JP2018515701A - Synthetic fiber having enhanced antifouling property, method for producing the same, and method for using the same - Google Patents

Abstract

Synthetic fibers having enhanced antifouling properties, yarns and carpets prepared from these fibers, and compounds and methods for their production are provided.

Description

  The present disclosure relates to a synthetic fiber having a soil resistance-affecting additive and a reinforced soil resistance made therefrom. The present disclosure also relates to articles prepared from these fibers and methods for making and using them.

  In the manufacture of fabrics such as carpets and apparel, it is common to treat the substrate with the composition to impart desirable properties such as resistance to particulates and dirt from dry dirt.

  Various fluorochemical compositions and their methods of application have been described for commercial use to impart antifouling properties to carpets.

  For example, Goeman U.S. Pat. No. 5,882,762 discloses a carpet yarn comprising a plurality of filaments of a thermoplastic polymer having a fluorochemical or non-fluorochemical hydrophilicity imparting compound dispersed within the filaments. It has been found that the presence of a hydrophilicity imparting compound in the filament allows for the production of carpet yarns with reduced spin finish or even without the spin finish normally required. Carpets made using such yarns were less susceptible to soiling.

  U.S. Pat. No. 8,247,519 discloses an article comprising a fluoroether functionalized aromatic moiety made from polyamide and having antifouling and oil resistance.

  U.S. Pat. No. 8,304,513 discloses an antifouling polyester polymer, in particular poly (trimethylene terephthalate) containing fluorovinyl ether functionalized aromatic repeat units.

  US Pat. No. 8,697,831 discloses antifouling polyamides, particularly nylon 6,6 and nylon 6, which contain fluoroether functionalized aromatic repeat units.

  Accordingly, there is a need to provide polymer fibers with improved incorporated antifouling properties.

  One aspect of the present invention relates to a synthetic fiber comprising a first fiber-forming polymer and an antifouling additive.

  In one non-limiting embodiment, the antifouling additive is present in the fiber in the range of about 0.1 to 10% by weight.

  In one non-limiting embodiment, at least a portion of the antifouling additive is present on the surface of the fiber. This portion present on the surface is preferably sufficient to impart antifouling properties to the fiber.

  In one non-limiting embodiment, at least a portion of the antifouling additive is not polymerized with the first fiber-forming polymer.

  In one non-limiting embodiment, at least a portion of the antifouling additive coats the surface of the fiber.

  In one non-limiting embodiment, the first fiber-forming polymer of synthetic fibers is polyamide, polyester, or polyolefin, or any combination thereof.

  In one non-limiting embodiment, the synthetic fiber antifouling additive is an aromatic sulfonate or an alkali metal salt thereof. In another non-limiting embodiment, the antifouling additive is a polymer.

  Another aspect of the present invention relates to a synthetic fiber comprising a first fiber-forming polymer, a second polymer, and an antifouling additive. In one non-limiting embodiment, the first fiber-forming polymer is present in the range of about 80-99% by weight and the second polymer is present in the range of about 0.2-10% by weight to prevent The fouling additive is present in the fiber in the range of about 0.1 to 10% by weight.

  In one non-limiting embodiment, the second polymer of the synthetic fiber has a melting point that is lower than the melting point of the first fiber-forming polymer and / or does not fibrillate the synthetic fiber.

  In one non-limiting embodiment, the second polymer is a polyolefin, polylactic acid, or polystyrene or any combination thereof.

  In one non-limiting embodiment, the synthetic fiber antifouling additive is an aromatic sulfonate or an alkali metal salt thereof.

  Another aspect of the invention relates to a product that includes at least a portion of one or more of these synthetic fibers. Non-limiting examples of these products include yarns and fabrics formed from synthetic fibers and carpets formed from the yarns.

  Yet another embodiment of the present invention relates to a method for producing a synthetic fiber having enhanced antifouling properties.

  In one non-limiting embodiment, the method includes forming a polymer melt of a first fiber forming polymer and an antifouling additive. In this non-limiting embodiment, the antifouling additive is present in the range of about 0.1 to 10% by weight. A synthetic fiber is then formed from the polymer melt.

  In another non-limiting embodiment, the method includes forming a polymer melt that includes a first fiber-forming polymer and a masterbatch compound. In this non-limiting embodiment, the masterbatch compound includes a second polymer and an antifouling additive. In this non-limiting embodiment, the first fiber-forming polymer is present in the range of about 80-99% by weight and the masterbatch compound is present in the range of about 0.2-20% by weight. A synthetic fiber is then formed from the polymer melt.

