JPH09170112A - Internally lubricated fiber, hydrophobic staple fiber which can be carded from said fiber and method for manufacturing and using said fiber - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a polyolefin-containing fiber, comprising a specific polysiloxane, excellent in hydrophobicity and processability and useful as a nonwoven fabric for sanitary goods, etc., such as a disposable diaper or an incontinence pad. SOLUTION: This internally lubricated fiber is obtained by blending (A) a polyolefin such as polyethylene, polypropylene, an ethylene-propylene copolymer or its mixture with (B) preferably <=10wt.% polysiloxane of the formula [X and Y are each a <=22C aliphatic group and its ether; (z) is 10-50 or above; R<1> and R<2> are each a <=22C aliphatic group or an arene] having 15000-450000 molecular weight.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to hydrophobic polyolefin fibers, their secondary processing, and nonwoven fabrics produced thereby.

[0002]

BACKGROUND OF THE INVENTION Synthetic polymer fibers have found a wide range of uses, from textiles for clothing to reinforcing materials for tires. The particular application for making fibers requires the required physical and chemical properties. Synthetic fibers are particularly useful in absorbent products, especially in diapers, incontinence articles and coverstock fibers for sanitary articles such as sanitary napkins, tampons, pants and the like. Polyolefin and cover stock and
Other fibers used in similar fabrics that allow liquids to flow through are hydrophobic. In order to facilitate the flow of liquids throughout, they contain a generally hydrophilic finish so that the liquids flow adequately. Leg circumference of such products,
Related parts such as waistbands and medical barriers are also
It is used to treat a stream of liquid as a barrier rather than as a conduit. Therefore, it is desirable that the particular fibers used in their relevant portions are not only hydrophobic, but also have a fiber / finishing surface that is hydrophobic.

In order to achieve the desired hydrophobicity,
Silicone oil is added to the fiber surface using a device such as a spray or roller. Traditionally, silicone oils have also been applied as surface lubricants, thus the use of silicone oils on the fiber surface provides lubricated, hydrophobic fibers. If silicone oils are used as hydrophobic finishes, they must first be diluted in a solvent in order to allow their application to the fiber surface in a controlled manner. In most cases, the silicone oils used in conventional hydrophobic polypropylene fibers are emulsified in aqueous solution with the aid of wetting agents. One problem encountered with the use of emulsified silicones is the reduction in hydrophobicity imparted by the silicone to the fiber surface due to the presence of the wetting agent used in the emulsifier. Another problem with using topically applied silicone oils is that a certain amount of the required friction is lost due to the lubricity of the silicone oil. Certain typical fiber processing operations, such as crimping and carding, require a minimum amount of friction between the fibers and the processing equipment in order for the fibers to be manipulated in the equipment. In order to compensate for the reduced friction, such operations must be done at line low speeds and the whole process must be slow.

Another problem that arises from the use of applied silicone (hydrophobic) lubricants resulting from the substitution of the surface properties of the fibers is that the fibers are processed into staple fibers and crimped and carded into a web. Even at times, topically applied silicone lubricants interfere with the adhesion of the web, causing the carded staple fibers to rub through each other and cause the web to fall apart during processing. To compensate, the processing speed must be reduced again.

Yet another problem arises with the use of antistatic finishes, which are typically hydrophilic in nature. These finishes are often applied to the fibers to facilitate handling of the fibers during processing. However, they reduce the effectiveness of the lubricating finish on the fiber and require reapplication of the lubricant.

There is a balance between lubricating the helix fibers passing through the processing equipment and the friction required by such equipment to hang and manipulate the fibers. Silicone oils are typically applied to the surface of the fibers in very small amounts (<0.3% by weight) to reduce friction. Controlling such small amounts of topically added silicone to achieve uniform application at the fiber surface is very difficult. Also, due to fiber friction (due to excessive application of silicone)
The severe reduction causes various processing problems, including reduced line speed. On the other hand, to avoid problems with small amounts of silicone, hydrophilic spin finish (spin finis
If h) is first applied to the fibers, the resulting fibers remain hydrophilic even when combined with a silicone lubricant.

More recent examples of fibers having a lubricant in the fiber correspond to Shmaltz US Pat. No. 4,938,832 and EP 0486158 A2 (corresponding to US patent application No. 914,213 filed Jul. 15, 1992). , Which are incorporated by reference, in which the spun fibers are treated with a finish containing neutralized phosphate ester and polysiloxane compounds.

Johnson and Theyson, US Pat.
3,426 and EP 0516412 A2, the disclosures of which are both incorporated herein by reference, include neutralized phosphate esters and esters, polyesters,
Very polar or ionic structural materials such as glycols, capped glycols, alkoxylated products (polyoxyethylene or polyoxypropylene) and methylammonium methylsulfate made with them and described therein A cardable, hydrophobic polyolefin-containing fiber made with a finish composition that includes a lubricant such as other compounds is described. Optionally, such a finish is a coated finish (ov) comprising neutralized phosphoric acid and optionally polysiloxane.
erfinish) used in combination with.

Harrington has published European Patent Publication No. 0557024 A
No. 1 and US Patent Application No. 08 / 016,346 (February 14, 1992)
Filed on 07 / 835,895, filed on 1993.
Filed Feb. 11, 2012, the disclosures of which are incorporated herein by reference), having at least one neutralized C _3-12 alkyl or alkenyl phosphate alkali metal or Alkaline earth metal salts and glycols, polyglycols, glycol ethers and general formulas: (MO) _x- (PO)-(O
(R ₁ ) _n R) _y (wherein M is an alkali metal or an alkaline earth metal or hydrogen, R is a C ₁₆ -C ₂₂ alkyl or alkenyl group, and R ₁ is ethylene oxide or propylene oxide. , N is 1 to 10, and x
Describes a polyolefin fiber comprising an antistatic composition comprising a neutralized phosphate ester salt having 1 to 2 and x + y = 3) and nonwoven products made therefrom. The finish may also contain lubricants such as mineral oil, paraffin wax, polyglycols and silicones.

Nohr and MacDonald, US Pat. No. 4,923,
No. 914 describes a fiber or film forming polyolefin composition having certain polysiloxane additives that are generally hydrophobic. The additive is compatible with the polyolefin at the melt extrusion temperature, but is incompatible at lower temperatures and consists of two parts, defined by the same or different additives, of another additive. In both cases both are incompatible with the polyolefin at all temperatures. This part is both an alkoxy group,
In one case, the groups cap the ends of the siloxane chain, and in other cases, the groups are pendant from the backbone. As a result of incompatibility, the additive is increasing in concentration within the fiber from the fiber axis to the surface.

Lovgren et al., In US Pat. No. 4,446,090, blend high viscosity silicone oils of various compositions into various different thermoplastic polymers. The ratio of high viscosity silicone oil to thermoplastic polymer is in the range of 0.005 to 200.0. This method is particularly useful for flame retardant silicone oils.

Riffle and Yilgor, US Pat. No. 4,659,77
No. 7 describes polysiloxane / polyoxazoline copolymers that provide fibers that are wetted by polar and non-polar liquids when mixed into a fiber forming composition.

Foster and Metzler, US Pat.
No. 113 describes an olefin polymer composition containing a siloxane additive that is useful in making films. The siloxane comprises pendant from the polymer backbone, a monovalent organic group having at least one ethylene oxide group, an adjacent epoxy group or an amino group.

Steklenski, in US Pat. No. 4,473,676, incorporated a crosslinked silicone polycarbinol into a film forming composition to provide a polymer composition having a low coefficient of friction and useful as a protective layer in photographic elements. To manufacture.

Hansen et al., US Pat. No. 5,456,982, discloses that a surface-active substance, such as an emulsifier, a surface-active agent or a detergent, is placed in an armor and core-type bicomponent fiber armor component and the fibers are mixed. It is soluble.

