Basf Corporation

Honeywell International Inc.

James R Bristow

Matthew B Hoyt

Diane R Kent

Charles F Helms, Jr

Phillip E Wilson

Wendel L Burton

The present invention provides a process for producing yarn having reduced heatset shrinkage. Preferably, the fibers used in making the yarn are bicomponent fibers. The present invention also provides a process for producing yarn having reduced heatset shrinkage at reduced heat temperatures.

Process for producing yarn having reduced heatset shrinkage

Multicomponent fibers and methods and apparatus for producing the same are provided such that an inter-domain boundary layer is interposed between distinct domains formed of incompatible polymers so as to minimize (if not eliminate entirely) separation of the domains at their interfacial boundary. The inter-domain boundary layer is formed of a heterogeneous mixture of the polymers forming the respective adjacent domains between which the boundary layer is interposed. The inter-boundary layer will most preferably include rivulets or fingers of each polymer forming the adjacent domains which interlock with one another in a randomly tortuous manner. These different polymer rivulets thereby effectively increase the surface area and mechanical interlocking at the interfacial boundary between the fiber domains thereby increasing the adhesion therebetween.

Process of making a multiple domain fiber having an inter-domain

Multiple domain fibers having inter-domain boundary compatibilizing

Novel bicomponent fibers have a polyamide domain and an amorphous non-fiber-forming polymer domain which is embedded entirely within, and thereby completely surrounded by, the polyamide domain. The preferred bicomponent fibers have a sheath-core structure wherein the polyamide domain constitutes the sheath and the amorphous non-fiber-forming polymer constitutes the core. Surprisingly, even though the core is formed of a non-fiber-forming polymer, the bicomponent fibers exhibit properties which are comparable in many respects to fibers formed from 100% polyamide. Preferably, the fibers are concentric sheath-core bicomponent fibers having a nylon sheath and a core formed from polystyrene, polyisobutene and poly(methyl methacrylate). Polystyrene, and particularly atactic polystyrene, is preferred as the amorphous polymer domain.

Biocomponet fibers having distinct crystaline and amorphous polymer

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Asheville, NC, United States of America

James R Bristow