FIG. 6 is a plot showing the soil performance after hot water extraction before soiling the carpet sample. This plot shows the durability of the soil performance of carpet samples. Referring to FIG. 1, the example according to the embodiment of the present invention exerted the best force after the HWE treatment. FIG. 2 is a plot of colorimetric L ^* progression in a single set of carpet fouling and vacuuming (S & V) and hot water extraction (HWE) cycles. H indicates that this carpet was pre-wefted 3 times before testing to mimic soiling. 2 is a SEM micrograph of a trilobal filament from one embodiment of the present invention. Depicted is colored 1.0% by weight dimethyl 5-sulfoisophthalate, sodium salt (NaSIM) in polyester fiber, where the NaSIM masterbatch carrier is polypropylene. It is a set of the SEM micrograph and XDS spectrum of the longitudinal section of one Embodiment of this invention. Illustrated are NaSIM trilobal filaments in colored PET, where the NaSIM masterbatch carrier is polypropylene. It is a SEM micrograph of an example of one embodiment of the present invention. Depicted are colored 0.5 wt% 5-sulfoisophthalic acid, sodium salt (SSIPA) trilobal filaments in polyester fibers added with a polypropylene masterbatch carrier.

  The present disclosure provides reinforced antifouling yarns, fabrics and carpets made from these fibers and methods and masterbatch compositions for their production.

  In one non-limiting embodiment, the synthetic fiber includes a first fiber-forming polymer and an antifouling additive.

  Examples of first fiber-forming polymers that can be used in this embodiment include, but are not limited to, polyamides, polyesters, and polyolefins and any blends or combinations thereof.

  It is well known in the art that suitable polyamides are suitable for the formation of bulk continuous filament fibers having sufficient viscosity, strength, chemical stability, and crystallinity to be at least moderately durable in such applications. And fiber-forming polyamides known in US Pat. Polyamide is nylon 5,6, nylon 6,6, nylon 6, nylon 7, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon DT, nylon 6T, nylon 6I, and blends or copolymers thereof. May be selected from the group consisting of In one embodiment, the polyamide is a nylon 6,6 polymer.

  Suitable polyolefins include polypropylene.

  Suitable polyesters include fiber forming polyesters known in the art. The polyester resin may be selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polylactic acid (PLA), and blends or copolymers thereof.

  In this embodiment, the first fiber-forming polymer is present in the synthetic fiber in the range of about 90-99% by weight.

  It has long been known to enhance the stain resistance of polyamide fibers by forming fibers from polyamides prepared by copolymerizing monomers containing sulfonate moieties. U.S. Patent No. 6,133,382, U.S. Patent No. 6,334,877 and U.S. Patent No. 6,589,466 include fiber-forming polyamides and sulfonated polyester concentrates as fiber-forming polyamide compositions; A method for improving the stain resistance of polyamide fibers by melt compounding after polymerization of the polyamide and concentrate and before fiber formation is disclosed. US Pat. No. 6,433,107 and US Pat. No. 6,680,018 include similar compositions and combinations of sulfonated polyester concentrates and thermoplastic carrier resins, and fiber-forming polyamides. Is disclosed by melt blending after polyamide polymerization and before fiber formation to improve the stain resistance of the polyamide fibers.

  Furthermore, none of the above disclosures considers the improvement in antifouling properties of polyester fiber compositions where the fiber composition predominates with polyester. Furthermore, polyester compositions having up to 2% by weight of a sulfonic acid component are not considered effectively antifouling. As a result, there has long been a felt need to provide improved antifouling properties to polymeric materials, particularly polyester-based materials.

  Through undue experimentation, the inventors have surprisingly found that the antifouling properties of synthetic fibers can be improved by the addition of the antifouling additives disclosed herein.

  The synthetic fiber of this embodiment further includes an antifouling action additive. In one non-limiting embodiment, the antifouling action additive is an aromatic sulfonate or an alkali metal salt thereof. Non-limiting examples include 5-sulfoisophthalic acid, sodium salt (SSIPA) and dimethyl 5-sulfoisophthalic acid, sodium salt (NaSIM). In another non-limiting embodiment, the antifouling action additive is a polymer. A non-limiting example of a polymer useful as an antifouling action additive in this embodiment is polypropylene.

