Basf Corporation

Honeywell International Inc.

Randall A Sferrazza

Otto M Ilg

Matthew B Hoyt

Charles F Helms, Jr

John A Hodan

Dominick A Burlone

Richard Kotek

Carol W Morgan

Terry D Roberts

Fang A Wang

Ronald G Morrow

Ann S Johnson

David M Waddington

BCF yarn is melt-spun, drawn and textured to provide morphologically stable BCF yarns. The yarn texturizing includes a relatively low efficiency fluid jet texturizer, that is a fluid jet texturizer operating at a sufficiently low fluid jet velocity and a sufficiently high fluid jet temperature to obtain a yarn skein shrinkage of less than about 0.50 inch, more preferably about 0.25 inch or less. Most preferably, the BCE yarns are formed of nylon-6 and exhibit an alpha-crystalline content of less than about 45%, and usually between about 45% to about 55%.

Methods for making morphologically stable bulked continuous filaments

Morphologically stable BCF yarns, and the methods and systems for making such BCF yarns are provided. More specifically, the BCF yarn is melt-spun, drawn and textured. The yarn texturizing includes a relatively low efficiency fluid jet texturizer, that is a fluid jet texturizer operating at a sufficiently low fluid jet velocity and a sufficiently high fluid jet temperature to obtain a yarn skein shrinkage of less than about 0.50 inch, more preferably about 0.25 inch or less. Most preferably, the BCF yarns are formed of nylon-6 and exhibit an alpha-crystalline content of less than about 45%, and usually between about 45% to about 55%.

Morphologically stable bulked continuous filaments and methods and systems for making the same

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions in the reactor zone to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly from the reactor zone and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

Continuous polymerization and direct fiber spinning and systems for accomplishing same

Continuous anionic polymerization and melt-spinning of a polycaprolactam includes forming a reaction mixture by bringing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator into contact with one another, and then subjecting the reaction mixture to anionic polymerization reaction conditions to obtain a molten polycaprolactam. The molten polycaprolactam is the directly (i.e., without intermediate solidification) transferred to, and extruded through, a fiber-forming orifice of a spinneret to form a fiber thereof. One exemplary system to achieve such continuous anionic polymerization and melt-spinning of polycaprolactam includes a mixer for receiving and mixing at least two streams of liquid caprolactam respectively containing a polymerization initiator and co-initiator, and a reactor and melt-spinning apparatus downstream of the mixer. The reactor and melt-spinning apparatus most preferably is formed of multiple plates which establish a reactor zone having a flow path for the reaction mixture which is sized and configured to achieve a predetermined residence time of the reaction mixture therein, and a temperature control zone in thermal communication with the reactor plate for controlling the temperature of the reaction plate to achieve anionic polymerization reaction conditions while the reaction mixture is flowing along the defined flow path therein to obtain the molten polycaprolactam. A spinneret zone downstream of the reactor zone thus receives the molten polycaprolactam directly and forms a fiber therefrom by extruding it through the spinneret's fiber-spinning orifice.

Processes and apparatus are provided whereby the morphology of bulked continuous filament (BCF) yarns can be variably controlled. More specifically, according to the present invention, the BCF yarn is melt-spun, drawn and textured, most preferably in a one-step spin-draw-texture (SDT) process, wherein prior to texturing, the yarn is subjected to a differential temperature condition. Most preferably, such differential temperature condition is accomplished using the duo rolls employed in drawing the BCF, such that one of the rolls is maintained at a greater temperature as compared to the other of the rolls. Most preferably, it is the upstream-most roll (relative to the general conveyance path of the filament toward the texturizer) which is the hotter of the duo rolls.

Processes and systems for making synthetic bulked continuous filament yarns

Continuous polymerization and direct fiber spinning and apparatus for accomplishing same

Growing community of inventors

Asheville, NC, United States of America

Randall A Sferrazza