Toray Industries, Inc.

Tadakazu Endo

Masanori Takahashi

Hirotsugu Suzuki

Shigemitsu Saitoh

Kiyoshi Nakagawa

Itaru Nakamura

Hideo Komatsu

Masanori Takeuchi

Tuneo Hanada

A process for producing thermal-insulating nonwoven bulky product characterized by its structural make up of substantially continuous single filaments of from about 0.01 to 2 denier which are stabilized on themselves in the product by a surface binder on the filaments.

Process for making a thermal-insulating nonwoven bulky product

Disclosed is a method of making a thick-and-thin fiber or fibers, wherein the fineness thereof changes gradually and periodically along the longitudinal direction thereof. The method comprises (1) a step wherein molten fiber forming polymer is extruded through spinneret holes at a constant throughput, (2) a step wherein the extruded filaments run through a short gaseous gap whose length is in the range of 0.1 to 6 millimeters before they plunge into liquid for abrupt solidification by cooling, (3) a step wherein the solidified undrawn filaments are touched by at least one vibrating substance before being withdrawn at a constant speed, (4) a step wherein the undrawn filaments are drawn by some roller systems, and (5) a step wherein the drawn filaments are thermally set.

Method of making thick-and-thin fibers

Disclosed is a thick-and-thin fiber or fibers, wherein the fineness thereof changes gradually and periodically along the longitudinal direction thereof, and is characterized by (a) the thick-and-thin recurring length of five to 500 millimeters, (b) the thick-and-thin ratio of four to 50, (c) the average fineness of 0.05 to 2000 deniers, and (d) almost constant cross section areas at both the thick and the thin portions, respectively. Also disclosed is a thick-and-thin staple fiber or fibers formed therefrom by cutting the thick-and-thin fibers at a predetermined interval. Additionally, disclosed is a fabric made of the thick-and-thin fibers or staple fibers as a component thereof. Disclosed is a method to produce the thick-and-thin fibers comprising (1) a step wherein molten fiber forming polymer is extruded through spinneret holes at a constant throughput, (2) a step wherein the extruded filaments run through a short gaseous gap whose length is in the range of 0.1 to 6 millimeters before they plunge into liquid for the abrupt solidification by cooling, (3) a step wherein the solidified undrawn filaments are touched by at least one vibrating substance before being withdrawn at a constant speed, (4) a step wherein the undrawn filaments are drawn by some roller systems, and (5) a step wherein the drawn filaments are thermally set.

Thick-and-thin fibers and products therefrom

A thermal-insulating nonwoven bulky product characterized by its structural make up of substantially continuous single filaments of from about 0.01 to 2 denier which are stabilized on themselves in the product by a surface binder on the filaments and process for making the same.

Thermal-insulating nonwoven bulky product

A polyester filament in which a polyether-polyester block copolymer is dispersed as fine striae along the filament axis, at least one of which is substantially endless. Process for preparing the same includes a melt spinning apparatus with static mixing elements interposed between separate molten polymer feed passageways and spinneret holes.

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Ohtsu, Japan

Tadakazu Endo