  In this embodiment, the antifouling additive is present in the synthetic fiber in the range of about 0.1 to about 10 weight percent.

  In another non-limiting embodiment, the synthetic fibers of the present disclosure include a first fiber-forming polymer, a second polymer, and an antifouling additive.

  Examples of first fiber-forming polymers that can be used in this embodiment include, but are not limited to, polyamides, polyesters, and polyolefins and any blends or combinations thereof.

  It is well known in the art that suitable polyamides are suitable for the formation of bulk continuous filament fibers having sufficient viscosity, strength, chemical stability, and crystallinity to be at least moderately durable in such applications. And fiber-forming polyamides known in US Pat. Polyamide is nylon 5,6, nylon 6/6, nylon 6, nylon 7, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon DT, nylon 6T, nylon 6I, and blends or copolymers thereof. May be selected from the group consisting of In one embodiment, the polyamide is a nylon 6,6 polymer.

  Suitable polyolefins include polypropylene.

  Suitable polyolefins include polypropylene. Suitable polyesters include fiber forming polyesters known in the art. The polyester resin may be selected from the group consisting of polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polylactic acid (PLA), and blends or copolymers thereof.

  In this embodiment, the first fiber-forming polymer is present in the synthetic fiber in the range of about 80-99% by weight.

  The synthetic fiber of this embodiment further includes an additive that affects antifouling properties. In one non-limiting embodiment, the antifouling additive is an aromatic sulfonate or an alkali metal salt thereof. Non-limiting examples include 5-sulfoisophthalic acid, sodium salt and dimethyl 5-sulfoisophthalate, sodium salt.

  In this embodiment, the antifouling additive is present in the synthetic fiber in the range of about 0.1 to about 10 weight percent.

  The synthetic fiber of this embodiment further includes a second polymer. The second polymer preferably has a melting point that is lower than the melting point of the first fiber-forming polymer. It is also preferred that the synthetic fiber is not fibrillated due to the presence of the second polymer. Examples of second polymers useful in the present disclosure include, but are not limited to, polyolefins, polylactic acid and polystyrene, or any blend or combination thereof. In one non-limiting embodiment, the polyolefin is an unmodified polyolefin. In another non-limiting embodiment, the second polymer is polypropylene.

  In one non-limiting embodiment, the second polymer is present in the synthetic fiber in the range of about 0.5 to about 10% by weight.

  In the synthetic fiber of the present invention, at least a part of the antifouling additive is present on the surface of the fiber. This portion present on the surface of the fiber is preferably sufficient to impart antifouling properties to the fiber.

  Further, in the synthetic fibers of the present disclosure, at least a portion of the antifouling additive is not polymerized with the first fiber-forming polymer. Instead, preferred in the synthetic fibers of the present disclosure is that at least a portion of the antifouling additive is coated on the surface of the fibers.

  In one non-limiting embodiment, the synthetic fibers of the present disclosure have a multilobed cross section. In another non-limiting embodiment, the majority (meaning greater than 50%) of the antifouling additive present on the surface of the fiber, at least 75% or substantially all is located in the region between the leaves. To do.

  The present disclosure also relates to products comprising at least a portion of the synthetic fibers of the present disclosure. Examples of such articles include, but are not limited to, yarns made from synthetic fibers, and fabrics and carpets made from synthetic fibers and / or yarns.

  The present disclosure also provides a method for forming these synthetic fibers having enhanced antifouling properties.

  In one non-limiting embodiment, the method includes forming a polymer melt that includes a first fiber-forming polymer and an antifouling additive. In this non-limiting embodiment, the antifouling additive is present in the range of about 0.1 to 10% by weight. A synthetic fiber is then formed from the polymer melt. In this embodiment, the antifouling additive used in the method may be an aromatic sulfonate or an alkali metal salt thereof, or a polymer. Non-limiting examples include 5-sulfoisophthalic acid, sodium salt; dimethyl 5-sulfoisophthalate, sodium salt; polypropylene.

  In one non-limiting embodiment, the antifouling additive is added to the polymer melt by powder addition. In another non-limiting embodiment, the antifouling additive is added as a powder capsule.

