US5281378A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process of making high thermal bonding fiber
Assignee: Fibervisions Lp
•
Filing: 1992-05-20
•
Granted: 1994-01-25
•
Expires: 2012-05-20
Abstract
Abstract High strength spun melt fiber is prepared by utilizing threadline oxidative chain scission degradation of hot fiber spun from polymer component(s) having a broad molecular weight distribution in conjunction with a delayed quench step.
Inventors
- 👤 Randall E. Kozulla
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 14:14
CPC Classifications
D; D01; D01F; D01F8/00; D01F8/04; D01F8/06; D01F6/00; D01F6/02; D01F6/04; D01F1/00; D01F1/02; D01F1/10; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/2929; Y10T428/2931; Y10T442/00; Y10T442/60; Y10T442/681
Claims Analysis
Total Claims: 73
Claim 1
Independent Claim
73 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to effect oxidative chain emission degradation of the surface to obtain at least one polypropylene containing fiber or filament.
Claim 2
Dependent Claim
73 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to effect oxidative chain emission degradation of the surface to obtain at least one polypropylene containing fiber or filament.
Claim 3
Dependent Claim
21 words
The process according to claim 1, wherein the polypropylene containing material has a molecular weight distribution of at least about 6.59.
Claim 4
Dependent Claim
21 words
The process according to claim 2, wherein the polypropylene containing material has a molecular weight distribution of at least about 7.14.
Claim 5
Dependent Claim
21 words
The process according to claim 3, wherein the polypropylene containing material has a molecular weight distribution of at least about 7.75.
Claim 6
Dependent Claim
28 words
The process according to claim 1, wherein the polypropylene containing material subjected to extrusion includes a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof.
Claim 7
Dependent Claim
26 words
The process according to claim 1, wherein the polypropylene containing material subjected to extrusion includes at least one of phenylphosphites and a N,N' bis-piperidinyl diamine derivative.
Claim 8
Dependent Claim
46 words
The process according to claim 1, wherein the polypropylene containing material is extruded from an extruder and includes a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to control chain scission degradation of polymeric components in the extruder.
Claim 9
Dependent Claim
48 words
The process according to claim 1, wherein the controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere to effect oxidative chain scission degradation of the surface of the at least one fiber or filament includes controlling rate of quenching of the hot extrudate.
Claim 10
Dependent Claim
20 words
The process according to claim 8, wherein the controlling quenching comprises delaying quenching of the at least one hot extrudate.
Claim 11
Dependent Claim
26 words
The process according to claim 9, wherein the oxygen containing quenching atmosphere comprises a cross-blow quench, and an upper portion of the cross-blow quench is blocked.
Claim 12
Dependent Claim
16 words
The process according to claim 10, wherein up to about 5.4% of the cross-blow is blocked.
Claim 13
Dependent Claim
25 words
The process according to claim 8, wherein the controlling quenching includes immediately blocking an area as the at least one hot extrudate exits a spinnerette.
Claim 14
Dependent Claim
25 words
The process according to claims 1, wherein the at least one polypropylene containing fiber or filament comprises a monocomponent or a bicomponent fiber or filament.
Claim 15
Dependent Claim
23 words
The process according to claim 1, wherein the polypropylene containing material is extruded at a temperature of about 250° C. to 325° C.
Claim 16
Dependent Claim
23 words
The process according to claim 14, wherein the polypropylene containing material is extruded at a temperature of about 275° C. to 320° C.
Claim 17
Dependent Claim
61 words
The process according to claim 1, wherein the controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to effect oxidative chain scission of the surface comprises maintaining the temperature of the at least one hot extrudate above about 250° C. for a period of time to obtain oxidative chain scission degradation of the surface.
Claim 18
Dependent Claim
19 words
The process according to claim 16, wherein the controlling quenching includes blocking an upper portion of a cross-blow quench.
Claim 19
Dependent Claim
22 words
The process according to claim 16, wherein the controlling quenching includes passing the at least one hot extrudate through a blocked zone.
Claim 20
Dependent Claim
17 words
The process according to claim 18, wherein the blocked zone is open to the oxygen containing atmosphere.
Claim 21
Dependent Claim
25 words
The process according to claim 16, wherein the controlling quenching includes immediately blocking an area as the at least one hot extrudate exits a spinnerette.
Claim 22
Dependent Claim
142 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface, the polypropylene containing material including a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to at least substantially limit chain scission degradation of polymeric components in the extruder; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to effect oxidative chain scission degradation of the surface, the controlling quenching including maintaining the at least one hot extrudate at a temperature for a sufficient period of time to permit oxidative chain scission degradation of the surface of the hot extrudate to obtain at least one polypropylene containing fiber or filament.