Silicone additives that are incompatible with bulk polymers at ambient temperature but compatible at spinning temperature, as described by Nohr and MacDonald (above), take advantage of the problem of using such additives. . In such additives, the higher molecular weight makes the additive soluble in polypropylene (and also in other polyolefins). However, the use of low molecular weight silicone reduces the thermal stability of the lubricating additive.

Also, as noted above, 1% of the total finish composition.
It is very difficult to control the topical application of applied surface finishes with components in amounts of only one tenth of the. Therefore, it is very difficult to provide a uniform finish composition with about 0.3% silicone additive, and it is very difficult to provide a uniform coating of such a finish on the fibers. The use of insufficient amounts of lubricant in finishes can be very destructive to industrial operations. Also, the use of too much silicone (which can be only one tenth of 1%) makes the fibers very slippery for processing, especially crimping, at industrial speeds. Moreover, the fibers can be crimped, and the strength of the web is greatly reduced, even when processed into a nonwoven web. Silicone oils on the surfaces of the fibers that are bonded (eg, heat bonded) interfere with the bonding of the fibers to each other.

[0018]

In view of the above, it would be beneficial to provide highly hydrophobic fibers that are easily processed without causing processing difficulties.

It is also beneficial to provide such hydrophobic fibers with which the aqueous lubricant applied together does not compromise the desired hydrophobic properties of the fibers. Aqueous lubricants that are applied as surface finishes are easier to apply and remove, are less toxic, and are easier to disperse (and thus the fibers) than non-aqueous surface lubricants (such as silicone oils). It provides an advantage in the uniformity of the lubricant coating after it has been applied to the surface.

It is a further advantage to provide such fibers with improved hydrophobicity for improved barrier layer properties and to increase industrial processing speeds.

Yet another advantage is to provide an inherently lubricated hydrophobic fiber which is effective in processing the fiber into a carded nonwoven article without the application of a lubricious finish. . In connection with the state of the art, such fibers are
It provides an improvement over conventional processing by eliminating the step of applying one or more lubricious finishes.

Yet another advantage is to provide such hydrophobic fibers that are heat stable and have inherent lubricity.

Yet another advantage is that the contact angle, especially the advancing contact angle (ad), which is greater than the intrinsic contact angle of such polyolefins.
to provide an as-spun polyolefin-containing fiber having a vancing contact angle).

In another aspect, the present invention provides fiber forming melt compositions useful for melt spinning as-spun fibers having improved hydrophobicity and improved lubricity.

[0025]

The novel polymer melt preferably comprises a homogeneous mixture of polysiloxane with a fiber-forming polyolefin, in particular a polyolefin having ethylene and / or propylene units.

In yet another aspect, the present invention provides an internally lubricated polyolefin fiber having an essentially non-extractable internal lubricant, which is also preferably hydrophobic.

The present invention also includes an internal polysiloxane,
Provided are novel as-spun polyolefin fibers having a greater contact angle than hydrophobic polyolefin fibers without internal polysiloxane. The increased contact angle means that the new as-spun fibers are more hydrophobic than those containing no internal polysiloxane. The fibers of the present invention are preferably at least 95 degrees, more preferably at least about 96 degrees, even more preferably at least about 100 degrees, even more preferably at least about 105 degrees and most preferably at least about 110 degrees. It has the above specific contact angle.

By providing these and other advantages, in one embodiment the present invention has a hydrophobic fiber with an internal lubricant (ie, it can be processed without a topical lubricant finish composition applied). I will provide a. Optionally, the fibers may be provided with a topically applied hydrophilic antistatic finish. In either case,
The fibers can be processed into carded nonwovens at industrial rates while maintaining their hydrophobicity.

[0029]

More specifically, in another aspect, the invention provides a compound of the general formula X- [Si (R ¹ ) (R ² ) -O-] _z-.
Y, wherein X, Y, R ¹ and R ² are hydrophobic, non-polar groups, preferably hydrocarbyl groups, more preferably about
Individually selected from alkyl, alkenyl, alkynyl, cycloalkyl and / or aralkyl groups having up to 22 and more preferably up to about 16 carbon atoms and / or aryl substituted with any of the above groups and their ethers. R ¹ and R ² are also individually selected from hydrophobic non-polar alkyl, aryl and heterocyclic groups, and z is a sufficiently high positive number such that the polysiloxane is hydrophobic). Providing a polyolefin-containing fiber or a polyolefin-containing fiber-forming composition containing the represented internal polysiloxane, depending on whether it is in the molten or solidified state. At least 50% by weight, preferably at least about
"Polyolefin-containing" when 75% by weight, more preferably at least about 90% by weight and even more preferably at least about 95% by weight of the fiber's structural component (ie, without additives) is a polyolefin. Polysiloxanes are hydrophobic in the sense that they do not have an affinity for water, and functionally, in connection with certain preferred embodiments of the present invention, are useful for hydrophobic fiber surfaces, especially barrier wall articles. Provide a hydrophobic fiber surface for the hydrophobic fiber. In a preferred aspect, R ¹ and R ² are about
Unsubstituted and substituted hydrophobic linear and branched chain alkyl groups having up to 16 carbon atoms, more preferably up to about 8 carbon atoms, and aryls optionally substituted with up to 3 hydrophobic alkyl groups. It is individually selected from the group (phenyl group). In another preferred embodiment, X and Y are lower alkyl groups having up to about 16 carbon atoms and more preferably having about 8 carbon atoms. In still other preferred embodiments, z ranges from about 10 to about 50 or more.

The present invention also includes at least 95 degrees, more preferably at least about 100 degrees, even more preferably at least about 105 degrees and most preferably at least about.
Provided is an as-spun polyolefin fiber having an inherent contact angle of 110 degrees or more. What is the "specific contact angle"? As-spun contact angle before application of topical finish. Therefore, the novel as-spun fibers of the present invention are:
It has a greater contact angle after spinning than compatible as-spun fibers without internal lubricant, without the application of topical lubricant. The novel fibers are essentially free of any surfactant present on their surface.

In yet another aspect, the invention is essentially free of non-extractable lubricants. The novel fibers with internal lubricant of the present invention are not capable of having lubricant removed from the surface of the fiber as opposed to fibers having only topically applied lubricant.

In yet another aspect, the present invention provides a novel method of using these fibers, particularly the manufacture of nonwoven articles, and
Preferably, there is provided a fiber forming composition comprising a major portion of the polyolefin and a compatible polysiloxane homogeneously mixed therewith, spinning the fiber forming composition into one or more fibers, and drawing the fibers. Manufacture of products from them, including crimping the fibers, cutting the crimped fibers into staple lengths and carding and adhering the fibers to produce non-woven articles. A method of using these fibers in is provided.
The non-woven article is preferably further processed into a hygiene article such as a diaper. If necessary or desired, a locally hydrophobic finish, preferably an aqueous finish, can optionally be applied to the fiber.

The present invention relates to a polyolefin-containing lubricated fiber-forming composition, fibers made therefrom, and intermediates and final articles made therefrom.
By "fiber forming" composition is meant a composition that can be spun into fibers, preferably by melt spinning. The lubricant is preferably a hydrophobic polysiloxane.

Fiber forming compositions useful in the present invention preferably have at least 2 carbon atoms, preferably about 2.
Of straight and branched chain olefins having from 1 to about 8 or more carbon atoms, more preferably from about 2 to about 4 carbon atoms and most preferably 2 or 3 carbon atoms (polyethylene and polypropylene), preferably Included are melt-spinnable polyolefins derived from alkene monomers. The polyolefin may be a homopolymer or copolymer (e.g. a terpolymer) used alone or mixed or blended in various proportions with other polyolefin-containing homopolymers or copolymers. Examples of suitable polyolefins include, without limitation, polyethylene, polypropylene, poly (1-butene), poly (4-methyl-1-pentene), poly (α-methylstyrene), poly (о-methylstyrene), polybutadiene. Etc. and their compatible mixtures and blends. The most preferred composition is polypropylene, especially propylene homopolymer or at least 50% by weight, more preferably at least 75% by weight and most preferably at least 90% by weight propylene and ethylene, butene,
Copolymers derived from the residue derived from hexene and their mixtures.

