Process for producing bicomponent filaments with special cross-section

Claim 2

Process for the production of side-by-side bicomponent polyester filaments having improved crimp properties, said process comprising simultaneously and side-by-side melt spinning two polyester polymers by passing melted sparingly cross-linked polybutylene terephthalate polymer having therein at least about 0.20 mole percent of trifunctional or tetrafunctional ester-forming cross-linking agent and having a melted state viscosity VF of at least about 2000 poises at 260° C. through a plurality of channels in a distribution plate of a spinneret assembly into, in the form of jets or streams, a cavity between said distribution plate and the spinneret plate of said assembly, separately introducing melted polyethylene terephthalate polymer into said cavity to surround and envelope said jets or streams of polybutylene terephthalate, and thereafter passing the jets of polybutylene terephthalate and associated polyethylene terephthalate through a plurality of bores in said spinneret plate of said spinneret assembly, said bores of larger diameter than said channels, each bore associated with a corresponding channel, the axis of each bore displaced from the axis of each channel at least the distance equal to the differences between the radiuses of said bore and said channel to produce side-by-side polyester filaments wherein the polyethylene terephthalate partly envelopes the polybutylene terephthalate, wherein at least 45% of the periphery of the polybutylene terephthalate is covered by said polyethylene terephthalate.

Claim 3

Process of claim 1, wherein said sparingly cross-linked polybutylene terephthalate has a melted state viscosity VF of at least 4000 poises at 260° C.

Claim 4

Process of claim 1, wherein the polyethylene terephthalate has a melted state viscosity VF of about 1000 to about 3000 poises at 290° C.

Claim 5

Process of claim 1, wherein each of said jets or streams is directed into the corresponding bore by impingement upon a chamfer provided at the entrance to said bore.

Claim 6

Process of claim 1, wherein the polyethylene terephthalate is independently introduced into said cavity through channels in said distribution plate which are different from the channels through which the polybutylene terephthalate is introduced.

Claim 7

Process of claim 1, wherein in cross-section, said bicomponent filament is substantially circular, said polyethylene terephthalate polymer is substantially crescent shaped, and said sparingly cross-linked polybutylene terephthalate polymer lies inside said crescent.

Claim 8

Process of claim 1, wherein said cross-linking agent is trimethylol propane.

Claim 9

Process of claim 7, wherein said trimethylol propane is used in an amount of 0.3 to 0.4 mole percent, based on the amount of terephthalic acid units in said sparingly cross-linked polybutylene terephthalate.

Claim 10

Process for producing side-by-side bicomponent polyester filaments having improved crimp properties, comprising: (i) providing a melted sparingly cross-linked polybutylene terephthalate polymer having therein at least about 0.20 mole % of trifunctional or tetrafunctional ester-forming cross-linking agent, based on the terephthalic acid content of said sparingly cross-linked polybutylene terephthalate and having a melted state viscosity VF of at least about 2000 poises at 260° C.; (ii) providing a spinneret assembly comprising a distribution plate and a spinneret plate, said distribution plate and spinneret plate defining a cavity therebetween, said distribution plate being provided with a plurality of channels, and said spinneret plate being provided with a plurality of bores, said bores being of larger diameter than said channels, each of said bores being associated with a corresponding channel such that the axis of each bore is displaced from the axis of the corresponding channel by a distance equal to at least the difference between the radii of said bore and said corresponding channel; (iii) passing said melted sparingly cross-linked polybutylene terephthalate polymer through said plurality of channels in said distribution plate into said cavity to form streams or jets of said polymer in said cavity; (iv) introducing melted polyethylene terephthalate polymer into said cavity separately from said sparingly cross-linked polybutylene terephthalate polymer to surround and envelop said jets or streams of sparingly cross-linked polybutylene terephthalate polymer; and (v) passing said jets or streams of sparingly cross-linked polybutylene terephthalate enveloped with said polyethylene terephthalate through said plurality of bores in said spinneret plate to give side-by-side bicomponent polyester filaments in which, in cross-section, the polyethylene terephthalate partly envelops the sparingly cross-linked polybutylene terephthalate to an extent such as to cover at least about 45% of the periphery of said sparingly cross-linked polybutylene terephthalate.

Claim 11

Process for producing side-by-side bicomponent polyester filaments having improved crimp properties, comprising: (i) providing a melted sparingly cross-linked polybutylene terephthalate polymer having therein at least about 0.20 mole % of trifunctional or tetrafunctional ester-forming cross-linking agent, based on the terephthalic acid content of said sparingly cross-linked polybutylene terephthalate and having a melted state viscosity VF of at least about 2000 poises at 260° C.; (ii) providing a spinneret assembly comprising a distribution plate and a spinneret plate, said distribution plate and spinneret plate defining a cavity therebetween, said distribution plate being provided with a plurality of channels, and said spinneret plate being provided with a plurality of bores, said bores being of larger diameter than said channels, each of said bores being associated with a corresponding channel such that the axis of each bore is displaced from the axis of the corresponding channel by a distance equal to at least the difference between the radii of said bore and said corresponding channel; (iii) passing said melted sparingly cross-linked polybutylene terephthalate polymer through said plurality of channels in said distribution plate into said cavity to form streams or jets of said polymer in said cavity; (iv) introducing melted polyethylene terephthalate polymer into said cavity separately from said sparingly cross-linked polybutylene terephthalate polymer to surround and envelop said jets or streams of sparingly cross-linked polybutylene terephthalate polymer; and (v) passing said jets or streams of sparingly cross-linked polybutylene terephthalate enveloped with said polyethylene terephthalate through said plurality of bores in said spinneret plate to give side-by-side bicomponent polyester filaments in which, in cross-section, the polyethylene terephthalate partly envelops the sparingly cross-linked polybutylene terephthalate to an extent such as to cover at least about 45% of the periphery of said sparingly cross-linked polybutylene terephthalate.

Claim 12

Process of claim 6, wherein about 50 to about 70% of the periphery of said sparingly cross-linked polybutylene terephthalate is covered by said polyethylene terephthalate.