Claim 23
Dependent Claim
142 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface, the polypropylene containing material including a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to at least substantially limit chain scission degradation of polymeric components in the extruder; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to effect oxidative chain scission degradation of the surface, the controlling quenching including maintaining the at least one hot extrudate at a temperature for a sufficient period of time to permit oxidative chain scission degradation of the surface of the hot extrudate to obtain at least one polypropylene containing fiber or filament.
Claim 24
Dependent Claim
97 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to obtain at least one fiber or filament having a decreasing weight average molecular weight towards the surface of the at least one fiber or filament, and an increasing melt flow rate towards the surface of the at least one fiber or filament.
Claim 25
Dependent Claim
97 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to obtain at least one fiber or filament having a decreasing weight average molecular weight towards the surface of the at least one fiber or filament, and an increasing melt flow rate towards the surface of the at least one fiber or filament.
Claim 26
Dependent Claim
30 words
The process according to claim 22, wherein the at least one fiber or filament comprises an inner zone including a weight average molecular weight of about 100,000 to 450,000 grams/mole.
Claim 27
Dependent Claim
22 words
The process according to claim 23, wherein the inner zone comprises a weight average molecular weight of about 100,000 to 250,000 grams/mole.
Claim 28
Dependent Claim
19 words
The process according to claim 23, wherein the inner zone comprises a melt flow rate of about 5-35 dg/min.
Claim 29
Dependent Claim
46 words
The process according to claim 23, wherein the at least one fiber or filament comprises on a outer zone including the surface of the at least one fiber or filament, and the outer zone comprises a weight average molecular weight of less than about 10,000 rams/mole.
Claim 30
Dependent Claim
22 words
The process according to claim 26, wherein the outer zone comprises a weight average molecular weight of about 5,000 to 10,000 grams/mole.
Claim 31
Dependent Claim
37 words
The process according to claim 26, including an intermediate zone positioned between the inner zone and the outer zone having a weight average molecular weight and melt flow rate intermediate the inner zone and the outer zone.
Claim 32
Dependent Claim
22 words
The process according to claim 26, wherein the inner zone has a high birefringence, and the outer zone has a low birefringence.
Claim 33
Dependent Claim
50 words
The process according to claim 22, wherein the polypropylene containing material is extruded from an extruder and includes a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to control chain scission degradation of polymeric components of the hot extrudate in the extruder.
Claim 34
Dependent Claim
23 words
The process according to claim 22, wherein the at least one fiber or filament comprises a monocomponent or a bicomponent fiber or filament.
Claim 35
Dependent Claim
26 words
The process according to claim 22, wherein the at least one fiber or filament comprises an inner zone having a melt flow rate of 5-35 dg/min.
Claim 36
Dependent Claim
21 words
The process according to claim 22, wherein the polypropylene containing material has a molecular weight distribution of at least about 6.59.
Claim 37
Dependent Claim
21 words
The process according to claim 33, wherein the polypropylene contain material has a molecular weight distribution of at least about 7.14.
Claim 38
Dependent Claim
21 words
The process according to claim 34, wherein the polypropylene containing material has a molecular weight distribution of at least about 7.75.
Claim 39
Dependent Claim
186 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface, the polypropylene containing material including a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to control chain scission degradation of polymeric components of the hot extrudate in the extruder; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to obtain at least one polypropylene containing fiber or filament having a decreasing weight average molecular weight towards the surface of the at least one fiber or filament, and an increasing melt flow rate towards the surface of the at least one fiber or filament, the at least one fiber or filament comprising an inner zone including a weight average molecular weight of about 100,000 to 450,000 rams/mole, and an outer zone, including the surface of the at least one fiber or filament, including a weight average molecular weight of less than about 10,000 grams/mole.
Claim 40
Dependent Claim
186 words
A process for preparing at least one polypropylene containing fiber or filament, comprising: extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form at least one hot extrudate having a surface, the polypropylene containing material including a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof, in an effective amount to control chain scission degradation of polymeric components of the hot extrudate in the extruder; and controlling quenching of the at least one hot extrudate in an oxygen containing atmosphere so as to obtain at least one polypropylene containing fiber or filament having a decreasing weight average molecular weight towards the surface of the at least one fiber or filament, and an increasing melt flow rate towards the surface of the at least one fiber or filament, the at least one fiber or filament comprising an inner zone including a weight average molecular weight of about 100,000 to 450,000 rams/mole, and an outer zone, including the surface of the at least one fiber or filament, including a weight average molecular weight of less than about 10,000 grams/mole.