Also preferred is a spinnable blend or mixture of polymers containing at least 50% by weight, more preferably at least 75% by weight and most preferably at least 90% by weight propylene homopolymer.

Accordingly, the fiber-forming composition includes one or more fiber-forming polymers that are compatible with the polyolefins present therein. The fiber forming composition comprises at least 75
While a polyolefin content of wt% is suitable for a particular application, it is preferred to have at least 90 wt% polyolefin, with the minimum amount of polyolefin being about 50 wt% or greater. Suitable polymers for blending or alloying with polyolefins are selected from polyesters, polyamides, polyaramids and the like, which are compatible with other components. A preferred blend is poly (ethylene terephthalate) ("PET") and polypropylene. Preferred polyolefins include polyethylene homopolymers,
Included are polypropylene homopolymers and ethylene-propylene copolymers and mixtures thereof. Particularly preferred are about 19: 1 to about 1:19, about 10: 1 to about 1:
10, about 6: 1 to about 1: 6 and about 1: 1 about a mixture of polyethylene and polypropylene in about equal weight proportions, essentially about an equal weight of 2 from pure ethylene homopolymer or propylene homopolymer. Any amount up to two homopolymers, one of which may be replaced with an ethylene-propylene copolymer.

In the polyolefin-containing fiber-forming composition (preferably in the form of polymer particles prior to melting),
At least one polysiloxane of the formula X- [Si ((R ¹ ) (R ² ) -O-] _Z- Y is added.
Wherein X and Y are the same or different and are hydrophobic, non-polar groups, preferably hydrocarbyl groups, more preferably
Aliphatic groups such as alkyl, alkenyl, alkynyl and cycloalkyl groups, preferably C _1-22 , more preferably C _1-16 , even more preferably C _1-8 , most preferably C _1-3 , and them. Ethers such as those individually selected from their octyl, octyl siloxy ethers. R ¹ and R ² are the same or different, preferably about 22 or less carbon atoms, more preferably about 16 or less carbon atoms, even more preferably about 8 or less carbon atoms and most preferably 1 to 3 carbon atoms. Atoms, particularly preferred are aliphatic hydrophobic groups selected from straight-chain or branched alkyl, alkenyl, alkylnyl and cycloalkyl groups having one carbon atom, and also preferably arene groups, preferably 3 Preferably no more than two, optionally substituted with an aliphatic group as previously defined for R ¹ and R ² (eg, aralkyl such as dimethylphenyl), most preferably R ¹ and R ² are , An unsubstituted C _1-3 alkyl and an unsubstituted phenyl group. The various aliphatic groups are preferably straight chains, although branched chains are also suitable. R ¹ and R ² are preferably alkyl, alkenyl, alkynyl, cycloalkyl, araliphatic, aryl and any of the above (eg aralkylphenyl) substituted with any of the above, and their hydrophobicity. It is preferably selected from non-polar derivatives. Preferred non-polar derivatives include their ethers such as methoxy, ethoxy, ethoxymethoxy, benzoxy and the like. Accordingly, the general formula of the ^{polysiloxane, X-A 1 - [Si} (A 2 R 1)
_{^{(A 3 R 2) -O-]}} z -A 4 -Y ( ^{wherein, A} 1,
A ² , A ³ and A ⁴ may be individually selected from a bond or oxygen and the others are as defined above). The chain length z is a positive number large enough that the polysiloxane is hydrophobic and is preferably compatible with the polymer in both the melted and aggregated states, and z is generally 10 to 50 or less. It is more than that. Examples of suitable polysiloxanes for inclusion in the fiber-forming composition of the present invention include Schm
US Patent No. 4,938,832 by Altz, US Patent Application No. 07
/ 614,650 and 07 / 914,213 and European Patent Application No. 486,
No. 158 and US patent application Ser. No. 07 / 706,45 by Johnson et al.
0 and 07 / 973,583 and European Patent Application 516,412, all of which are incorporated herein by reference. Preferred polysiloxanes are poly (dimethylsiloxane) and poly (alkylaryl siloxanes), especially poly (dimethylsiloxane) and poly (methylphenylsiloxane). The preferred molecular weight of the poly (dialkylsiloxane) is at least about 15,0.
00, more preferably about 60,000 to about 450,000, more preferably about 75,000 to about 275,000. For trimethylsiloxy-terminated poly (alkylphenylsiloxanes), the preferred molecular weight is about 1,500 to about 3,500, more preferably about 2,000 to about 3,000, with poly (methylphenylsiloxane) much higher. A molecular weight can be used, but preferably has a molecular weight of about 2,600 (the molecular weight of the polysiloxane can be number average or weight average molecular weight).

The polysiloxanes suitable for the present invention are:
At ambient temperature, it is preferably miscible with the polyolefin-containing spinnable composition even during suitable conditions for spinning. In contrast to those polysiloxanes suitable for the present invention, the low molecular weight alkyl siloxanes typically incorporated into engineering resins are immiscible with the polyolefin-containing spinnable composition and are bulk polymers at ambient conditions. It migrates (blooms) to the surface of its part because it is immiscible with. As shown in the examples below, the spinnable melt of the present invention and the fibers spun from it are
After more than 2 years, lubricated with a polysiloxane conditioned to have very little migration of polysiloxane to the surface of the fiber, as evidenced by minimal surface extraction of the internal polysiloxane. The use of poly (ylalkylaryl siloxanes) in the present invention also provides the advantage of improved thermal stability of polysiloxanes at spinning temperatures due to the presence of aryl groups. In a preferred embodiment, the polysiloxane is (a) R ¹ and R selected from arene groups.
Selected from those having at least one of ² , and (b) having a molecular weight of at least 15,000 as defined in others.

The internal polysiloxane is typically about the fiber.
Up to 10% by weight, generally at least about 0.01% by weight,
More preferably, it is generally provided as an additive in an amount of from about 0.05% to about 5%, most preferably from about 0.1% to about 1.0%. For certain additions of polysiloxane, lower amounts are preferred as their molecular weight increases. For example, certain polyolefin compositions containing 1% by weight of poly (dialkylsiloxane) having a molecular weight of about 100,000 are suitable for certain applications, and poly (dialkylsiloxane) having a molecular weight of about 200,000 is preferably more Fewer this additive is used to achieve the same suitable results. The amount of polysiloxane used is effective to increase the hydrophobic nature of the polyolefin fiber surface over that of the as-spun fiber without polysiloxane. It is also preferred that the amount of polysiloxane used be effective to lubricate as-spun fibers (reduce surface friction) over those without the additive.

As noted, in one aspect of the invention, the main portion of the polyolefin and the formula, X-, as defined above, are used.
^{A 1 - [Si (A 2} R 1) (A 3 R 2) -O-] z -A 4
Included are the novel spinnable melts described above, which preferably comprise a polysiloxane represented by -Y in an amount of from about 0.01% to about 10% by weight of the spinnable composition.

The melted, spinnable, fiber-forming composition may be a single fiber or a bicomponent fiber or a side-by-side fiber.
), A sheath and a nucleus, a matrix with multiple nuclei (eg, islands-in-the-s
ea)) and multilobal-like arrangements of bicomponent fibers. An exemplary compositional arrangement includes:
A side-by-side array of the same or different polyolefins (eg, polyethylene / polypropylene or both polyolefins having different molecular weights) is included, such that when such fibers are heated, different polyolefin moieties undergo different shrinkage, thereby producing fibers May be bent or rolled (eg self-crimping fibres.
ber). Similarly, exemplary armor / core arrangements include polyalkylene / polyalkylene, polyalkylene / polyester such as polyethylene / polypropylene, polyethylene / PET and polypropylene / PET. The fibers of the present invention are individually supplied as monofilament fibers, as multifilament yarns, as spin bonded nonwovens as meltblown nonwover or as tows, bundles or fabrics.

