Self-crimping fluoropolymer and perfluoropolymer filaments and fibers

Abstract

Disclosed is a method and device for creating three dimensional (3D) self-crimping fluoropolymer(s) and perfluoropolymer(s) filaments via extrusion through a spinneret plate orifice with a hole and elliptical gap and using die swell to close the elliptical gap in the filament forming a seam causing uneven stresses in the longitudinal length of the filament while cooling thereby causing the filament to self-crimp toward the seam.

1 . A method for self-crimping fluoropolymer(s) and perfluoropolymer(s) comprising;
 heating said fluoropolymer(s) and/or said perfluoropolymer(s) to a molten state, extruding said fluoropolymer(s) and/or said perfluoropolymer(s) under pressure through spinneret plate(s) orifice(s) creating a filament or filaments that exhibit die swell, wherein said filament(s) in a glass transition temperature range expand sectionally along a longitudinal length of said filament, and   wherein said spinneret plate orifice(s) comprise a round hole shape with an ellipsoid peninsula creating an ellipsoid cove gap in one section of said filament and opposing sides of said ellipsoid cove gap close creating a seam between said opposing sides such that differential die swell around said ellipsoid cove gap creates uneven stresses along one portion of said filament thereby causing said filament to crimp, bend, deform and/or twist toward said seam in a preferred manner.   
     
     
         2 . The method of  claim 1 , wherein differential cooling is provided in that said seam between opposing sides of said filament allows for slower cooling within said filament than cooling of the external surfaces of said filament, providing uneven stresses to one portion of said filament as said filament cools, thereby causing said filament to crimp, bend, deform and/or twist toward said seam in a preferred manner. 
     
     
         3 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said spinneret plate orifice is a hole with an ellipsoid cove peninsula for creating said ellipsoid cove gap along said longitudinal length of said filament and wherein the rate of cooling of said filament allows for control of said stresses within said filament. 
     
     
         4 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said fluoropolymer(s) and/or said perfluoropolymer(s) extruded through said holes with said ellipsoid cove gap incurring said die swell, said filament will crimp, bend, deform and/or twist toward said seam to provide a 3-dimensional helical crimped filament that may or may not be spiraled. 
     
     
         5 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said fluoropolymer(s) and perfluoropolymer(s) may be extruded in a horizontal plane, a vertical plane or any angle in between said horizontal or said vertical plane. 
     
     
         6 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein extruding said filament may be either a staple fiber produced during short and optionally discontinuous drawing and/or chopping time periods or as long continuous filaments produced during long and optionally discontinuous drawing and/or chopping periods time periods. 
     
     
         7 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein pulling said filament may be in a straight line or at an angle from said spinneret plate orifice. 
     
     
         8 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein improving concentricity of said filament results in improved appearance, properties and performance characteristics as well as strengthening said filament and products comprised of said filament. 
     
     
         9 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said filaments are self-crimping filaments comprising a combination of any blend of polyamide, polyester, polypropylene, PEEK, PES, PVA, PPS, PLA, PBT, perfluoropolymers, and/or liquid crystal polymers. 
     
     
         10 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said filaments are provided to produce a variety of woven, non-woven and knitted forms. 
     
     
         11 . The method for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein self-crimping techniques provide filaments that are individually or collectively useful as filtration support media. 
     
     
         12 . A device for self-crimping fluoropolymer(s) and perfluoropolymer(s) comprising;
 heating said fluoropolymer(s) and/or said perfluoropolymer(s) to a molten state, extruding said fluoropolymer(s) and/or said perfluoropolymer(s) under pressure through spinneret plate(s) orifice(s) creating a filament or filaments that exhibit die swell, wherein said filament(s) in a glass transition temperature range expand sectionally along a longitudinal length of said filament, and   wherein said spinneret plate orifice(s) comprise a round hole shape with an ellipsoid peninsula creating an ellipsoid cove gap in one section of said filament and opposing sides of said ellipsoid cove gap close creating a seam between said opposing sides such that differential die swell around said ellipsoid cove gap creates uneven stresses along one portion of said filament thereby causing said filament to crimp, bend, deform and/or twist toward said seam in a preferred manner.   
     
     
         13 . The device for self-crimping fluoropolymer(s) and perfluoropolymer(s) as in  claim 1 , wherein said spinneret plate orifice is a hole with an ellipsoid cove peninsula for creating said ellipsoid cove gap along said longitudinal length of said filament and wherein the rate of cooling of said filament allows for control of said stresses within said filament. 
     
     
         14 . A self-crimping fluoropolymer(s) or perfluoropolymer(s) filament wherein said filament comprises;
 heating said fluoropolymer(s) and/or said perfluoropolymer(s) to a molten state, extruding said fluoropolymer(s) and/or said perfluoropolymer(s) under pressure through a spinneret plate orifice with one or more holes, creating said filament that exhibits die swell, wherein said filament, as a molten polymer, expands to fill a plowed furrow in a specific section of said filament, and   wherein said spinneret plate of one or more orifices creates a single or multiple ellipsoid cove gap in one section of said filament and a corresponding fill, creating a seam between said opposing sides.   
     
     
         15 . The filament of  claim 14 , wherein differential cooling is provided in that said seam between opposing sides of said filament allows for slower cooling within said filament than cooling the external surfaces of said filament, providing uneven stresses to one portion of said filament as said filament cools, thereby causing said filament to crimp, bend, deform and/or twist toward said seam in a preferred manner. 
     
     
         16 . The filament of  claim 14 , wherein said spinneret plate orifice includes one or more holes with an ellipsoid cove peninsula for creating said ellipsoid cove gap along said longitudinal length of said filament. 
     
     
         17 . The filament of  claim 14 , wherein as said filament is extruded through said holes with said ellipsoid cove gap incurring said die swell, said filament will crimp, bend, deform and/or twist toward said seam to provide a 3-dimensional helical crimped filament that may or may not be spiraled. 
     
     
         18 . The filament of  claim 14 , wherein said filament may be extruded in either a horizontal plane or a vertical plane. 
     
     
         19 . The filament of  claim 14 , wherein producing said filament extrusion is the result of either a chopped staple fiber produced during short and optionally discontinuous spinning time periods or as a long continuous filaments produced during long spinning time periods. 
     
     
         20 . The filament of  claim 14 , wherein pulling said filament may be in a straight line or at an angle from said spinneret plate orifice. 
     
     
         21 . The filament of  claim 14 , wherein concentricity results in improved appearance, properties and performance characteristics as well as strengthening said filament and products comprised of said filament. 
     
     
         22 . The filament of  claim 14 , wherein said filaments are self-crimping filaments of polyamide, polyester, polypropylene, PEEK, PES, PVA, PPS, PLA, PBT, perfluoropolymers, and liquid crystal polymers or polymeric compositions comprising blends of any of polyamide, polyester, polypropylene, PEEK, PES, PVA, PPS, PLA, PBT, perfluoropolymers, and liquid crystal polymers. 
     
     
         23 . The filament of  claim 14 , wherein said filaments are provided to produce a variety of woven, non-woven and knitted forms. 
     
     
         24 . The filament of  claim 14 , wherein self-crimping techniques provide filaments that are individually or collectively useful as filtration support media.