  In another non-limiting embodiment, the method includes forming a polymer melt comprising a first fiber-forming polymer and a masterbatch compound. In this non-limiting embodiment, the masterbatch compound includes a second polymer and an antifouling additive. The first fiber-forming polymer is present in the range of about 80-99% by weight and the masterbatch compound is present in the range of about 1-20% by weight. In one non-limiting embodiment, no additional steps are required to remove volatile materials while forming the polymer melt. A synthetic fiber is then formed from the polymer melt. In this embodiment, the antifouling additive used in the method may be an aromatic sulfonate or an alkali metal salt thereof. Non-limiting examples include 5-sulfoisophthalic acid, sodium salt and dimethyl 5-sulfoisophthalate, sodium salt.

  The present disclosure also provides a masterbatch compound. The masterbatch compound includes a thermoplastic carrier, also referred to herein as a second polymer. Examples of thermoplastic carriers useful in the masterbatch include, but are not limited to, polyolefins, polylactic acid, polystyrene, or blends or copolymers thereof. In one non-limiting embodiment, the thermoplastic carrier is a polyolefin. In one non-limiting embodiment, the thermoplastic carrier is an unmodified polyolefin. In another non-limiting embodiment, the thermoplastic carrier is polypropylene.

  In one non-limiting embodiment, the thermoplastic carrier is present in the masterbatch compound in the range of about 40 to about 90% by weight. In one non-limiting embodiment, the masterbatch compound comprises about 50% thermoplastic carrier.

  The masterbatch compound further includes an antifouling additive. Suitable antifouling additives include, but are not limited to, aromatic sulfonates such as 5-sulfoisophthalic acid, sodium salt and dimethyl 5-sulfoisophthalate, sodium salt and alkali metal salts thereof. In one non-limiting embodiment, the antifouling additive is present in the masterbatch compound in the range of about 10 to about 60% by weight.

  In one non-limiting embodiment, the masterbatch compound has a moisture content of less than about 200 ppm, more preferably less than about 50 ppm. In another non-limiting embodiment, the masterbatch compound is not dried or conditioned before forming the polymer melt.

  The masterbatch compound may further comprise other additives as used to provide further advantages to the article after polymer melt extrusion and melt spinning. Examples of such additives are inorganic pigments and ultraviolet (UV) light absorbers or optical brighteners. Examples of inorganic pigments are titanium dioxide, barium sulfate, carbon black, manganese dioxide, and zinc oxide. Examples of UV light absorbers or optical brighteners are 2,2 ′-(1,2-ethenediyldi-4,1 phenylene), marketed by Eastman Chemical Company under the trade name Eastobrite® OB-1. Bisbenzoxazole, and Mayzo, Inc. under the trade name Benetex® OB. 2,2 '-(2,5-thiophenediyl) bis (5-tert-butylbenzoxazole), commercially available from

  In one non-limiting embodiment, the masterbatch compound is present in the fiber in the range of about 1 to about 20% by weight.

  The present disclosure also relates to products comprising synthetic fibers that are at least partially manufactured according to this process. Non-limiting examples include yarns made from synthetic fibers made by this method, and fabrics and carpets made from these synthetic fibers and / or yarns.

In a non-limiting embodiment, a masterbatch was prepared using the following antifouling additive:
5-sulfoisophthalic acid, sodium salt

Dimethyl 5-sulfoisophthalate, sodium salt

The masterbatch was added to a standard bottle grade PET resin at 0.5 wt% and 2 wt% activity with an extrusion hopper. The resulting colored trilobal PET fibers were processed and tufted into a residential cut pile carpet of 30 oz / square yard. It has been found that the characteristic stain resistance of PET is not adversely affected by blends with antifouling additives. Furthermore, the Vetterman drum performance was similar to the equivalent control.
However, in an accelerated Drum fouling test (ASTM D6540-12), carpets prepared from fibers of the present disclosure containing 4% by weight masterbatch benefit from 4 to 5.5 ΔE units compared to untreated PET. Corresponding to PET carpet treated with antifouling chemicals containing synthetic clay nanoparticles (Laponite® S482) at 2% owf, and synthetic clay nanoparticles (Laponite® S482) and fluorochemicals Better performance than PET carpet treated with 1.2% owf with antifouling chemicals including (Capstone® RCP). In general, the filaments according to the present disclosure have an external modification ratio (R2 / R1) that can be about 1.50 to 3.00, more specifically about 2.15 to 2.85. The degree of deformity (MR) of the control product was nominally 2.5 as well. Determining the degree of profile, especially in the case of trilobal bulk continuous filaments, is disclosed in EP 1,518,948 and US Patent Publication No. 2015/0275400.