The novel fibers of the invention so produced and the woven and non-woven articles made therefrom are preferably hydrophobic. The fibers of the present invention are desirably at least about 30 mm, more preferably at least about 62 mm, even more preferably at least about at least 30 mm, as measured using the improved Suter apparatus technique described in Example 6. 102 mm and even more preferably has a hydrostatic head of water of at least about 150 mm. Similarly, the non-woven fabric preferably has a hydrostatic head of at least about 25 mm, more preferably at least about 50 mm, even more preferably at least about 75 mm and even more preferably at least about 100 mm (in about 15% adhesive surface pattern). Have. The average nonwoven output is preferably at least about 30%, even more preferably at least about 50%, even more preferably at least about 70%, even more preferably at least about 90% and most preferably at least about 90%. Or more.

Another measure of the hydrophobicity of the inventive fibers is that the as-spun fibers have a greater contact angle than the as-spun fibers of the same polymer composition without the inventive polysiloxane additive. Is. The contact angle of as-spun fibers is defined herein as the "inherent contact angle". The intrinsic contact angle of as-spun polypropylene homopolymer fibers is generally less than 95 degrees. The intrinsic contact angle of a fiber according to the present invention having a polysiloxane therein as described above, is at least 95 degrees, more preferably at least about
96 degrees, even more preferably at least about 100 degrees and even more preferably the intrinsic contact angle is at least about 105 degrees or greater. The contact angle is the Wilhelmy equation, θ = cos ⁻¹ [F _w ÷ γP], where F _w is the wetting force, P is the fiber perimeter and γ is the surface tension of the liquid. Can be determined from In general, force balance is used to describe the wetting force and thus the contact angle, as described in the examples, and instead the microscopic method (ie, the fiber is actually viewed under a microscope to view the contact angle). Other methods such as (see) are easily known and suitable.

The fibers of the present invention are inherently or internally modified as opposed to surface modified fibers. Thus, the fibers of the present invention offer the advantage of having improved hydrophobicity. Prior art fibers are rendered hydrophobic by applying a hydrophobic finish composition to the surface of the fiber and by adding a blooming hydrophobic agent to the surface of the fiber. Prior art hydrophobic additives typically exist in a variety of industrial operations, including contact with guides, rollers and various forming (eg, burning, carding) equipment and contact with steam or other agents. It exists on the surface in the form of being removed by the process of. On the other hand, the novel fibers of the present invention are essentially unremoved, essentially unextracted, and essentially unbloomed on their surface. More specifically, the lubricant is essentially not removed or extracted at room temperature with a non-polar solvent. For example, as described in the prior art section, the surface finish is typically about 0.
Applied to the fibers in an amount of 1 to about 0.2% by weight, after application, the surface finish can be extracted almost entirely with organic solvents. On the other hand, the novel fibers of the present invention, when subjected to the same extraction step, have their lubricants to a much lesser extent, preferably at least about 50% less than those extracted from locally lubricated fibers. , And more preferably at least about 60% less, yielding those lubricants. The less internal lubricant that can be extracted from the fiber surface, the more preferred.

Since the fibers of the present invention do not require a topical lubricant, the fibers of the present invention essentially contain an emulsifier (or other surface active agent typically used with external finishes) on their surface. Not lubricated fibers are also provided. Accordingly, in another aspect, the present invention substantially comprises a solvent or emulsifier for a lubricant suitable for spinning into fibers, comprising a spinnable polyolefin-containing polymer composition and a lubricating composition, preferably polysiloxane. To provide a melt that is not included in.

The fibers (as well as the melt from which they are made) also contain antacids (eg calcium stearate),
It may contain conventional additives such as antioxidants, degrading agents and pigments and / or colorants (such as titanium dioxide) and the like. For example, the components of the melt of the invention from which the fibers are spun, in addition to the polymer and polysiloxane additives being spun, are all generally about
Antioxidants (eg, Irgafos 168), calcium stearate and titania are included in amounts of 0.01% to about 1.0% by weight. The fibers of the present invention also
Preferably it also contains a biocide or an antibacterial agent. The additives are individually present in individually varying amounts, and 0.01% to 3% of the composition comprises one or more of these conventional additives.

As noted above, the polysiloxane is preferably added to the fiber forming composition prior to melting, and if desired the additive can be incorporated into the melt. The fiber forming composition is then spun into the novel continuous length fibers of the present invention. If desired, the fibers are further drawn to draw the fibers to a particular degree by techniques known in the art. The final fiber is preferably about 0.11 to 44 decitex (dtex, 1 dpf = 1.1 decitex), more preferably about 0.55 to 6.6 decitex and preferably about 1.1 to 3.3 decitex.
Staple fibers are described by Kozulla in US patent application Ser. Nos. 07 / 474,897, 07 / 683,635, 07 / 836,438,
07 / 887,416 and 07 / 939,857 and European Patent Application No.
No. 445,536, US patent application 07 / 818,772 by Gupta et al.
And 07 / 943,190, Schmalz, US Pat. No. 4,9
38,832, US Patent Applications Nos. 07 / 614,650 and 07/91
4,213 and European Patent Application No. 486,158 and US Patent Application No. 07 / 706,450 by Johnson et al. (Filed May 28, 1991) and 07 / 973,583 (filed November 6, 1992). ) And European Patent Application No. 516,412, which may be produced according to the invention by extrusion, spinning, drawing, crimping and cutting, the disclosures of which are incorporated herein by reference.

In various product embodiments, a hydrophilic spin finish composition is applied to the fibers for processing and handling. In making fibers, water soluble hydrophilic spin finishes are used to reduce various processing problems such as may occur during crimping. The advantage of the internal polysiloxane is that it facilitates removal of the hydrophilic finish, i.e. maintains the hydrophobicity of the fiber. Hydrophilic finishes having both lubricious and antistatic properties are especially preferred. An exemplary finish of this type is a mixture of polyethylene glycol 400 monolaurate and polyoxyethylene (5) tridecyl phosphate neutralized with diethanolamine (George as LUROL pp-912.
A. Goulston Co., available from Monroe, NC). Other such finishing agents are John
It is described in the above patents and applications to Son and Theyson. In accordance with the present invention, a proportionally or relatively more hydrophilic antistatic finish composition (eg, sodium oleate) is provided for improved ease of removal from the fiber surface due to the presence of an internal lubricant. Can be used.

In the manufacture of nonwoven materials, it is desirable to impart some crimp to the fibers. Crimping is typically accomplished by collecting the tow of fibers in a duct through which the fibers are drawn. Steam and water circulate in the duct, which effectively packs and crimps the fibers into a steam-heated box. The steam and water act as a lubricant to help crimp the fibers, and this hot, moist environment inside the box typically acts, with essentially all hydrophobic finish compositions. If not, remove most. A preferred crimping method and apparatus is U.S. patent application Ser. No. 08/23, filed April 29, 1994 by Sibal et al.
5,306, the disclosures of which are incorporated herein by reference.

