Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/08—Melt spinning methods
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/06—Dyes
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D01F6/30—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising olefins as the major constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf

Definitions

• the present disclosure relates to fiber comprising a propylene based polymer composition comprising a propylene homopolymer and from 15 wt% to 45 wt% of a recycled polypropylene composition.
• an object of the present disclosure is a fiber comprising:
• the Melt Flow Rate of the polypropylene composition ranges from 5.2 g/10 min to 23.2 g/10 min; preferably from 8.2 g/10 min to 21.2 g/10 min, more preferably from 10.0 g/10 min to 17.3 g/10 min;
• the recycled polypropylene composition A) can be a Post-Industrial Resin (PIR) or a Post-Consumer Resin (PCR).
• PIR Post-Industrial Resin
• PCR Post-Consumer Resin
• Post-industrial waste is a material diverted from the waste stream originating from a manufacturing process.
• Post-industrial resin refers to a plastic material originating from the mechanical recycling of a post-industrial waste (PIW).
• PCR Post-Consumer Resin
• the recycled polypropylene composition component A) does not contains limonene.
• the recycled polypropylene composition component A) contains a organic compound with a chemical structure based on isoquinoline, that serves as a dye, e.g. red.
• the recycled polypropylene composition component A has at least one of the following features:
• the propylene homopolymer component B) has Charpy impact strength at 23°C ranging from ranging from 2.0 to 12.0 kJ/m2, more preferably ranging from 3.0 to 10.0 kJ/m2: more preferably ranging from 3.5 to 9.2 kJ/m2.
• the propylene homopolymer component B) preferably has a Tensile modulus ranging between 980 and 1980 MPa, preferably between 1080 and 1780 MPa; more preferably between 1180 and 1680 MPa.
• the recycled polyolefin composition according to the present disclosure preferably has a Tensile modulus ranging between 900 and 1800 MPa, preferably between 1050 and 1700 MPa; more preferably between 1150 and 1600 MPa.
• the recycled polyolefin composition preferably has a Charpy impact strength at 23°C ranging from 3.0 to 9.0 kJ/m 2 , more preferably ranging from 3.8 to 7.0 kJ/m 2: more preferably ranging from 4.3 to 6.2 kJ/m 2 .
• copolymer refers to polymers with two different recurring units in the chain.
• ambient temperature and “room temperature” is meant a temperature of 25 °C.
• crystalline polypropylene is meant in the present application a propylene polymer having an amount of isotactic pentads (mmmm), measured by 13C-MNR on the fraction insoluble in xylene at 25° C, higher than 70 molar %; by "elastomeric” polymer is meant a polymer having solubility in xylene at ambient temperature higher than 50 wt%.
• Component B) can be obtained by polymerizing propylene with processes commonly known in the art.
• Component B for example can be commercially available.
• Components B) can be prepared by polymerizing propylene in the presence of a catalyst comprising the product of the reaction between:
• the internal donor is preferably selected from the esters of mono or dicarboxylic organic acids such as benzoates, malonates, phthalates and certain succinates. Examples of internal donors are described in US 4522930A , EP 045977A2 and international patent applications WO 00/63261 and WO 01/57099 . Particularly suited are the phthalic acid esters and succinate acids esters. Alkylphthalates are preferred, such as diisobutyl, dioctyl and diphenyl phthalate and benzylbutyl phthalate.
• the particles of solid component (i) may have substantially spherical morphology and average diameter ranging between 5 and 150 ⁇ m, preferably from 20 to 100 ⁇ m and more preferably from 30 to 90 ⁇ m.
• particles having substantially spherical morphology those are meant wherein the ratio between the greater axis and the smaller axis is equal to or lower than 1.5 and preferably lower than 1.3.
• the amount of Mg may preferably range from 8 to 30% more preferably from 10 to 25wt. %.
• the amount of Ti may range from 0.5 to 7% and more preferably from 0.7 to 5wt. %.
• the solid catalyst component (i) can be prepared by reacting a titanium compound of formula Ti(OR)q-yXy, where q is the valence of titanium and y is a number between 1 and q, preferably TiCl4, with a magnesium chloride deriving from an adduct of formula MgCl2•pROH, where p is a number between 0.1 and 6, preferably from 2 to 3.5, and R is a hydrocarbon radical having 1-18 carbon atoms.
