KR900005000B1 - Improvements in polyester fiberfill - Google Patents

Abstract

(a) 60-95 wt.% of crimped polyester staple fibre (I); and (b) 5-40 wt.% of crimped staple binder fibre (II). (I) has a cured coating of a slickener comprising chains of poly (alkylene oxide), pref. being a segmented copolymer of poly (ethylene terephthalate) and poly (ethylene oxide) in amt. 0.1-1 wt.% w.r.t. (I); and (II) comprises a polymer having a binding temp. lower than the softening temp. of (I). The fibre blend is used as fibre fill to form lofted bonded batts for sleeping bags, cushions and pilows. The slickener gives improved durability and moisture transport, soft hand and low flammability and is easier to bond than fibre coated with silicone slickener.

Description

Improved Polyester Fiber Filler

FIELD OF THE INVENTION The present invention relates to the improvement of polyester fiber filler materials, commonly referred to as polyester fiber fillers, and more particularly to providing polyester fiber fillers in a form suitable for blending with binder fibers, thermally combining desirable properties. A combination capable of providing a useful binding product (e.g., a combined batt) with the resulting binding batt and other products incorporating the same.

Polyester fiber fillers are commonly used in other products, such as sleeping bags, cushions, duvets, and pillows, in addition to various garments. Particularly useful and preferred forms of polyester fiber fillers include, for example, cured polysiloxane coatings [usually silicone gloss] as described in US Pat. No. 3,271,189 (Hoffmann) and US Pat. No. 3,454,422 (Mead et al). Having a slickener, because the coating improves certain desirable properties such as handling, volume-stability and woolenness. Although the above silicone-slickened-polyester fiber fillers are widely used commercially, such coatings have long been recognized as having significant disadvantages with desirable properties. As reported by U.S. Patent No. 4,281,042 (pamm) and U.S. Patent No. 4,304,817 (Frankosky), silicone coatings are particularly suitable for heat treating blends of glossy polyester fiber fillers and binder fibers. By binding at the intersection, it becomes nearly impossible to functionalize the binder fibers. The bond is very weak and it is believed that even after the bond, the bond between the residues of the binder fibers, the bicomponent fibers, in which the core remains. Thus, it is not practical to use such silicone-glossy fiber fillers to produce through-bonded batts or molded articles that are suitably bonded and durable to the end use.

The main object of the present invention is to adequately take advantage of the form of advantage that could only be obtained from unbound minerals in the past, in parallel with the improved performance (especially durability) previously achievable only with binding batters from "dry" fiber fillers. To provide a through-bonded bat. Another object is to improve the elasticity and structural stability of polished fiber filler products. Other objects will be described later.

This specification cites US Pat. No. 3,702,260 to Jayme et. Al. Jane describes a surface-improved polyester fiberfiller product with improved compression resilience and other salient properties (see columns 2 to 3) and methods of making the same. The coating is co-crystallized on the surface of crimped polyester staple fibers, which is present in about 20 to 95% by weight of poly (oxyalkylene) units and present in the polyester staple fiber substrate. Copolyesters containing about 80 to 5% by weight of the same ester units as those of the The batt of the coated fiber may or may not be bonded, preferably not bonded (2 columns, 57 to 59 lines). The binder resin is applied to the bat by spraying both surfaces in the form of a water emulsion, for example, followed by drying and curing (5 columns, 15 to 21 lines) to prevent subsequent fiber leakage and / or the bat upon final application. Can be prevented from moving. Jane did not mention binder fibers, and Jane's fiber fillers are not known commercially.

The inventors have found that replacing the existing commercial silicone gloss with a hydrophilic coating having poly (alkylene oxide) chains or segments on the polyester fiber filler surface can achieve the desired purpose and other advantages. Such coated polyester fiber fillers can be combined more effectively than silicone-glossy fiber fillers, for example from blends with binder fibers, and have other advantages of reduced flammability and improved moisture transfer as described below. In other words, the hydrophilic coating is properly "cured" on the polyester fibers, i.e. the poly (alkylene oxide) chain is essentially removed from the surface of the polyester fibers permanently, i.e. by washing or other treatments encountered in normal processing or use. It is important to make sure that they are stuck.