Claim 41
Dependent Claim
42 words
The process according to claim 36, wherein the fiber or filament includes an intermediate zone positioned between the inner zone and the outer zone having a weight average molecular weight and melt flow rate intermediate the inner zone and the outer zone.
Claim 42
Dependent Claim
21 words
The process according to claim 36, wherein the polypropylene containing material has a molecular weight distribution of at least about 6.59.
Claim 43
Dependent Claim
21 words
The process according to claim 38, wherein the polypropylene containing material has a molecular weight distribution of at least about 7.14.
Claim 44
Dependent Claim
21 words
The process according to claim 39, wherein the polypropylene containing material has a molecular weight distribution of at least about 7.75.
Claim 45
Dependent Claim
123 words
A process for preparing at least one polyolefin polymer containing fiber or filament, comprising: extruding a mixture comprising a board molecular weight distribution polyolefin polymer and an effective amount of a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof under conditions to control oxidative chain scission degradation of polymeric components within the mixture prior to entering an oxygen containing atmosphere as a hot extrudate; and exposing the hot extrudate to an oxygen containing atmosphere under conditions to effect oxidative chain scission degradation of a surface of the hot extrudate to obtain at least one polyolefin polymer containing fiber or filament having a highly degraded surface zone of lower molecular weight compared to an inner zone of the hot extrudate.
Claim 46
Dependent Claim
123 words
A process for preparing at least one polyolefin polymer containing fiber or filament, comprising: extruding a mixture comprising a board molecular weight distribution polyolefin polymer and an effective amount of a member selected from the group consisting of antioxidants, stabilizers, and mixtures thereof under conditions to control oxidative chain scission degradation of polymeric components within the mixture prior to entering an oxygen containing atmosphere as a hot extrudate; and exposing the hot extrudate to an oxygen containing atmosphere under conditions to effect oxidative chain scission degradation of a surface of the hot extrudate to obtain at least one polyolefin polymer containing fiber or filament having a highly degraded surface zone of lower molecular weight compared to an inner zone of the hot extrudate.
Claim 47
Dependent Claim
38 words
The process according to claim 44, comprising controlling quenching of the resulting partially degraded extrudate to obtain a fiber or filament having a degraded surface zone of lower molecular weight, and the inner zone having higher molecular weight.
Claim 48
Dependent Claim
22 words
The process according to claim 42, wherein the mixture contains polypropylene, and has a molecular weight distribution of at least about 5.5.
Claim 49
Dependent Claim
19 words
The process according to claim 43, wherein the mixture has a molecular weight distribution of at least about 6.59.
Claim 50
Dependent Claim
19 words
The process according to claim 44, wherein the mixture has a molecular weight distribution of at least about 7.14.
Claim 51
Dependent Claim
19 words
The process according to claim 45, wherein the mixture has a molecular weight distribution of at least about 7.75.
Claim 52
Dependent Claim
57 words
The process according to claim 41, wherein the exposing of the hot extrudate to an oxygen containing atmosphere so as to effect oxidative chain scission of the surface comprises maintaining the temperature of the at least one hot extrudate above about 250° C. for a period of time to obtain oxidative chain scission degradation of the surface.
Claim 53
Dependent Claim
19 words
The process according to claim 47, wherein the controlling quenching includes blocking an upper portion of a cross-blow quench.
Claim 54
Dependent Claim
22 words
The process according to claim 47, wherein the controlling quenching includes passing the at least one hot extrudate through a blocked zone.
Claim 55
Dependent Claim
17 words
The process according to claim 49, wherein the blocked zone is open to the oxygen containing atmosphere.
Claim 56
Dependent Claim
104 words
A process for preparing at least one fiber or filament comprising: extruding a broad molecular weight distribution polyolefin containing material at a temperature and an environment under conditions minimizing oxidative chain scission degradation of polymeric components within the extruder; exposing resulting hot extrudate to an oxygen containing atmosphere to permit oxygen diffusion into the hot extrudate to obtain oxidative chain scission degradation of a surface of the resulting hot extrudate; and quenching the resulting hot extrudate to obtain at least one fiber or filament having a surface zone of lower molecular weight, and an inner zone having higher molecular weight than the surface zone.
Claim 57
Dependent Claim
104 words
A process for preparing at least one fiber or filament comprising: extruding a broad molecular weight distribution polyolefin containing material at a temperature and an environment under conditions minimizing oxidative chain scission degradation of polymeric components within the extruder; exposing resulting hot extrudate to an oxygen containing atmosphere to permit oxygen diffusion into the hot extrudate to obtain oxidative chain scission degradation of a surface of the resulting hot extrudate; and quenching the resulting hot extrudate to obtain at least one fiber or filament having a surface zone of lower molecular weight, and an inner zone having higher molecular weight than the surface zone.