  Further testing was performed to confirm that the antifouling additives of the present disclosure did not migrate out of the synthetic fiber by themselves, during the dyeing process, or by wet cleaning. The cleaning carpet was vigorously hot water extracted and then fouled and monitored for changes in performance. Sustained anti-contamination performance data indicated that the additive did not leach from the polymer fibers.

  Accordingly, it has been found that the synthetic fibers of the present disclosure have significantly improved soil performance in carpet form. Carpets made from these synthetic fibers have "built-in" or fiber binding, antifouling performance that exceeds the effectiveness of current fluorochemical-based local antifouling treatments. Furthermore, this built-in resistance is more durable than the antifouling topical treatment known for “walking” by wear and walking, where local chemicals are no longer effective. Furthermore, the use of synthetic fibers of the present disclosure eliminates the need for topical application of chemicals by downstream carpet manufacturing plants. The use of non-fluorinated compounds to enhance antifouling reduces environmental concerns.

  The following sections provide further examples of the synthetic and knitted fabrics of the present invention and comparative fibers and knitted fabrics therefrom. These examples are illustrative only and in no way limit the scope of the invention.

Test Method Accelerated drum fouling is recorded as Delta E and measured according to ASTM D6540. Within the limits of the reproducibility of this test, the relative soil performance of variously processed samples can be determined. This test simulates carpet soiling in a residential or commercial environment to a traffic level of about 100,000 to 300,000. According to ASTM D6540, a soil test can be performed on up to six carpet samples simultaneously using a drum. The basic color of the sample (using the L, a, b color space) is measured using a handheld color measurement device sold by Minolta Corporation as “chromameter” model CR-310 (Camden). This measurement output is in the form of L ^* , a ^* and b ^* values and describes the color values of the color space. This is the original color value. The carpet sample is placed on a thin plastic sheet and placed on a drum. Place 250 grams (250 g) of dirty Zytel 101 nylon beads (DuPont Canada, Mississauga, Ontario) over the sample. Dirty beads are obtained by mixing 10 grams (10 g) of AATCC TM-122 synthetic carpet soil (manufacturer Textile Innovators Corp., Windsor, NC) with 1000 grams (1000 g) of new Nylon Zytel 101 beads. Prepare. Add 1000 grams (1000 g) of a 3/8 inch diameter steel ball bearing into the drum. Run the drum for 30 minutes with the direction reversed, and remove the sample. After removal, the carpet is cleaned with a vacuum cleaner and the chromameter is used again to re-measure the color of the cleaned carpet. The difference in color measurements (before and after contamination and cleanup) for each carpet is the total color difference ΔE *, known to those skilled in the art, based on the L ^* , a ^* and b ^* color differences of the color space, It is shown by the formula.

AATCC TM175-stain resistance test: pile flooring, and ASTM D5417-Vetterman drum test

  Comparative Examples 1, 2, and 5 and Examples 3, 4, 6, and 7 were made using a pilot scale machine. The pilot equipment included a 12 inch twin screw extruder with 5 heating zones, filter screen packs, any desired spinneret selection, fiber quench zone, godet roll and winder. Using standard spinning methods, fibers were produced from a pilot scale machine as follows: The polymer was extruded through a spinneret and divided into two 184 filament sections. The molten fiber was then rapidly quenched with a chimney sent past the filament at about 10 to 15 ° C. through the quench zone at 450 cubic feet per minute [300 to 600 cfm]. The filaments were then coated with a lubricant for drawing and crimping. Using a pair of heated draw rolls, the coated yarn was drawn at 2422 yards / min (2.9 x draw ratio) per minute. The drawing roll temperature was 160 ° C. The filament is then sent to a double impingement hot air bulking jet similar to that described in the teachings of Coon US Pat. No. 3,525,134, incorporated herein by reference, to provide two BCF yarns (1000 denier, 5.4 dpf) was formed. The temperature of the air in the bulking jet was 180 ° C.

  The spun, drawn and crimped BCF yarn was tufted onto the carpet and heat set at a set temperature of 290 ° C. with a Superba heat setting machine. The residence time in the set zone was about 60 seconds. Heatset carpets were tested according to standard test methods ASTM D6540-pile yarn flooring accelerated fouling, AATCC TM193-aqueous liquid water repellency, AATCC TM175-contamination resistance, pile flooring, and ASTM D5417-Vetterman drum.