Thus, substantially from (a) about 60 to about 95 weight percent of crimped polyester staple fibers and (b) about 5 to about 40 weight percent of crimped staple binder fiber supplemented to a total of 100 weight percent, said poly Improved polyester, characterized in that it contains a polymer having a bonding temperature lower than the softening temperature of the ester staple fibers, wherein the polyester staple fibers have a cured coating of a gloss agent consisting substantially of a poly (alkylene oxide) chain Fiber filler blends are provided.

Two commercial poly (alkylene oxide) copolymers having two different “curing” mechanisms are described in particular below. One of them is applied to the surface of a polyester fiber containing poly (ethylene terephthalate) repeating unit, and the poly (ethylene oxide) and poly (ethylene terephthalate) which is fixed to the fiber when cured at about 170 ° C. Block copolymers. The mechanism to be cured is not fully understood but is believed to be co-crystallization of polyester segments on polyester fibers. Another curing mechanism is achieved by crosslinked poly (alkylene oxide) chains modified with reactive groups that allow crosslinking with or without the addition of a catalyst or crosslinker. These two routes can be carried out using commercially available polymers with many fragments of poly (ethylene oxide) and / or poly (propylene oxide), preferably poly (ethylene oxide).

According to one aspect of the invention, the crimp is supplemented substantially to (a) about 60 to about 95 weight percent, preferably about 80 to about 90 weight percent and (b) 100 weight percent total crimped polyester staple fiber. About 5% to about 40% by weight, preferably about 10% to about 20% by weight of the prepared staple binder fiber, and contains a polymer having a lower melting point than the polyester staple fiber, wherein the polyester staple fiber is poly (ethylene Terephthalate) and a poly (ethylene oxide) copolymer segment to provide a polyester fiber filler blend coated in an amount of about 0.1 to about 1 weight percent of the polyester staple fiber weight.

According to another aspect of the invention, substantially 5 to 40 weight percent crimped staple binder fiber supplemented to substantially (a) about 60 to about 95 weight percent of crimped polyester staple fibers and (b) 100 weight percent in total. And containing a polymer having a lower melting point than polyester staple fibers, wherein the polyester staple fibers are of polyester staple fiber weight with modified poly (alkylene oxide) grafted with functional groups to enable crosslinking. A polyester fiber filler blend coated in an amount of about 0.1 to about 1 weight percent is provided.

The formulations of the present invention allow for the provision of a combined fibrous filler product having advantages over conventionally available products, which will be described in detail below, but can be summarized as follows: Improved performance, especially durability, as compared to “dry” (ie, non-glossy) fiber fillers. Flexibility combined with elasticity and structural stability resulting from superior bonding. Good moisture transfer. Compared with "dry" fiber fillers, the flammability deterioration that was not obtained with the conventional silicone-glossy fiber fillers described above.

The main element of the present invention is to provide a preferred hydrophilic coating of the poly (alkylene oxide) chain on the polyester fiber filler using an appropriate coating material. As already pointed out, some of these materials are commercially available.

Suitable coating materials for use in accordance with the present invention include copolyesters consisting essentially of poly (ethylene terephthalate) segments and poly (alkylene oxide) segments derived from poly (oxyalkylene) molecular weights of 300 to 6,000. Segment is included. These various copolyesters and their dispersants are described in US Pat. Nos. 3,416,952, 3,557,039 and 3,619,269 (McIntyre et al), and many other patent applications also include poly (ethylene terephthalate) fragments and poly ( Fragmented copolymers containing alkylene oxide) fragments are described. Preferred poly (alkylene oxides) will be commercially useful poly (ethylene oxide). One such product is commercially available from ICI America Incorporated as a textile treatment and is sold under the trademark "ATLAS" G-7264. This product is marketed in Europe by ICI Specialty Chemicals, Brussels. Alternatively, E.I. du Pont de Nemours and Company sells it as "ZELCON" 4780. Other materials are described in US Pat. No. 3,981,807 (Raynolds). Other suitable materials include modified poly (ethylene oxide) / poly (propylene oxide) grafted with functional groups that are cross-linked, for example by treatment with 5% by weight citric acid. This product is sold by Union Carbide Company as "UCON" 3207A. Other materials that may include particularly useful compositions are described in Teijin EP 159882 and ICI Americas EP 66994, more details of which are pending at the same time. It is described in the specifications DP-3720-B and DP-4185.