In another embodiment, a hydrophobic finish is applied to the fiber. Preferably, the above-mentioned Harrington application, European Patent Publication No. 0557024 A1 and US Patent Application No. 08 / 016,34.
6 (filed on February 11, 1993; continuation application of 07 / 835,895 filed on February 14, 1992), Schmalz's patent, US Pat. No. 4,938,832 and European Patent Publication 0846158 A2 (1992).
(Corresponding to U.S. Patent Application No. 914,213, filed July 15,) and Johnson and Theyson's U.S. Pat.
An antistatic composition, such as any of those described by 426 and European Patent Publication 0516412 A2 (incorporated herein by reference in its entirety for all such patents and applications), is applied to the fiber. Suitable hydrophobic finish composition, antistatic agent in combination with a lubricant such as a polysiloxane, a more specific example, C ₄ together with poly (dimethylsiloxane) - or C ₆ - potassium alkyl phosphate, with hydrogenated polybutene C ₁₀ - includes alkyl potassium phosphate. Since the present invention includes the lubricant added homogeneously with the fiber component, a suitable choice for the amount of lubricant in the fiber avoids the need for the use of lubricant in the finishing composition. Thus, the present invention provides the advantage of significantly reducing, if not eliminating, the amount of lubricant applied to the fiber in addition to the antistatic agent.
In addition, the novel fibers of the present invention provide various coating finishes (ov) without eliminating the inherent hydrophobicity of the fibers of the present invention.
erfinishes), antistatic agent, etc. can be applied.

For nonwoven products, the fibers are then chopped to staple lengths, typically about 5-350 mm. The preferred length is about 25 to 250 mm, more preferably about 25
It is 25 to 75 mm, most preferably about 30 to 50 mm. The fibers can be mixed denier if desired for a particular application, but are preferably uniform denier in the ranges described above.

The hydrostatic head test on these staple fibers (eg carried out as described in Example 6) preferably has a value of at least 100 mm, more preferably at least about 135 mm and even more preferably at least about 170 mm. give.

The crimped staple length fibers are then carded to form a non-woven web, heat bonded, needle punched, hydroentangling.
fixation using any of a variety of techniques known to those of skill in the art, including angling) and the like. Carding is preferably carried out with a continuous belt and adhesion is preferably achieved by contact with a heated calender roll. Other methods of thermal bonding have other typical heat sources (eg,
Hot air, heat lamp), sonic bonding (ultrasonic bonding) and laser bonding, the non-woven fabric having a basis weight of about 6 to 108 g / m ² and
Have an adhesive surface of at least about 10% and at least about 1.93N
It has a lateral strength of / 5-cm (Newton per 5 cm, 150 g / inch). More preferably about 12 to 36 g
A non-woven fabric having a basis weight of / m ² and an adhesive surface of at least 15 to 45% and a transverse strength of at least about 3.86 N / 5-cm. And most preferably about
18 to 36 g / m ² basis weight and at least 18 to 30
% Adhesive surface and may have a lateral strength of at least about 6.755 N / 5-cm.

The fibers of the present invention in the form of crimped staple fibers have, compared to other fibers, that they prevent the fibers from adhering to each other to form a non-woven article and are hydrophobic at the fiber surface. Since it has no silicone, it gives higher strength. The internally lubricated fibers of the present invention are lubricated to increase processing speed,
Provide a non-woven article with higher adhesive strength, have improved hydrophobicity, resulting in an improved hydrophobic non-woven article.

The fibers of the present invention are preferably at least about 0.
It has a settling time of 8 hours (ASTM D-1117-79) and the nonwoven has a% outflow value of at least about 80% (described later).
Having. More preferably, the fibers have a settling time of at least about 4 hours and the nonwoven has a% outflow value of at least about 85%. Most preferably, the fibers have a settling time of at least about 20 hours and the nonwoven has a% outflow value of at least about 90%.

The fibers of the present invention can be processed under typical industrial processing conditions. Fiber production is preferably at least about
200 pounds / hour, more preferably at least about 1000 pounds / hour, and most preferably at least about 1500 pounds / hour.

As noted, the present invention provides conventional hydrophobic polyolefin fibers, and in particular includes polypropylene, which has improved hydrophobicity. This improved property, especially when achieved with lubricating compositions such as the polysiloxanes of this invention, improves the liquid barrier of the fibers and articles (woven and non-woven) made therefrom. To do. This improved property also allows the use of more environmentally benign finishes to impart aqueous (eg hydrophilic), antistatic, lubricated and other properties to the fiber surface. .

The fibers of the present invention can be processed into woven and non-woven manufactured articles. During the various steps of such processing, the fibers are provided with the spin finishes, intermediate finishes and overfinishes described in the various patents and applications incorporated herein above. It is suitable for the process used and is desirable for the particular processing technique to obtain the desired article. Various specific aspects of the invention are further described with respect to the following specific examples, which are meant to exemplify the invention and limit the invention to the particular materials and conditions described. Not a thing.

[0059]

EXAMPLES Examples 1A and 1B Polypropylene resin (melt flow rate of 12 g per 10 minutes, Himon
T. Inc. (available from Wilmington, Del.) is a poly-polyethylene having a molecular weight of 17,250 and a viscosity of 500 cS (centimeter stroke) of 0.05 wt% (Example 1A) and 0.30 wt% (Example 1B). (Dimethyl siloxane). The mixture was melted and spun into fine denier multifilament fibers. Spin finish containing poly (ethylene glycol) 400 monolaurate and polyoxyethylene-5-tridecyl phosphate neutralized with diethanolamine (GA Goulston Co.
LUROL PP from (Monroe, NC)
Available as -912) based on the weight of its fiber at about 0.
3% by weight applied to the fiber. The fiber was drawn to 2.42 dtex and then crimped. After crimping, a neutralized phosphoric acid ester (LUROLL®) AS-Y, named G.P. A. Goulston Co.
A hydrophobic finish, including (available from Monroe, NC) and poly (dimethylsiloxane) (available from Union Carbide Chemical Company (Danbury, CT)) is applied to the fiber and the fiber is applied. It was cut into 37.5 mm staple fibers.

The staples were then carded onto the nonwoven web at a line speed of 76.2 m / min, followed by a calender (approx. 15% adhesive surface pattern) of 24 g / m ² basis weight. Bonded to a nonwoven web having a line speed and fabric weight typical of industrial operation.

Examples 2A and 2B Following the same general procedure as described in Examples 1A and 1B, 0.50 wt% and 1.
It was mixed with 0% by weight of poly (dimethylsiloxane) having a molecular weight of 62,700 and a viscosity of 10,000 cS and processed into staple fibers.

Examples 3A, 3B, 3C and 3D Following the same general procedure as described in Examples 1A and 1B, 0.1% by weight polypropylene resin, 0.3% polypropylene resin, respectively.
%, 0.5% and 1.0% by weight of poly (dimethylsiloxane) having a molecular weight of 139,000 and a viscosity of 100,000 cS and mixed into staple fibers.

Examples 4A, 4B and 4C Following the same general procedure as described in Examples 1A and 1B, 0.1% by weight polypropylene resin and 0.3% polypropylene resin, respectively.
% By weight and 0.5% by weight, molecular weight of 2,600 and 500 cS
It was mixed with poly (methylphenylsiloxane) having a viscosity of and processed into staple fibers.

Example 5 A control fiber was prepared by mixing polypropylene flakes with an antioxidant and calcium stearate, following the same general procedure, and processed into staple fibers.

In all of the above embodiments, the above L
The UROLPP-912 composition was applied to the fibers as a spin finish before crimping. The fibers had the characteristics as shown in Table 1.

[0066]

[Table 1]

The various fibers produced in these examples were then tested for settling time and fabric run-off and the results are shown in Table 2. The Settling Time Test (ASTM D-1117-79) was used to characterize the extent of fiber wetting by determining the settling time to settle below the surface of the water for a 5 g sample placed in a 3 g basket. The runoff amount test of the cloth was performed as follows. Two 27.5 cm x 12.5 cm non-woven fabric samples with rough side (ie pattern side)
A sheet of Eaton-Dikeman # 939 paper was placed face up on a length of 12.5 x 26.9 cm, and the cloth and two sheets of paper were placed on a board tilted 10 degrees. 2.5c from the tip of the cloth to the end of the separatory funnel
Then, the cloth sample was placed 2.5 cm above the center of the cloth sample, and the weighed paper towel was placed 0.625 cm from the bottom of the sample. Fill the separatory funnel with 25 ml of synthetic urine, open the funnel of the funnel and collect the effluent on the previously weighed paper, weigh the damp paper to the nearest 0.1 g, calculate the% effluent and test it. Was repeated 5 times and the average was calculated. The higher the% outflow, the more hydrophobic the fabric.