Comparative Example 1: PET BCF without melt additive and without topical anti-soil treatment
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. Various color pigments were mixed with PET polymer products from Indorama, Spartanburg, SC, USA. In the screw feeder, the pigment and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It was tufted onto a carpet with 1/2 inch pile height, 16 stitches / inch, 30 ounces / square yard pile carpet on a 1/8 gauge tufting machine. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Comparative Example 2: PET BCF treated with topical antifouling agent without melt additive
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. Various color pigments were mixed with PET polymer products from Indorama, Spartanburg, SC, USA. In the screw feeder, the pigment and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It tufts into a carpet with 1/2 inch pile height, 16 stitches / inch, 30 ounces / square yard pile carpet on a 1/8 gauge tufting machine, and clay is applied to this tufted carpet 1.2% antifouling chemicals including nanoparticles (Laponite (R) S482, BYK-Chemie GmbH, Wesel, Germany) and fluorochemicals (Capstone (R) RCP, Chemours Co., Wilmington, DE USA) Antifouling treatment was performed by spraying with owf. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Example 3: Masterbatch Additive, 1.0 wt% Masterbatch PET BCF
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. A masterbatch (1: 1 weight ratio) of polypropylene and sodiosulfonated isophthalic acid, dimethyl ester was added to the PET polymer product from Indorama, Spartanburg, SC, USA at 1% by weight as a melt. In the screw feeder, the master batch and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It was tufted onto a 1/8 gauge tufting machine onto a carpet having a 1/2 inch pile height, 16 stitches / inch, 30 ounces / square yard pile carpet. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Example 4: Masterbatch Additive, 4 wt% Masterbatch PET BCF
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. A masterbatch (1: 1 weight ratio) of polypropylene and sodiosulfonated isophthalic acid, dimethyl ester was added to the PET polymer product from Indorama, Spartanburg, SC, USA at 4 wt% in the melt. In the screw feeder, the master batch and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It was tufted onto a 1/8 gauge tufting machine onto a carpet having a 1/2 inch pile height, 16 stitches / inch, 30 ounces / square yard pile carpet. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Comparative Example 5: PET BCF with no melt additive, treatment with topical antifouling agent, 50 oz / yd ² carpet
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. Various color pigments were mixed with PET polymer products from Indorama, Spartanburg, SC, USA. In the screw feeder, the pigment and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It tufts onto a 1/8 gauge tufting machine onto a carpet with a 1/2 inch pile height, 50 ounces / square yard pile carpet, and the tufted carpet is coated with clay nanoparticles (Laponite ( An antifouling treatment was performed by spraying an antifouling chemical substance containing 1.2% owf, including fluorochemical (Capstone® RCP). The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Example 6: Masterbatch Additive, 1.0 wt% Masterbatch PET BCF
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. A masterbatch (1: 1 weight ratio) of polypropylene and sodiosulfonated isophthalic acid, dimethyl ester was added to the PET polymer product from Indorama, Spartanburg, SC, USA at 1% by weight as a melt. In the screw feeder, the master batch and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It was tufted onto a carpet having a 1/2 inch pile height, 50 ounces / square yard pile carpet on a 1/8 gauge tufting machine. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

Example 7: Masterbatch Additive, 4 wt% Masterbatch PET BCF
PET bulk continuous filaments (BCF, 1000 denier, 184 filaments) were made on a pilot scale machine. A masterbatch (1: 1 weight ratio) of polypropylene and sodiosulfonated isophthalic acid, dimethyl ester was added to the PET polymer product from Indorama, Spartanburg, SC, USA at 4 wt% in the melt. In the screw feeder, the master batch and PET were mixed. The fiber was spun without interruption of the process. The BCF yarn had a wool beige color. It was tufted onto a carpet having a 1/2 inch pile height, 50 ounces / square yard pile carpet on a 1/8 gauge tufting machine. The carpets were tested for accelerated fouling, soil water repellency and abrasion resistance, as shown in Table 1 and FIGS.