The coating material can be applied to the polyester fibers on staples, or preferably on tows, shrunk in a shrinkage chamber, especially after withdrawal. The coating material is cured on the fiber by a process involving co-crystallization or crosslinking depending on the nature of the material. The fiberfiller may then be blended with the binder and packaged, or it may be packaged separately and blended with the binder fiber prior to processing the product on a standard batting machine. If desired, the bat is generally processed, for example in an oven, to bind the binder with the fiber filler and to achieve the specificity of the bat described herein. The coating may also be applied to the fiber filler staples and blended with the binder fibers without curing at the end of the process line, after cutting and pre-packaging. The blend is processed in a standard carding apparatus and curing is carried out in an oven at the same time as being joined by the binder. However, since the coating material generally has less friction between fibers, a smoother shrinkage is formed, which results in better results than those applied before or during the shrinking process, which also contributes to improved durability and increased flexibility, and that bonding is a result of the past. It appears to be good relative to the curing results. The binder fiber blend is processed on a conventional carding device, shredded and heat treated in an oven to join the fiber filler and binder fiber.

The binder is preferably heat-activated, so it dissolves or softens at temperatures below 50 ° C. below the melting point of the polyester fiber filler so that the bond does not affect the integrity of the fiber filler itself. Commercially available coatings / cores having a copolymer coating of poly (ethylene terephthalate) homopolymer core and poly (ethylene terephthalate / isophthalate) (60/40) modified to reduce melting point 50/50 2 Component binder fibers have been used with poly (ethylene terephthalate) fiber fillers in making batts of the invention. Although coating / core binder fibers are preferred, monocomponent binders can also be used as an improvement in controlling the binder and fiber filler without coating. The denier of the binder fibers will generally be about 3 to about 30 dtex, preferably less than about 20 dtex. Further information regarding binder fibers is described in pending specification DP-3720-B and US Pat. Nos. 4,281,042 and 4,304,817, both of which are filed concurrently with the present application.

The fibrous filler may be from about 1 to about 30 dtex and may be solid or tubular with a single or multiple pores and have a round or malformed cross section.

Low denier is often used where insulation is an important factor, such as clothing, slipping bags and special sleeping articles for public use. In these applications the formulations of the present invention exhibit several advantages over commercially available polyester gloss bat or binder fiber formulations. The bonded bats exhibit good thermal insulation with flexibility and good bonding. Flexibility is preserved even if the coating is washed several times due to its resistance to washing and the batt shows excellent tear resistance due to good bonding with the binder fiber core. The performance of this bonding bat is very surprising in that it was difficult to bond the fiber fillers polished with the prior art silicone gloss. These batts have the same flammability as the properties of non-glossy fiber bats with the above preferred flexibility and also in contrast to the flammability of fibers polished with silicone.

Volumetric measurements are typically performed on an Instron instrument to measure the height and compressive force of each pillow or cushion sample compressed into a foot of appropriate diameter (10 or 20 cm) attached to the Instron.

Foot B (20 cm in diameter) is used for low density products having a maximum pressure of 100 N and a support area (SB) at 30 N (expressing the height of the pillow in cm under average head weight). In this case the flexibility corresponds to the height difference (cm) between the initial height (IH ₂ ) and the support area at the beginning of the second compression cycle; (Absolute) flexibility = IH ₂ -SB (height at 30N). Flexibility is sometimes expressed in terms of relative flexibility, ie in percent of IH ₂ .

Foot A (10 cm in diameter) is used for high density products (e.g. furniture cushions, mattresses) with a maximum pressure (in this case equal to the support volume) at 60 N (corresponding to the pressure provided by the seated person). In this case the flexibility corresponds to the height difference between the initial height (IH ₂ ) at the beginning of the second compression cycle and the height at 7.5; That is, (absolute) flexibility in this case = volume at IH ₂ -7.5N. Flexibility is also expressed in terms of relative flexibility with respect to IH ₂ in some cases. The firmness of the cushion is related to the strong support area and conversely to the flexibility.