[0068]

[Table 2]

As shown by the results in Table 2, the staple fibers of the present invention did not wet after 2 hours of water exposure (ie, settling time greater than 2 hours). The fabric also gave greater than 90% efflux values for synthetic urine, typically 95%. On the other hand, the staples from the control (Example 5) and the fabrics from them gave poor hydrophobicity as shown by the settling time and runoff data from Table 2.

Example 6A The following ingredients were mixed in a Henschel mill: polypropylene resin (above, having a melt flow rate of 12 g per 10 minutes); 1.3.
% By weight, poly (dimethylsiloxane) having a viscosity of 10,000 cSt and a molecular weight of about 62,700; 0.02% by weight of antioxidant (IRGFOS168, available from Ciba Geigy Corporation, Additive Division, Ardsely, NY) ); 0.05% by weight calcium stearate and 0.20% by weight titanium dioxide. The resulting mixture was melt extruded through a spinneret into a large number of finely denier as-spun fibers. Spin finish containing 2.0% neutralized phosphate ester in water (Lurol
AS-Y) was applied to the as-spun fibers in an amount of 0.05% based on the dried fibers with the finish on the fibers. Pull the fiber to 2.2 dpf (2.4 decitex), crimp and Lurol AS-Y (above)
Was applied to the crimped fiber in an amount of 0.08%. The fiber was then cut into staple lengths of 37.4 mm. No topical lubricant (as a finish or otherwise) was applied to the fibers.

The staple fibers were carded into a nonwoven web at an industrial line speed of 76.2 M / min, then:
It was bonded using a heated calender (approx. 15% adhesive surface pattern) into a fabric web with a basis weight of 24 g / m ² . Line speeds and fabric weights were typical of industrial operation.

Without the use of topical lubricants at any point in the operation, the fibers were processed without difficulty at industrial speeds (eg spun, drawn, crimped and carded). ). The fibers and nonwovens had excellent hydrophobic characteristics, settling times longer than 24 hours, an average fiber outflow of 98% and a hydrostatic head of 100 mm for the fabric and 175 mm for the fibers. Fabric runoff and settling time were determined as described above.

The hydrostatic head was replaced with AATCC 1952-18 British St.
It was determined using a modified "Suter" device as an alternative to the andard 2823 device. Hydrostatic pressure was applied to the carded staple fiber web and controlled by an ascending column of water at a rate of 290 cc / min, the staple fiber holder has a screen at the top and multiple holes for water flow With a cap, it was 3.7 cm (ID) x 3.0 cm long. The diameter of the exposed fiber sample was 3.7 cm. A mirror was attached so that the underside of the fiber sample could be observed. The height of the water column above the sample screen is 60.0 cm x 3.7 cm (I
D), water was added to the column through a 0.5 cm diameter vertical hole 2.0 cm above the sample screen. 0.50 cm
A hole of diameter 1 was placed 0.5 cm above the sample screen of the column to remove water after each test. To start the test,
The drain hole of the column was plugged and 5 g of carded fiber was placed in the sample holder and compressed tightly therein.
Water was pumped through the sample into the column until a leak occurred. The test was repeated 5 times. In addition, the carded glued fabric was tested with a fabric sample holder having the same dimensions as the fiber sample holder. To test the cloth, place a 10 cm x 10 cm piece of cloth on the sample holder,
Pressed on the bottom of the column.

Example 6B Fine denier as-spun fibers made in Example 6A were tested to determine contact angles with respect to control fibers. The fibers in question, as described in Example 6A, were 1.
It contained 3% by weight of internal poly (dimethylsiloxane). A control fiber was made by melt spinning a polypropylene homopolymer composition containing 0.03 wt% Irgafos 168 antioxidant, 0.1 wt% calcium stearate and 0.06 wt% titania.

Approximately 5.5 inches (14 cm) of the as-spun fiber of Example 6A was cut, one end of the fiber was attached to a platinum weight and the other end was attached to a hook, and the adhesive was applied. Allowed to dry overnight.

A solution was prepared by adding a 1% by weight Zonyl solution from water. Zonil is EIDuPont de Ne
Fluorosurfactant wetting agent available from mours & Co. (Wilmington, Del.). That water is about
It was deionized water with a minimum surface tension of 71 dynes / cm. The literature value for the surface tension of a 1% aqueous zonyl surface-active solution was 17.4 dynes / cm.

As mentioned above, the contact angle θ is (o) the wetting force between the wetting liquid and the surface, this characteristic being measured, and (ii)
For the surface tension of the wetting liquid, this relationship is defined by the Wilhelmy equation θ = cos ⁻¹ [F _w ÷ γP]. The system for measuring these parameters includes a fiber sample to be tested and a fluid bath in which the fibers are partially present. Motion with respect to each other fibers and fluid in the direction of gravity, the fibers F _T is wetting power F _w
And buoyancy F _B. For those fibers, the device used is a motor-driven, wetting fluid container moved to produce the fibers (bonded to the hook).
Includes a suspended movable stage. The device is located in a holder that isolates the material from the air stream. The fiber is hung from a balance that connects to an electric balance, which also connects to the desk computer, its printer and chart recorder at the interface.

Briefly, the surface tensions of both water and the surfactant solution were measured. The average value for the surface tension of water is 72
Dyne / cm, using literature values for the surfactant. Then raise the stage with the fibers suspended above the container of wetting fluid, soak the fibers in the wetting fluid until the weight is just submerged, and then calibrate the device to zero. Thereafter, the dampening fluid is moved further up and the weight of new fiber is recorded as the stage moves (this is processed by an automatic electric balance available from the Cahn Instrument Company). Since the fibers are soaked in the wetting fluid, this is a measure of the developing contact angle (opposite the reprocessed contact angle when the fibers are drawn from the wetting fluid). Having the initial weight of the fiber (proportional to the total force F _T ) and the second weight of the fiber (buoyancy F _B ) in the developing contact angle, the wetting force F _w can be calculated algebraically. Wilhelmy
The developing contact angle is obtained by measuring the surface tension of the fiber and the wetting liquid combined with the equation Table 3 shows the measurement of the obtained contact angle.

[0079]

[Table 3]

As can be seen from these results, all control fibers do not have a developing contact angle above about 95 degrees, while the fibers of the present invention always have a developing contact angle above about 95 degrees. Appeared. The average developing contact angle for the inventive fibers was about 15% greater than the control developing contact angle. Furthermore, it can be seen that the intrinsic hydrophobicity of the control fiber is increased by the present invention.

Example 6C Using the same fine denier fibers prepared as described by Example 6A, comparing those fibers to control fibers, if any lubricant was extracted. The quantity was measured. The fibers of the present invention are obtained from commercial R-190 ™ polypropylene fibers (Hercules Incorporated, Wilmington, Del.) With a typical polysiloxane topical finish composition applied from the surface of the fibers. Possible).

When testing this comparison, the fibers of the present invention containing 1.3% by weight of internal poly (dimethylsiloxane) lubricant were about 2.5 years old (ie, about 2.5 years after being spun). , The control fiber was a little more than a year old.

For each test, a 4 g sample of fiber was added to 0.00
It was weighed to 01 g and placed in an extraction cylindrical filter paper. About 50 ml of methylene chloride (CH ₂ Cl ₂ ) was poured into the filter paper and added dropwise to the aluminum cup placed under the filter paper. After the gravity drip was stopped, pressure (approx. 40 psi) was applied until all the drip was over.

Next, the fiber was taken out from the cylindrical filter paper, placed on a piece of aluminum foil, and heated on a steam bath to dry.

The extract in the cup was heated in a steam bath and dried. The extraction residue was dissolved 3 times by mixing with 1.5 ml of m-xylene, then added with m-xylene to a total volume of 10 ml.