• the adduct can be suitably prepared in spherical form by mixing alcohol and magnesium chloride, operating under stirring conditions at the melting temperature of the adduct (100-130°C).
• the adduct is mixed with an inert hydrocarbon immiscible with the adduct thereby creating an emulsion which is quickly quenched causing the solidification of the adduct in form of spherical particles.
• spherical adducts prepared according to this procedure are described in USP 4,399,054 and USP 4,469,648 .
• the so obtained adduct can be directly reacted with Ti compound or it can be previously subjected to thermal controlled dealcoholation (80-130°C) so as to obtain an adduct in which the number of moles of alcohol is of lower than 3, preferably between 0.1 and 2.5.
• the reaction with the Ti compound can be carried out by suspending the adduct (dealcoholated or as such) in cold TiC14; the mixture is heated up to 80-130°C and kept at this temperature for 0.5-2 hours.
• the treatment with TiCl4 can be carried out one or more times.
• the electron donor compound can be added in the desired ratios during the treatment with TiCl4.
• the alkyl-Al compound (ii) is preferably chosen among the trialkyl aluminum compounds such as for example triethylaluminum, triisobutylaluminum, tri-n-butylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum. It is also possible to use alkylaluminum halides, alkylaluminum hydrides or alkylaluminum sesquichlorides, such as AlEt2Cl and Al2Et3Cl3, possibly in mixture with the above cited trialkylaluminums.
• the Al/Ti ratio is higher than 1 and may preferably range between 50 and 2000.
• silicon compounds (iii) in which a is 1, b is 1, c is 2, at least one of R7 and R8 is selected from branched alkyl, cycloalkyl or aryl groups with 3-10 carbon atoms optionally containing heteroatoms and R9 is a C1-C10 alkyl group, in particular methyl.
• Examples of such preferred silicon compounds are methylcyclohexyldimethoxysilane (C donor), diphenyldimethoxysilane, methyl-t-butyldimethoxysilane, dicyclopentyldimethoxysilane (D donor), diisopropyldimethoxysilane, (2-ethylpiperidinyl)t-butyldimethoxysilane, (2-ethylpiperidinyl)thexyldimethoxysilane, (3,3,3-trifluoro-n-propyl)(2-ethylpiperidinyl)dimethoxysilane, methyl(3,3,3-trifluoro-n-propyl)dimethoxysilane.
• C donor methylcyclohexyldimethoxysilane
• D donor dicyclopentyldimethoxysilane
• diisopropyldimethoxysilane (2-ethylpipe
• examples of such preferred silicon compounds are cyclohexyltrimethoxysilane, t-butyltrimethoxysilane and thexyltrimethoxysilane.
• the external electron donor compound (iii) is used in such an amount to give a molar ratio between the organoaluminum compound and said external electron donor compound (iii) of from 0.1 to 200, preferably from 1 to 100 and more preferably from 3 to 50.
• the fibers according to the present invention can be stable fibers or spunbond fibers.
• the fibers of the present invention can also contain additives commonly employed in the art, such as antioxidants, light stabilizers, heat stabilizers, nucleating agents, colorants and fillers.
• the fibers of the disclosure typically exhibit a value of tenacity at least equal to or higher than 15.0 cN/tex, preferably higher than 16.0. cN/tex, more preferably higher than 17.0 cN/tex with a titre of 3.8 dTex. Tenacity being lower than 30 cN/tex
• the fibers according to the present disclosure have a titre ranging from 1 to 8 dtex, preferably from 1.5 to 4.0 dtex.
• the fibers of the disclosure when have a titre of 3.8 dTex exhibit a value of elongation at break higher than 280 %; preferably higher than 330% the higher value being 800%.
• the fibers of the present disclosure can be efficiently spun at speeds that are typically higher than 3000 m/min, preferably higher than 3300 m/min, more preferably higher than 3500 m/min.
• the fibers of the present disclosure can be spun at temperatures generally varying from 200° to 300° C.
• the spinning temperature is lower than 250°C, even more preferably, the spinning temperature is comprised between 230° and 250°C.
• the fibers of the present disclosure for a titre of 3.8d/tex preferably have an elongation at break higher than 280 %; preferably higher than 320 %, preferably lower than 800%.
• the fibers of the present invention can be used for the manufacture of fabric and non-woven fabrics, in particular carpet showing excellent properties.
• non-woven fabrics may be produced with various methods, preferably through the well-known spunbonding technique.
• the spunbonding process is a non-woven manufacturing technique, whereby polymers are directly converted into endless filaments and stochastically deposited to form a non-woven material.