Elasticity is measured as Work Recovery (WR), ie as the area ratio under the total recovery curve, calculated as percent area under the overall compression curve. The higher the WR, the better the elasticity.

Durability—Multiple layers of each bat (50 × 50 cm) are stacked to make a weight of about 850 g. The number of layers is adjusted to provide pillows with a minimum weight difference. These are covered with fibers and measured by foot A. The initial density of the pillow is 12-15 g / l depending on the volume of each item. These low density "pillows" are repeatedly compressed to a maximum pressure of 1,225 N at a rate of 1,200 times / hour for 10,000 times. The pillow is measured again and the volume loss is calculated.

Another series of cushions was made by stacking multiple layers to yield a cushion of 850 ± 15 g. The cushion is compressed using a button to produce a furniture back cushion with a density of 25 to 28 g / l (depending on whether measurements are taken around or at the top of the button). These back cushions are stomped using a human hip shape with an area of 37 × 43 cm and a pressure of 8.8 KPa. Stumping is repeated at a rate of about 1,000 times / hour for 10,000 times. After the test, the cushion is measured again and the volume loss is calculated.

Flammability: Two tests are used: Methaneamine ring test is U.S. It is based on the Federal method (U.S. Federal Method, Flammability Standard for Carpets DOCFF 1-70).

45 degree open flame test DIN 54335.

In both cases, measure and record the area broken and record the rate at which the flame spread in the open flame test.

Strength: Grab Test The bond strength is evaluated according to DIN 53857 (the results are generally normalized to the standard 200 g / m ² ).

Wash test: Quilt one layer (40 × 40 cm) of each bat (in the garment fabric) and sew the center. The compressive force of the two layers is measured by Instron (foot B-diameter 20 cm, maximum pressure 240 N). All samples are washed together three times at 40 ° C. in the washer. Wash the sample again after washing and calculate the thickness difference.

The invention is further illustrated in the following examples, where all parts and percentages are by weight unless otherwise indicated. All heights are measured in cm and are sometimes referred to as "bulk".

Example 1

Conventional tubular, non-glossy polyester fiber filler (6.1 dtex) is 0.35 wt. Cover with% (solid) and then air dry at room temperature. The coated staples are blended with the coating / core binder fibers 4.4 dtex described above (85/15). The blend is processed by superimposing four layers in parallel so that they do not intersect and overlap to produce a one meter wide batt having a density of about 180 g / m ² . The bat is thermally bonded to a temperature of 160 ° C. in a conventional 3.5 m wide oven; This heat treatment has the dual effect of curing the coating on the polyester fiber filler and activating the bond coating of the binder fiber to bond the bat. The various properties of the bound batts are measured and recorded by tests that clearly demonstrate the superiority of Item 2 of the present invention over Control Item 1, wherein Control 1 uses the same base fiber filler and binder fibers in exactly the same way. Provided that no hydrophilic poly (ethylene oxide) -containing coating is applied. Both products are processed under the same conditions and combined by heat treatment in parallel for the same time in the same oven.

1-Test Bat 2 is much softer and more elegant, but very different from the product of silicone-gloss.

2-Table 1 shows improved flexibility and durability over control.

The bond to the 3-binder fiber is much better than 0.3% silicone-glossy, 70% of the contrast strength in the machine direction and 50% in the reverse direction, which is very significant because no cross-lamination is present in this example. Not an enemy

The flammability of 4-Test Item 2 was very similar to Control 1 at 1.0 second flame duration (= control) and the break length was 8.4 cm for 6.0 cm control, whereas the silicon-glossy bat had a 40 second flame duration. As totally destroyed.

TABLE 1

Although the coated fiber filler was not pre-cured (ie not heat treated prior to bonding), the batting strength of the bat was surprisingly high and about 70% of the control, thus demonstrating the superior adhesion of the coating to the fiber filler. do. The following examples illustrate the improvements obtained by curing the coating and using cross-laminated webs.