FIG. 6 is a plot showing the soil performance after hot water extraction before soiling the carpet sample. This plot shows the durability of the soil performance of carpet samples. Referring to FIG. 1, the example according to the embodiment of the present invention exerted the best force after the HWE treatment. FIG. 2 is a plot of colorimetric L ^* progression in a single set of carpet fouling and vacuuming (S & V) and hot water extraction (HWE) cycles. H indicates that this carpet was pre-wefted 3 times before testing to mimic soiling. 2 is a SEM micrograph of a trilobal filament from one embodiment of the present invention. Depicted is colored 1.0% by weight dimethyl 5-sulfoisophthalate, sodium salt (NaSIM) in polyester fiber, where the NaSIM masterbatch carrier is polypropylene. It is a set of the SEM micrograph and XDS spectrum of the longitudinal section of one Embodiment of this invention. Illustrated are NaSIM trilobal filaments in colored PET, where the NaSIM masterbatch carrier is polypropylene. It is a set of the SEM micrograph and XDS spectrum of the longitudinal section of one Embodiment of this invention. Illustrated are NaSIM trilobal filaments in colored PET, where the NaSIM masterbatch carrier is polypropylene. It is a set of the SEM micrograph and XDS spectrum of the longitudinal section of one Embodiment of this invention. Illustrated are NaSIM trilobal filaments in colored PET, where the NaSIM masterbatch carrier is polypropylene. It is a set of the SEM micrograph and XDS spectrum of the longitudinal section of one Embodiment of this invention. Illustrated are NaSIM trilobal filaments in colored PET, where the NaSIM masterbatch carrier is polypropylene. It is a SEM micrograph of an example of one embodiment of the present invention. Depicted are colored 0.5 wt% 5-sulfoisophthalic acid, sodium salt (SSIPA) trilobal filaments in polyester fibers added with a polypropylene masterbatch carrier.

Claims (60)