Claim 58
Dependent Claim
19 words
The process according to claim 51, wherein the resulting hot extrudate is immediately exposed to an oxygen containing atmosphere.
Claim 59
Dependent Claim
16 words
The process according to claim 51, wherein the inner zone is substantially not degraded by oxygen.
Claim 60
Dependent Claim
24 words
The process according to claim 51, wherein the polyolefin containing material contains polypropylene, and has a molecular weight distribution of at least about 5.5.
Claim 61
Dependent Claim
21 words
The process according to claim 54, wherein the polyolefin containing material has a molecular weight distribution of at least about 6.59.
Claim 62
Dependent Claim
21 words
The process according to claim 55, wherein the polyolefin containing material has a molecular weight distribution of at least about 7.14.
Claim 63
Dependent Claim
21 words
The process according to claim 56, wherein the polyolefin containing material has a molecular weight distribution of at least about 7.75.
Claim 64
Dependent Claim
19 words
The process according to claim 57, wherein the resulting hot extrudate is immediately exposed to an oxygen containing atmosphere.
Claim 65
Dependent Claim
179 words
A process for preparing a fiber having improved heat bonding properties and material strength, elongation and toughness, comprising: A. admixing an effective amount of at least one antioxidant/stabilizer composition into a dry melt spun mixture comprising a broad molecular weight distribution polyolefin polymer or copolymer, in the presence of an active amount of a degrading composition; B. heating and spinning the resulting spun melt mixture at a temperature and in an environment under sufficient pressure, to minimize or control oxidative chain scission degradation of polymeric components within said spun mixture prior to completion of spinning; C. taking up the remaining hot spun fiber under an oxygen-containing atmosphere maximizing gas diffusion into said hot fiber to effect threadline oxidative chain scission degradation of said fiber; and D. quenching and finishing the resulting partially-degraded spun fiber to obtain a spun fiber having a highly degraded surface zone of low molecular weight and low birefringence; and a minimally degraded, essentially crystalline birefringent inner configuration; said inner configuration and said degrade surface zone defining an intermediate zone having a gradation in oxidative degradation.
Claim 66
Dependent Claim
179 words
A process for preparing a fiber having improved heat bonding properties and material strength, elongation and toughness, comprising: A. admixing an effective amount of at least one antioxidant/stabilizer composition into a dry melt spun mixture comprising a broad molecular weight distribution polyolefin polymer or copolymer, in the presence of an active amount of a degrading composition; B. heating and spinning the resulting spun melt mixture at a temperature and in an environment under sufficient pressure, to minimize or control oxidative chain scission degradation of polymeric components within said spun mixture prior to completion of spinning; C. taking up the remaining hot spun fiber under an oxygen-containing atmosphere maximizing gas diffusion into said hot fiber to effect threadline oxidative chain scission degradation of said fiber; and D. quenching and finishing the resulting partially-degraded spun fiber to obtain a spun fiber having a highly degraded surface zone of low molecular weight and low birefringence; and a minimally degraded, essentially crystalline birefringent inner configuration; said inner configuration and said degrade surface zone defining an intermediate zone having a gradation in oxidative degradation.
Claim 67
Dependent Claim
16 words
The process according to claim 59, wherein the antioxidant; stabilizer composition comprises a hindered phenolic compound.
Claim 68
Dependent Claim
28 words
The process according to claim 59, wherein the polyolefin component of the dry spun melt mixture comprises polypropylene having a molecular weight distribution of at leas about 5.5.
Claim 69
Dependent Claim
22 words
The process according to claim 59, wherein the antioxidant/stabilizer composition comprises at least one of phenylphosphites and a N,N' bis-piperidinyl diamine derivative.
Claim 70
Dependent Claim
48 words
The process according to claim 59, wherein the highly degraded surface zone of the spun fiber has a weight average molecular weight of less than about 10,000, and the inner configuration of said spun fiber has a high birefringence and a weight average molecular weight of about 100,000-450,000.
Claim 71
Dependent Claim
28 words
The process according to claim 59, wherein the take up and quenching steps are carried out in the presence of an oxidizing environment under hot or ambient temperature.
Claim 72
Dependent Claim
31 words
The process according to claim 64, wherein the take up and quenching steps are carried out in the presence of an oxygen/nitrogen mixture varying in ratio by volume from about 100-10/0-90.
Claim 73
Dependent Claim
15 words
The process according to claim 59, wherein the fiber comprises a monocomponent or bicomponent fiber.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1997-01-24 | 1997-07-26 | 1998-01-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-01-24 | 2001-07-26 | 2002-01-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-01-24 | 2005-07-26 | 2006-01-25 | $7700.00 | Window Closed / Lapsed |