A series of standards was prepared by weighing up to 0.0001 g of poly (dimethylsiloxane) (PDMS) in separate flasks, each mixed with m-xylene as shown in Table 4.

[0087]

[Table 4]

Infrared spectra from 4,000 to 625 cm ^-1 were plotted for each of the standards in a 0.5 mm CaCl ₂ cell versus the m-xylene control. A background of m-xylene was subtracted from each measurement. (Between 1300 and 1200 cm ^-1, SiCH ₃ band is generally between 1260 to 1265cm _-1) between the peak maximum measured value and the baseline of 1260 cm ^-1
Of the PDMS value (0.0004, 0.0008
Etc.). Linear regression analysis was used to calculate the slope and disturbance of this standard curve. The slope is 0.22
Calculated to be 92.

Once the reference curve has been established, the original extract sample, now in 10 ml of xylene solution, is analyzed by infrared spectrometer with the extract in a 0.5 mm sample cell and the linear m in the reference cell.
-Measured with xylene. Tangent Baseline 1283
subtracted from cm ^-1 to 1235cm ^-1, and measuring the peak height of 1260 cm ^-1. The weight percent of PDMS in the extract is calculated by the equation, A ÷ X
= Mg of silicone in the extract (where A is the absorbance,
X is a coefficient factor (0.02292) and was calculated from 0.1 x [mg silicone] / [weight of sample (g)] is% of silicone finish extracted.

On average, 0.05% PDMS (fiber basis weight) was extracted from the fibers of the present invention and 0.12% PDM.
S was extracted from the control fiber. As noted above, the topical silicone finish was applied in an amount of 0.1 to 0.2% by weight. Therefore, essentially all the lubricant applied to the surface of the control fiber was extracted. On the other hand, the extraction of the novel fiber of the present invention containing 1.3% by weight of polysiloxane
After 2.5 years, it only produced 0.05% PDMS. The prior art predicted that the internal polysiloxane would migrate to the fiber surface, but the extraction of only about 4% of the internal polysiloxane present in the fiber after 2 years is contrary to such prediction, and the surface modification Nearly 100% of the polysiloxane removed from the surface of the quality fiber was greatly improved.
Accordingly, the present invention is essentially non-extractable internal lubricant, preferably of ^{formula, X-A 1 - [Si} (A 2 R 1) (A 3 R 2)
-O-] _z -A ⁴ -Y provides a polyolefin fiber having a lubricant represented by the formula:

Although various aspects of the present invention have been described, addition, deletion, substitution of certain compounds and modification of certain process parameters could be envisioned after reading this specification, as such. Such modifications are intended to be within the scope and spirit of the invention as defined by the appended claims.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number FI Technical display location D02G 3/04 D04H 1/42 N D04H 1/42 A41B 13/02 E A61F 13/18 310Z // (C08L 23/02 83:04) (71) Applicant 396022158 1313 N.M. Market Street, Hercules Plaza, Wilmington, Delaware, 19894-0001, United States of America (72) Inventor James H. Harrington, USA 30208, Stone Mountain, Windward Lane, 5760.

Claims (66)