Synthetic fibers,
a) a first fiber-forming polymer;
b) a synthetic fiber comprising an antifouling additive present in the fiber in the range of about 0.1 to 10% by weight.   The synthetic fiber according to claim 1, wherein at least a part of the antifouling additive is present on a surface of the fiber.   The synthetic fiber of claim 2, wherein the portion of the antifouling additive present on the surface of the fiber is sufficient to impart antifouling properties to the fiber.   The synthetic fiber of claim 1, wherein at least a portion of the antifouling additive is not polymerized with the first fiber-forming polymer.   The synthetic fiber according to claim 1, wherein at least a part of the antifouling additive is coated on a surface of the fiber.   6. The fiber according to any one of claims 1 to 5, wherein the fiber has a multi-leaf type cross section, and most of the antifouling additive present on the surface of the fiber is located in a region between the leaves. Synthetic fiber.   The fiber according to any one of claims 1 to 5, wherein the fiber has a multileaf type cross section, and at least 75% by weight of the antifouling additive present on the surface of the fiber is located in a region between the leaves. The described synthetic fiber.   The fiber according to any one of claims 1 to 5, wherein the fiber has a multi-leaf type cross section, and substantially all of the antifouling additive present on the surface of the fiber is located in a region between the leaves. The described synthetic fiber.   The synthetic fiber of claim 1, wherein the first fiber-forming polymer is selected from the group consisting of polyamides, polyesters, and polyolefins, and combinations thereof.   The synthetic fiber of claim 1, wherein the first fiber-forming polymer is polyester.   The synthetic fiber according to claim 10, wherein the polyester is selected from the group consisting of polyethylene terephthalate, polypropylene terephthalate and polybutylene terephthalate, and combinations thereof.   The synthetic fiber according to claim 1, wherein the antifouling additive is an aromatic sulfonate or an alkali metal salt thereof.   The synthetic fiber according to claim 12, wherein the antifouling additive is 5-sulfoisophthalic acid, sodium salt.   The synthetic fiber according to claim 12, wherein the antifouling additive is dimethyl 5-sulfoisophthalate, sodium salt.   The thread | yarn formed from the synthetic fiber of any one of Claims 1-14.   A carpet formed from the yarn of claim 15.   The cloth formed from the synthetic fiber of any one of Claims 1-14. Synthetic fibers,
(A) a first fiber-forming polymer present in the range of about 80-99% by weight;
(B) a second polymer present in the range of about 0.2 to 10% by weight;
(C) a synthetic fiber comprising an antifouling additive present in the fiber in a range of about 0.1 to 10% by weight.   The synthetic fiber according to claim 18, wherein at least a part of the antifouling additive is present on a surface of the fiber.   20. The synthetic fiber of claim 19, wherein the portion of the antifouling additive present on the surface of the fiber is sufficient to impart antifouling properties to the fiber.   The synthetic fiber of claim 19, wherein at least a portion of the antifouling additive is not polymerized with the first fiber-forming polymer.   The synthetic fiber according to claim 19, wherein at least a part of the antifouling additive is coated on a surface of the fiber.   The fiber according to any one of claims 18 to 22, wherein the fiber has a multi-leaf type cross section, and most of the antifouling additive present on the surface of the fiber is located in a region between the leaves. Synthetic fiber.   The fiber according to any one of claims 18 to 22, wherein the fiber has a multileaf type cross section, and at least 75% by weight of the antifouling additive present on the surface of the fiber is located in a region between the leaves. The described synthetic fiber.   The synthetic fiber of claim 18, wherein the second polymer has a melting point that is lower than the melting point of the first fiber-forming polymer.   The synthetic fiber of claim 18, wherein the presence of the second polymer does not fibrillate the synthetic fiber.   19. The synthetic fiber of claim 18, wherein the first fiber-forming polymer is selected from the group consisting of polyamide, polyester, and polyolefin, and combinations thereof.   19. The synthetic fiber of claim 18, wherein the first fiber-forming polymer is selected from the group consisting of polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate, and combinations thereof.   The synthetic fiber of claim 18, wherein the second polymer is selected from the group consisting of polyolefin, polylactic acid, and polystyrene, and combinations thereof.   The synthetic fiber of claim 18, wherein the second polymer is an unmodified polyolefin.   The synthetic fiber of claim 18, wherein the second polymer is polypropylene.   The synthetic fiber according to claim 18, wherein the antifouling additive is an aromatic sulfonate or an alkali metal salt thereof.   33. The synthetic fiber of claim 32, wherein the antifouling additive is 5-sulfoisophthalic acid, sodium salt.   The synthetic fiber according to claim 32, wherein the antifouling additive is dimethyl 5-sulfoisophthalate, sodium salt.   A yarn formed from the synthetic fiber according to any one of claims 18 to 34.   A carpet formed from the yarn of claim 34.   A fabric formed from the synthetic fiber according to any one of claims 18 to 34. A method for forming a synthetic fiber comprising:
a) forming a polymer melt comprising a first fiber-forming polymer and a masterbatch compound, the masterbatch compound comprising a second polymer and an antifouling additive; The fiber forming polymer is present in the range of about 80-99% by weight and the masterbatch compound is present in the range of about 0.2-20% by weight;
b) forming a synthetic fiber from the polymer melt.   40. The method of claim 38, wherein at least a portion of the antifouling additive is present on the surface of the fiber.   40. The method of claim 39, wherein the portion of the antifouling additive present on the surface of the fiber is sufficient to impart antifouling properties to the fiber.   40. The method of claim 38, wherein the masterbatch compound has a water content of less than about 200 ppm.   40. The method of claim 38, wherein the masterbatch compound has a water content of less than about 50 ppm.   40. The method of claim 38, wherein the masterbatch compound is not dried or conditioned prior to forming the polymer melt.   40. The method of claim 38, wherein no further steps are required to remove volatile materials during formation of the polymer melt.   40. The method of claim 38, wherein the second polymer has a melting point that is lower than the melting point of the first fiber-forming polymer.   40. The method of claim 38, wherein the presence of the second polymer does not fibrillate the synthetic fiber.   40. The method of claim 38, wherein the second polymer is present in the masterbatch compound in the range of about 20-80% by weight.   40. The method of claim 38, wherein the second polymer is selected from the group consisting of polyolefin, polylactic acid, and polystyrene, and combinations thereof.   40. The method of claim 38, wherein the second polymer is an unmodified polyolefin.   40. The method of claim 38, wherein the second polymer is polypropylene.   40. The method of claim 38, wherein the first fiber-forming polymer is selected from the group consisting of polyamides, polyesters, and polyolefins, and combinations thereof.   40. The method of claim 38, wherein the first fiber-forming polymer is polyethylene terephthalate.   39. The method of claim 38, wherein the antifouling additive is present in the masterbatch compound in the range of about 20-80% by weight.   39. The method of claim 38, wherein the antifouling additive is an aromatic sulfonate or an alkali metal salt thereof.   40. The method of claim 38, wherein the antifouling additive is 5-sulfoisophthalic acid, sodium salt.   40. The method of claim 38, wherein the antifouling additive is dimethyl 5-sulfoisophthalate, sodium salt.   57. A synthetic fiber formed from the method of any one of claims 38 to 56.   58. A fabric formed from the synthetic fiber of claim 57.   58. A yarn formed from the synthetic fiber of claim 57. 60. A carpet formed from the yarn of claim 59.