type structure, whereby filaments of one polymer component are dispersed in a matrix made using another polymer component, or the polymer components of bi-component continuous filaments in accordance with one or more aspects of the present disclosure may be arranged in a segmented pie-chart (or citrus) type structure. It is contemplated that these other types of bi-component continuous filament arrangements can have circular or non-circular arrangements, as might be preferred. It is further contemplated that these other types of bi-component filament arrangements can have symmetrical or asymmetrical arrangements, as might be preferred. In a method of generating bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present invention, first and second polymer components, as described in connection withFIGS.1-4and6, are selected for inclusion in a bi-component continuous filament. Though the polymer components often exist in a chip or pellet form, other forms of polymer components are contemplated. In a contemplated method, the first and second polymer components are mixed independently of one another. A binding agent, as described hereinabove, can be included in the polymer mix of one or both of the and second polymer components. In a contemplated embodiment, the binding agent is mixed with the second polymer component, which, inFIGS.1-4, forms the core of the resulting bi-component continuous filament.

Either or both of the and second polymer components can be solution-dyed prior to spinning. In contemplated embodiments, the solution dyeing process includes a pigment or each of a pigment and a solvent. As discussed hereinabove, solution dyeing the polymer components prior to spinning enables coloration of the polymer components (across a wide spectrum of colors, particularly when a solvent is included in the solution dyeing process). The solution-dyeing process can also enhance strength and durability in the polymer components so as to impart the resulting bi-component filament with desirable attributes for various end-use applications.

Each polymer mix is heated and stirred so that each of the first and second polymer components forms a melt that is ready for extrusion via a spinneret. The first and second polymer melts are fed through a spinneret selected to yield a bi-component filament10,110,210,310,410of a particular cross-sectional shape. After spinning, the resulting bi-component filament10,110,210,310,410can be further treated and/or texturized for implementation across a wide range of different end-use applications. The resulting filament further can be heat set, including, but not limited to, dry heat setting, steam heat setting, or a combination of both.

In one contemplated embodiment, the resulting bi-component filament10,110,210,310,410can be texturized to form bulk continuous filament suitable for tufting and weaving into floor coverings, such as carpets, or other textile products where durability, strength and/or color-fastness may be advantageous. In further preparation for end-use applications, bulk continuous filament bundles of the bi-component continuous filaments10,110,210,310,410can be intermingled with two or three bundles of the same color or a different color.

Additionally, or alternatively, the resulting bi-component filament10,110,210,310,410can be cable formed, whereby the filaments exhibit a pile construction with chunky tufts and longer pile height, or twist and heat set formed, whereby the filaments are twisted together and then heat set to help the twisted bundle stay intact and increase resistance to pile crush. Where bi-component continuous filaments are twisted, it is contemplated that single or multiple bundles of bulk continuous filaments (e.g., one, two or three bundles) of the same or different color can be twisted to satisfy the demands of various end-use applications. In this regard, it is contemplated that twisting can range from zero turns per meter up to approximately 300 turns per meter. Likewise, where bi-component continuous filaments are heat set, it is contemplated that single or multiple bundles of bulk continuous filaments (e.g., one, two or three bundles) of the same or different color can be heat set to satisfy the demands of various end-use applications. Heat setting can afford the filaments with enhanced dimensional stability as well as other desirable attributes, such as wrinkle resistance and/or temperature resistance. It is contemplated that heat setting can be accomplished by steam heating, by dry heating or by a combination of steam and dry heating.

In contemplated embodiments, bulk continuous filament generated using bi-component filaments10,110,210,310,410in accordance with one or more aspects of the present invention exhibits a denier per filament (DPF) ratio measuring from approximately 2 DPF to approximately 30 DPF. Furthermore, in contemplated embodiments, bulk continuous filament generated using bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present invention exhibits a weight measuring between approximately 500 denier to approximately 3500 denier.

Bi-component filaments10,110,210,310,410in accordance with one or more aspects of the present invention have broad utility across a range of end-use textile applications. In at least some embodiments, a polyamide sheath can provide a good visual appeal to pile change and, as such, the bi-component filament is well-suited for use in floor covering products. Furthermore, in at least some embodiments, a polyester or a polyolefin (e.g., polypropylene) core can provide enhanced moisture-repelling properties so that textile products incorporating such filaments are more durable and are quick-drying.

In various contemplated embodiments, bi-component continuous filaments10,110,210,310,410in accordance with one or more aspects of the present invention can be woven for production of any of a wide range of floor and surface coverings, including, but not limited to, door mats, bath rugs, area rugs, accent rugs, carpet tile rugs, broadloom carpet, automotive floor mats, automotive covering, automotive internal floor covering. It is further contemplated that bi-component filaments10,110,210,310,410in accordance with one or more aspects of the present invention may likewise be implemented in textile products such as sheeting, towels and other bed and bathroom textile needs.

Based on the foregoing description, it will be readily understood by those persons skilled in the art that the embodiments of the present disclosure are susceptible of broad utility and application. Many embodiments and adaptations of the present disclosure other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present disclosure and the foregoing descriptions thereof, without departing from the substance or scope of the present disclosure. Accordingly, while the present disclosure has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present disclosure and is made merely for the purpose of providing a full and enabling disclosure. The foregoing disclosure is not intended to be construed to limit the present disclosure or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present disclosure being limited only by the claims appended hereto and the equivalents thereof.