[Claims] 1. The formula, X- [Si (R ¹ ) (R ² ) -O.
-] _Z- Y, wherein X and Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, and z is in the range of from about 10 to about 50 or more;
(a) R ¹ and R ² are individually selected from aliphatic groups having up to about 22 carbon atoms and the polysiloxane has a molecular weight of at least about 15,000 or (b) at least R ¹ and R ² Polyolefin-containing fibers, one of which is an arene group and the other of which is an arene group or which is defined in (a)). 2. The polyolefin-containing fiber according to claim 1, wherein the polyolefin is polyethylene, polypropylene, an ethylene-propylene copolymer or a mixture thereof. 3. The polyolefin-containing fiber according to claim 2, wherein the polyolefin is polypropylene. 4. The polyolefin is at least 5 to 95.
The polyolefin-containing fiber according to claim 2, comprising wt% polypropylene and 95 to 5 wt% polyethylene. 5. A polyolefin-containing fiber according to claim 4, comprising approximately equal amounts of polyethylene and polypropylene. 6. The polyolefin-containing fiber according to claim 4, comprising 75 to 95% by weight of polyethylene and 25 to 5% by weight of polypropylene. 7. R ¹ and R ² are (i) a substituted or unsubstituted aliphatic group having 1 to 8 carbon atoms and (ii)
A polyolefin-containing fiber according to claim 1 individually selected from the group consisting of arene groups each optionally substituted with up to 3 aliphatic groups each having 1 to 3 carbon atoms. 8. A polyolefin-containing fiber according to claim 7, wherein R ¹ and R ² are individually selected from the group consisting of (i) aliphatic groups having 1 to 3 carbon atoms and (ii) arene groups. . 9. The polyolefin-containing fiber according to claim 8, wherein R ¹ is methyl and R ² is phenyl. 10. The polyolefin-containing fiber according to claim 7, wherein R ¹ and R ² are individually selected from aliphatic groups having 1 to 3 carbon atoms. 11. The polysiloxane comprises from about 15,000 to about 450,
The polyolefin-containing fiber according to claim 10, having a molecular weight in the range of 000. 12. The polyolefin-containing fiber according to claim 1, which is in the form of staple fiber. 13. The polyolefin-containing fiber of claim 1, further comprising a hydrophilic finish. 14. The polyolefin-containing fiber of claim 1, further comprising an antistatic coating finish. 15. The fiber of claim 1, wherein the polyolefin-containing fiber is provided in a form selected from the group consisting of monofilament fiber, multifilament yarn, spunbond nonwoven, meltblown nonwoven, and tow. 16. The polyolefin-containing fiber of claim 1, wherein the fiber is provided as a non-woven article, including staple fibers that are carded and adhered. 17. An internally lubricated as-spun polyolefin-containing fiber having an intrinsic contact angle greater than that of a fiber of the same polyolefin-containing composition that does not contain an internal lubricant. 18. The general formula X- [Si (R ¹ ) (R ² )-
O-] _z- Y, where X and Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, and z is sufficiently large to render the polysiloxane hydrophobic. , (A) R ¹ and R ² are individually selected from aliphatic groups having up to about 22 carbon atoms and the polysiloxane has a molecular weight of at least about 150,000 or (b) R ¹ and R ²
At least one of which is an arene group and the other of which is an arene group or is an aliphatic group having about 22 or less carbon atoms) in an amount of 10% by weight or less.
The fiber according to claim 17. 19. The fiber according to claim 18, wherein R ¹ and R ² are individually selected from (a) an aliphatic group having 8 or less carbon atoms and (b) an arene group. 20. R ¹ and R ² are individually selected from aliphatic groups having up to 8 carbon atoms, the polysiloxane being about 1
20. The fibers of claim 19, individually selected from aliphatic groups having a molecular weight of 5,000 to about 450,000. 21. As-spun, internally-lubricated polyolefin-containing fibers. 22. The fiber of claim 21, which is in the form of staple fiber. 23. The fiber of claim 21, wherein the fiber surface is substantially free of emulsifier and solvent. 24. The fiber according to claim 21, characterized in that it has a hydrostatic head of at least 62 mm. 25. Having a hydrostatic head of at least about 102 mm,
The fiber according to claim 24. 26. A multiplicity of fibers according to claim 22,
Non-woven, carded and glued. 27. A polyolefin-containing polymer and formula,
^{X- [Si (R 1) (} R 2) -O-] z -Y ( wherein, X
And Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, z ranges from about 10 to about 50 or more, and (a) R ¹ and R ² are About 22
Individually selected from aliphatic groups having the following carbon atoms, the polysiloxane has a molecular weight of at least about 15,000 or (b) at least one of R ¹ and R ² is an arene group and the other is an arene group. Or a polysiloxane represented by the formula) or an aliphatic group having up to about 22 carbon atoms). 28. A. A polyolefin-containing polymer and
^{Wherein, X- [Si (R 1)} (R 2) -O-] z -Y ( wherein, X and Y are independently selected from aliphatic groups and their ethers with about 22 or fewer carbon atoms in each , Z ranges from about 10 to about 50 or more, and (a) R ¹ and R
² is individually selected from aliphatic groups having up to about 22 carbon atoms, the polysiloxane having a molecular weight of at least about 15,000 or (b) R ¹ and R ²
At least one is an arene group and the other is an arene group or an aliphatic group having about 22 or less carbon atoms)
Supplying a spinnable polymer melt containing a polysiloxane represented by B. A method for producing a product, comprising the step of spinning the melt into as-spun fibers. 29. The method of claim 28, further comprising drawing the as-spun fiber to produce a filament fiber. 30. The method of claim 29, further comprising the step of cutting the filament fibers into staple fibers. 31. The method of claim 30, further comprising crimping the drawn fibers to produce crimped staple fibers. 32. The method of claim 31, further comprising the steps of carding crimped staple fibers into a web and adhering the web to produce a nonwoven article. 33. The method of claim 32, further comprising the step of fabricating the non-woven article into a portion of a hygiene article selected from disposable diapers, incontinence pads and sanitary articles. 34. A product produced by the method of claim 28. 35. A product produced by the method of claim 30. 36. A product manufactured by the method of claim 32. 37. The article of claim 36, wherein the nonwoven article has an average outflow of at least about 50%. 38. The article of claim 37, wherein the nonwoven article has an average outflow of at least about 90%. 39. at least two distinct components arranged in a desired arrangement, at least one of its constituent ^{members, X- [Si (R 1)} (R 2) -O-] z - Y
Where X and Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, and z is about 10
To about 50 or more, and (a) R ¹ and R
² is individually selected from aliphatic groups having up to about 22 carbon atoms, the polysiloxane has a molecular weight of at least about 15,000, or (b) at least one of R ¹ and R ² is an arene group, The other is an arene group or an aliphatic group having up to about 22 carbon atoms) and a hydrophobic polysiloxane represented by about 10% by weight of the polyolefin-containing composition.
A multicomponent fiber comprising a polyolefin-containing composition comprising: 40. The multi-component fiber of claim 39, wherein the fiber is a bi-component supplied in an armor and core arrangement. 41. The bicomponent fiber of claim 40, wherein the exterior component comprises the polyolefin and the polysiloxane. 42. The polyolefin is polyethylene,
42. The bicomponent fiber of claim 41 selected from polypropylene, ethylene-propylene copolymers and mixtures thereof. 43. The bicomponent fiber of claim 42, wherein the core component comprises poly (ethylene terephthalate). 44. The invention in the form of staple fibers.
39. The multi-component fiber according to 39. 45. A polyolefin-containing polymer and formula:
^{X- [Si (R 1) (} R 2) -O-] z -Y ( wherein, X
And Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, z ranges from about 10 to about 50 or more, and (a) R ¹ and R ² are About 22
Individually selected from aliphatic groups having the following carbon atoms, the polysiloxane has a molecular weight of at least about 15,000, or (b) at least one of R ¹ and R ² is an arene group and the other is an arene group. A disposable diaper, an incontinence pad, and a non-woven article consisting essentially of an adhered web of fibers in the form of staples, which comprises a polysiloxane represented by: Hygiene products selected from sanitary products. 46. A polyolefin-containing polymer and formula,
^{X- [Si (R 1) (} R 2) -O-] z -Y ( wherein, X
And Y are individually selected from aliphatic groups having up to about 22 carbon atoms and their ethers, z ranges from about 10 to about 50 or more, and (a) R ¹ and R ² are About 22
Individually selected from aliphatic groups having the following carbon atoms, the polysiloxane has a molecular weight of at least about 15,000 or (b) at least one of R ¹ and R ² is an arene group and the other is an arene group? Or an aliphatic group having up to about 22 carbon atoms).
A manufactured article selected from non-woven articles and woven articles, which contains 10% by weight or less of fibers. 47. A spinning process comprising a polyolefin and a polysiloxane, having an internal contact angle greater than that of the as-spun melt spun fiber free of said polysiloxane and being essentially free of emulsifiers and surfactants on its surface. Melt spun fiber as it is. 48. The polysiloxane has the formula X- [Si (R
_{^{1) (R 2) -O-]}} z -Y ( wherein, X and Y, about 22
Individually selected from aliphatic groups having the following carbon atoms and their ethers, z ranging from about 10 to about 50 or more, and (a) R ¹ and R ² are from about 22 carbon atoms or less. Individually selected from the aliphatic groups having a polysiloxane having a molecular weight of at least about 15,000 or (b) at least one of R ¹ and R ² is an arene group and the other is an arene group or about 22 A polysiloxane represented by the following is an aliphatic group having carbon atoms):
47. The melt spun fiber according to 47. 49. The fiber of claim 47, comprising at least 50% by weight polypropylene or polyethylene. 50. A bicomponent fiber selected from (i) a side-by-side arrangement on each side comprising said polyolefin and said polysiloxane, and (ii) an exterior-nucleus arrangement wherein at least one exterior comprises said polyolefin and said polysiloxane. 48. The fiber of claim 47 in the form of. 51. The as-spun fibers have at least about 30.
48. The fiber of claim 47, having an improved Suter test (updraft column) of. 52. The staple fiber comprises a homogenous mixture of a polyolefin and a polysiloxane compatible therewith, the surface of the staple fiber being substantially free of emulsifiers and surfactants, and the non-woven fabric has an average fabric run-off of at least 30%. An article of manufacture comprising a nonwoven fabric having carded and bonded staple fibers having. 53. The article of manufacture of claim 52, wherein the nonwoven has an average outflow of at least 50%. 54. The article of manufacture of claim 52, wherein the nonwoven has an average outflow of at least about 70%. 55. The article of manufacture of claim 53, wherein the nonwoven has an average outflow of at least about 90%. 56. The article of manufacture of claim 52, wherein the nonwoven fabric has a basis weight of 6 to 108 g / m ² . 57. The article of manufacture of claim 56, wherein the nonwoven has a basis weight of 12 to 36 g / m ² . 58. The article of manufacture of claim 57, wherein the nonwoven fabric has a basis weight of 18 to 32 g / m ² . 59. The denier of the fiber is from about 0.11 dtex to about 44 dt.
Claims 1, 17, 21, 34, 39, 47 and 50, which are in the range of ex
The fiber according to claim 1. 60. The fiber has a denier of about 0.55 dtex to about 6.6 d.
60. The fiber of claim 59, which is in the tex range. 61. The fiber has a denier of about 1.1 dtex to about 3.3 d.
61. The fiber of claim 60, which is in the tex range. 62. Any one of claims 1, 17, 21, 34, 39, 47 and 50, wherein the fibers are in the form of staple fibers.
The fiber according to claim. 63. The fiber of claim 62, wherein the fiber is crimped. 64. The fiber of claim 63, wherein the fiber is bonded to other such fibers. 65. A. A polyolefin-containing polymer and
^{Wherein, X- [Si (R 1)} (R 2) -O-] z -Y ( wherein, X and Y are independently selected from aliphatic groups and their ethers with about 22 or fewer carbon atoms in each , Z ranges from about 10 to about 50 or more, and (a) R ¹ and R
² is individually selected from aliphatic groups having up to about 22 carbon atoms, the polysiloxane has a molecular weight of at least about 15,000, or (b) at least one of R ¹ and R ² is an arene group, The other is an arene group or an aliphatic group having up to about 22 carbon atoms) and providing a spinable polymer melt comprising a polysiloxane represented by B. An as-spun lubricated fiber made by a method comprising spinning the melt into an as-spun fiber. 66. The product produced by the method of claim 65, further comprising the step of cutting the fibers into staple fibers.