Poly-trimethylene terephthalate solid core fibrillation-resistant filament having a substantially triangular cross section, a spinneret for producing the filament, and a carpet made therefrom

Abstract

In a first aspect the invention is a solid core fibrillation-resistant, synthetic polymeric filament having three substantially equal length convex sides. The sides through substantially rounded tips centered by a distance “a” from the axis of the filament. Each rounded tip has a radius substantially equal to a length “b”. Each tip lies on a circumscribed circle having a radius substantially equal to a length (a+b) and the midpoint of each side lies on an inscribed circle having a radius substantially equal to a length “c”. The filament has a denier-per-filament in the range 10<“dpf”<35; the distance “a” lies in the range 0.00025 inches (6 micrometers)<“a”<0.004 inches (102 micrometers); the distance “b” lies in the range from 0.00008 inches (2 micrometers)<“b”<0.001 inches (24 micrometers); the distance “c” lies in the range from 0.0003 inches (8 micrometers)<“c”<0.0025 inches (64 micrometers); and the modification ratio (“MR”) lies in the range from about 1.1<“MR”<about 2.0. In still another aspect the present invention is directed to a spinneret plate having a plurality of orifices formed therein for forming the solid core fibrillation-resistant, synthetic polymeric filament. Each orifice has a center and three sides with each side terminating in a first and a second end point and with a midpoint therebetween. The sides can be either concave or linear connected by either a circular or a linear end contour.

1 - 8 . (canceled) 
     
     
         9 . A carpet having a backing and a plurality of tufts attached to the backing, each tuft having a solid core, fibrillation-resistant, synthetic polymeric filament having a longitudinal axis extending therethrough and a three-sided cross section in a plane perpendicular to the longitudinal axis, the sides being substantially equal in length and convex in form, each side having a midpoint therealong, each midpoint lying on an inscribed circle centered on the central axis of the filament, the inscribed circle having a radius substantially equal to a length “c”, each side meeting an adjacent side through a substantially rounded tip centered on a respective circle of curvature, each circle of curvature having a radius substantially equal to a length “b”, each circle of curvature being spaced from the axis of the filament by a distance “a”, each tip of the filament lying on a circumscribed circle having a radius substantially equal to a length (a+b), the filament having a modification ratio (MR) defined by the ratio of the radius (a+b) of the circumscribed circle to the radius (c) of the inscribed circle, wherein the filament has a denier-per-filament (“dpf”) in the range 10<“dpf”<35; the distance “a” lies in the range 0.00025 inches (6 micrometers)<“a”<0.004 inches (102 micrometers); the distance “b” lies in the range from 0.00008 inches (2 micrometers)<“b”<0.001 inches (24 micrometers); the distance “c” lies in the range from 0.0003 inches (8 micrometers)<“c”<0.0025 inches (64 micrometers); and the modification ratio (“MR”) lies in the range from about 1.1<“MR”<about 2.0. 
     
     
         10 . The carpet of  claim 9  wherein filament has a tenacity greater than 1.5 grams per denier. 
     
     
         11 . The carpet of  claim 9  wherein the filament has a denier-per-filament (“dpf”) in the range 12<“dpf”<32; the distance “a” lies in the range 0.00035 inches (9 micrometers)<“a”<0.003 inches (76 micrometers); the distance “b” lies in the range from 0.00010 inches (3 micrometers)<“b”<0.00095 inches (25 micrometers); the distance “c” lies in the range from 0.0005 inches (10 micrometers)<“c”<0.002 inches (51 micrometers); and the modification ratio (“MR”) lies in the range from about 1.1<“MR”<about 2.0. 
     
     
         12 . The carpet of  claim 9  wherein the synthetic polymer is poly-trimethylene terephthalate. 
     
     
         13 . The carpet of  claim 12  wherein the poly-trimethylene terephthalate has a delusterant therein. 
     
     
         14 . The filament of  claim 12  wherein the poly-trimethylene terephthalate is pigmented. 
     
     
         15 . The carpet of  claim 9  wherein the poly-trimethylene terephthalate has a 1,3 propane diol that is biologically produced. 
     
     
         16 . The carpet of  claim 9  wherein the synthetic polymer is poly-ethylene terephthalate, nylon, polypropylene or blends thereof. 
     
     
         17 - 34 . (canceled)