US5281378A — Process of making high thermal bonding fiber

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.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
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

Process of making high thermal bonding fiber

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