• Melting temperature and crystallization temperature Determined by differential scanning calorimetry (DSC). Weighting 6 ⁇ 1 mg, is heated to 220 ⁇ 1° C at a rate of 20 °C/min and kept at 220 ⁇ 1° C for 2 minutes in nitrogen stream and it is thereafter cooled at a rate of 20° C/min to 40 ⁇ 2° C, thereby kept at this temperature for 2 min to crystallize the sample. Then, the sample is again fused at a temperature rise rate of 20° C/min up to 220° C ⁇ 1. The melting scan is recorded, a thermogram is obtained, and, from this, melting temperatures and crystallization temperatures are read.
• DSC differential scanning calorimetry
• Xylene-soluble fraction (XS) at 25°C have been determined according to ISO 16152: 2005; with solution volume of 250 ml, precipitation at 25°C for 20 minutes, 10 of which with the solution in agitation (magnetic stirrer), and drying at 70°C.
• Intrinsic Viscosity The sample is dissolved by tetrahydronaphthalene at 135 °C and then it is poured into the capillary viscometer.
• the viscometer tube (Ubbelohde type) is surrounded by a cylindrical glass jacket; this setup allows temperature control with a circulating thermostated liquid.
• the downward passage of the meniscus is timed by a photoelectric device.
• the passage of the meniscus in front of the upper lamp starts the counter which has a quartz crystal oscillator.
• the downward passage of the meniscus is timed by a photoelectric device.
• the passage of the meniscus in front of the upper lamp starts the counter which has a quartz crystal oscillator.
• One single polymer solution is used to determine
• PP repro is a mixture of polymers having an aliphatic hydrocarbon backbone (ethylene - E), propylene - P), and 1-butene (B, ⁇ 1.0 wt%), 1-hexene (H, ⁇ 1.0 wt%) and 1-octene (O, ⁇ 1.0 wt%) copolymers and possibly an aromatic hydrocarbon backbone (polystyrene and polyethylene terephthalate). Due to analytical complications in determining the composition of aromatic containing polymers via 13C NMR spectroscopy, the method was developed by using the combination of the results obtained via 1H and 13C NMR spectra.
• 13C NMR was used to determine the relative amount of ethylene, propylene 1-butene, 1-hexene and 1-octene copolymers
• 1H NMR provided a quantification of the composition of aliphatic and aromatic components and the relative amounts of polystyrene and polyethylene terephthalate when present.
• Molar content was transformed in weight using monomers molecular weight.
• PET Polyethylene terephthalate
• PS Polystyrene
• ethylene/propylene/1-butene/1-hexene/1-octene copolymers were obtained from 1H spectra.
• Molar content was transformed in weight percentage using monomers molecular weight considering the MW of CH2 to estimate the weight contribution from ethylene/propylene/1-butene/1-hexene/1-octene copolymers.
• a 100 mm-long segment is cut and single fibers randomly chosen.
• Each single fiber is fixed to the clamps of a Dynamometer and tensioned to break with a traction speed of 20 mm/min for elongations lower than 100% and 50 mm/min for elongations greater than 100%, the initial distance between the clamps being of 20 mm.
• the ultimate strength (load at break) and the elongation at break are determined in machine (MD) direction.
• the maximum spinning speed gives indication of the spinnability of the propylene polymer composition of the invention.
• the value corresponds to the highest spinning rate that can be maintained for 30 minutes with no filament break
• Component A) is a PCR derived from protective packaging waste and contains 2,9-bis(3,5-dimethylphenyl)anthra[2,1,9-def:6,5,10-d'e'f]diisoquinoline-1,3,8,10(2H,9H)-tetrone having the features reported in Table 1.
• the catalyst used has been prepared according to the procedure reported in example 1 of WO 2020244912
• Comparative component B1 is a propylene ethylene copolymer sold by Lyondellbasell with the tradename of Moplen HP552N having an MFR (230°C/2.16kg of 13 g/10 min, soluble in xylene at 25°C of 3.2 wt%.
• Comparative example 2 is the fiber obtained by using 100 wt% of Moplen HP552N.
• the blend of recycled polymer and the homopolymer of the present disclosure it is possible to have a fiber with higher tenacity even if a recycled polymer is used.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Compositions Of Macromolecular Compounds (AREA)

Priority Applications (1)

Applications Claiming Priority (1)

Publications (1)

Family

ID=92043185

Family Applications (1)

Country Status (1)

Citations (9)

• 2024
  • 2024-07-25 EP EP24190959.7A patent/EP4685277A1/fr active Pending

Patent Citations (9)

Non-Patent Citations (1)

Similar Documents

Legal Events