Example 2

1. This is the control described below.

2. The same 6.1 dtex tubular conventional dry shrinked polyester fiber filler staple substrate was essentially coated with 0.35% solids according to the procedure described in Example 1, followed by heating the staples at 170 ° C. for 5 minutes to apply the coating. Curing on the fibers. The cured coated fiber filler is then blended in the same fraction (85/15) as the same coating / core binder fibers as in Example 1. This blend is processed on cards and cross-laminators to produce batts of about 190 g / m ² density and combined at a rate of 1 m / min in an oven at 160 ° C. The following tables compare the bonding bat of this item 2 with a control bat (item 1) made from the same base polyester fiber filler without the hydrophilic coating according to the present invention and other batts prepared as follows.

3. The same basic polyester fiberfiller substrate is coated with 0.35% solids by spraying with a 20% solution of UCON 3207 A (with 5% citric acid added) and cured as in item 2 above.

4. This is a control similar to item 1, but using 13 dtex tubular shrink polyester fiber filler with the same 4.4 dtex binder fiber.

5. This is similar to control item 4, except that the polyester fiber filler is coated on a 13dtex fiber filler with 0.35% of "ATLAS" G-7264 and cured as in item 2.

6. This is similar to item 2 above, except that the polyester fiber filler substrate is coated as tow under factory conditions by applying an 8.2% underwater emulsion of "ATLAS" G-7264 to produce the same solid coating of 0.35% on the fibers. The tow is then relaxed at a temperature of 175 ° C. to cure and crimp the coating. The relaxed tow is cut 60 mm long with the tow of the coating / core binder fibers to produce an 85/15 fiber filler / binder blend. The mixture is converted to a bat and the bat is thermally bonded under essentially the same conditions as described above.

7. This item is prepared essentially the same as item 6, except that the coating is provided from UCON 3207A as in item 3.

Summary: Items 1 and 4 are controls, items 2, 5 and 6 are covered with ATLAS G-7264, while items 3 and 7 are covered with UCON 3207A: items 2, 3 and 5 are coated in staples to 170 ° C. While cured at, items 6 and 7 were coated in tow form before shrinking at 175 ° C .: items 1 to 3, 6 and 7 had a fiber filler of dtex 6.1 while item 4 and 5 were 13 dtex.

It will be noted that the weight and density of the bats are not the same. All appropriate amounts were calculated and "standardized" at the same weight of 200 g / m ² for proper comparison.

Table 2 provides compression data for all seven bonding batts and shows good results in all cases, ie good results compared to silicone-glossy fiber fillers that cannot be bound with the present invention.

Tables 3, 4 and 5 provide flammable data. Neither item shows flammability, and the broken areas are comparable to Controls 1 and 4 using non-glossy (dry) fiber fillers, ie the fiber filler coating does not significantly increase flammability beyond that of dry fiber fillers. In contrast, the flammability test was performed on controls 8 and 9 showing known flammability associated with the silicone-gloss product. Control 8 is a conventional silicone-glossy fiber filler batter as used in Examples 1 and 2 exclusively except for the silicone-gloss. Control 9 was 60/20 / of 60% non-glossy fiber filler as used in Examples 1 and 2, 20% gloss fiber filler as used in Control 8 and 20% of binder used in Examples 1 and 2. Made from 20 blends, this results in a very significant increase in flammability, even with minor additions of silicone-glossy fiber fillers, leading to undesirable consequences. The flammability test was not standardized.

Table 6 shows the tear strength measurements. The table at the top gives the different weights and actual measurements of each bat and the table at the bottom gives the calculated measurements, all standardized to the same weight of 200 g / m ² , which is somewhat advantageous for low weight control 1 Is easier. The very good burst strength of the preferred item 6 is most pronounced. The degraded aspects of items 3 and 7 are believed to be due to the nature of the coating and good results are expected from similar coatings (preferably) based on poly (ethylene oxide), but even these coatings are virtually free of bonds. It is significant that it provides significant binding in contrast to silicone-glossy fiber fillers that provide a product that does not (except between bicomponent binder fiber residues). These strength tests are only directly related to the durability of the furniture, but demonstrate strong bonding, which partly explains the superior support and durability.

Table 7 shows the results of the two-layer test and also shows the bond strength between the layers, in particular item 6 is preferred and much better than the control. The double layer test is a very important test because it is a major cause of breakage in some structures of furniture and mattresses and is important for sleeping bags and sportswear.

Table 8 records two data sets, in which A controls compared to item 6 compared to a control commodified with a compression cushion having a density of 25 to 28 g /. Comparing the data, item 6 has a higher height under relatively low loads (IH ₂ and 7.5N), but at a supportive level it has a lower volume. This indicates that the flexibility of the product, explained by the friction of the fibers with the fibers, is improved. Test item 6, although having a somewhat lower density, has very good durability at all loads than the conventional control. As shown in Table B, the volume difference is very large when the same item is considered an uncompressed decor cushion or pillow. Despite the significant density difference, Test Item 6 has the same volume loss and maintains a very large volume after the endurance test. Item 7 also shows a significant improvement in volume durability, especially in the supportive range, compared to conventional items. Items 3 and 7 made from Union Carbide 3207A are also very flexible and have the least amount of support. This may be of interest to applications such as sleeping bags where high compressibility is required. In essence, all test articles show better durability than controls, even if they have a somewhat lower density. The durability strengths of the product of the present invention over the control are very significant both in density and generally in the practical range of loads. Increased flexibility and durability advantages meet the real marketability demands, and the value of the product of the present invention is further increased due to the good bonding and non-flammability of this fiber filler. This property is particularly interesting for sportswear, sleeping bags and the like, as well as for applications such as furniture and mattresses. The data in Table 8 requires several notes:

Volume and volume durability are essential for furniture and mattresses.

The advantages of the product of the invention, in particular item 6, are in fact much greater than what is apparent from the data. It has better durability at lower densities expressed in g / l.

Table 9 shows the volume change after three hand washes at 40 ° C. This table also shows the excellent performance of most of the products of the present invention, as items 6 and 7 have the lowest changes even though they have significantly larger volumes than the control. Only item 3 is an exception, which may indicate a defect in the manufacture of this item.

TABLE 2

TABLE 3

TABLE 4

TABLE 5

TABLE 6

TABLE 7

TABLE 8

TABLE 9

Claims (10)

Substantially from (a) about 60 to about 95 weight percent of crimped polyester staple fibers, and (b) about 5 to about 40 weight percent of crimped staple binder fibers supplemented to a total of 100 weight percent, said polyester An improved polymer characterized by containing a polymer having a bonding temperature lower than the softening temperature of the staple fibers, said polyester staple fibers having a cured coating of a slickener substantially consisting of poly (alkylene oxide) chains Polyester fiber filler blend. The method of claim 1, wherein the polyester staple fibers are coated with a copolymer segment of poly (ethylene terephthalate) and poly (ethylene oxide) in an amount of about 0.1 to about 1% by weight of the polyester staple fiber. Formulation. The method of claim 1 wherein the polyester staple fibers are coated with an amount of about 0.1 to about 1 weight percent of the polyester staple fibers with a modified poly (alkylene oxide) grafted with functional groups to enable crosslinking. Formulated to do. The blend as claimed in claim 1, wherein the polyester staple fibers are coated with an amount of about 0.15 to about 0.6 weight percent of the polyester staple fibers with a gloss agent. A polyester fiber having a cured coating of a gloss agent consisting essentially of a poly (alkylene oxide) chain is blended with the binder fiber, the blend is formed into a batt, and the bat is heat treated to coat the binder fiber A method of making a bonding batt of polyester fiber filler by allowing it to bond at the intersection of the ester fiber filler. 6. The method of claim 5, wherein the binder fiber is a coating / core fiber, whereby the coating provides the binder and the core remains in the bonded batt to provide a polyester fiber filler coated at the point of bonding. 6. The method of claim 5 wherein the binder binds the coated polyester fiber filler at the intersection by using monocomponent binder fibers. 8. The method of any one of claims 5 to 7, wherein the blend is according to any one of claims 2 to 4. Through-bonded polyester fiber fillers with improved durability, water mobility, ductility and low ductility, characterized in that the polyester fibers are coated with a glaze comprising substantially poly (alkylene oxide) chains. )bat. 10. The bat of claim 9, wherein the gloss agent is as described in any of claims 2-4.