US2013157054A1PendingUtilityA1

High linear density, high modulus, high tenacity yarns and methods for making the yarns

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Assignee: CHITRANGAD BHATNAGARPriority: Dec 20, 2011Filed: Dec 20, 2011Published: Jun 20, 2013
Est. expiryDec 20, 2031(~5.4 yrs left)· nominal 20-yr term from priority
Inventors:Bhatnagar Chitrangad
D01F 6/605D01D 10/02D01D 5/06Y10T428/298
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Claims

Abstract

The present invention relates to a yarn, comprising (a) a plurality of fibers having an orientation angle of no more than 8.0 degrees and made of a para-aramid, (b) a linear density of at least 2666 dtex (2400 denier), (c) a modulus of at least 810 grams per dtex (900 grams per denier), and (d) a tenacity of at least 18 grams per dtex (20 grams per denier). The invention further relates to methods of making such yarn.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A yarn, comprising: (a) a plurality of fibers having an orientation angle of no more than 8.0 degrees and made of para-aramid, (b) a linear density of at least 2666 dtex (2400 denier), (c) a modulus of at least 810 grams per dtex (900 grams per denier), and (d) a tenacity of at least 18 grams per dtex (20 grams per denier). 
     
     
         2 . The yarn of  claim 1 , wherein there are 1100 to 2500 of the plurality of fibers and the fibers have a linear density of 1.10 to 2.50 dtex (1.00 to 2.25 denier). 
     
     
         3 . The yarn of  claim 1 , wherein the para-aramid is poly(p-phenylene terephthalamide). 
     
     
         4 . The yarn of  claim 1 , wherein the yarn has a linear density of 2666 to 3444 dtex (2400 to 3100 denier). 
     
     
         5 . The yarn of  claim 1 , wherein the modulus is from 810 to 990 grams per dtex (900 to 1100 grams per denier). 
     
     
         6 . The yarn of  claim 1 , wherein the tenacity is from 18 to 25 grams per dtex (20 to 28 grams per denier). 
     
     
         7 . The yarn of  claim 1 , wherein the orientation angle is 5.0 to 8.0 degrees. 
     
     
         8 . The yarn of  claim 1 , further comprising the fibers having an apparent crystallite size at the 110 intensity peak of 70 to 85 Angstroms. 
     
     
         9 . The yarn of  claim 1 , further comprising the fibers having a crystal perfection index of 55 to 70 percent. 
     
     
         10 . A continuous process for making a para-aramid yarn having a linear density of at least 2666 dtex (2400 denier), a modulus of at least 810 grams per dtex (900 grams per denier) and a tenacity of at least 18 grams per dtex (20 grams per denier), comprising:
 extruding an anisotropic solution of para-aramid in a solvent-through a spinneret having a plurality of holes forming a plurality of fibers,   passing the fibers through a gas and then a coagulating liquid,   combining the fibers into a yarn,   washing the yarn with a washing solution,   removing some of the washing solution from the surface of the yarn,   treating the yarn by heating the yarn from 120° C. to 260° C. under a tension of 0.90 to 2.25 grams per dtex (1.00 to 2.50 grams per denier) for a first heating time of 1.6 to 6.0 seconds, and   after the first treating step, treating the heated yarn from 300° C. to 400° C. under a tension of 2.25 to 4.50 grams per dtex (2.50 to 5.00 grams per denier) for a second heating time of 0.2 to 5.0 seconds,   cooling the yarn to a temperature of 125 to 170° C.,   applying a finish on the yarn, and   winding the yarn on a spool for the first time in the process.   
     
     
         11 . The process of  claim 10 , wherein the yarn further has a linear density of 2666 to 3444 dtex (2400 to 3100 denier) and the fibers have an orientation angle of 5.0 to 7.5 degrees. 
     
     
         12 . The process of  claim 11 , wherein the yarn further comprises the fibers having an apparent crystallite size at the 110 intensity peak of 70 to 85 Angstroms and a crystal perfection index of 55 to 70 percent. 
     
     
         13 . The process of  claim 10 , wherein the para-aramid is poly(p-phenylene terephthalamide). 
     
     
         14 . The process of  claim 10 , wherein in the first treating step, the yarn is heated from 150° C. to 200° C. for the first heating time. 
     
     
         15 . The process of  claim 10 , wherein in the second treating step, the yarn is heated from 340° C. to 380° C. for the second heating time. 
     
     
         16 . The process of  claim 10 , wherein in the first treating step, the yarn is heated in a first oven section or by a first plurality of hot rolls and in the second treating step, the yarn is heated in a second oven section or by a second plurality of hot rolls. 
     
     
         17 . The process of  claim 10 , wherein in the first treating step, the yarn is heated by a first plurality of hot rolls and the time that the yarn contacts the hot rolls is the first heating time. 
     
     
         18 . The process of  claim 17 , wherein the first plurality of hot rolls includes at least two steam heated rolls and the yarn contacts the steam heated rolls to remove most of the wash solution from the yarn. 
     
     
         19 . The process of  claim 18 , wherein the first plurality of hot rolls includes a first plurality of electrically heated rolls and the yarn contacts the at least two steam heated rolls before the yarn contacts the electrically heated rolls. 
     
     
         20 . The process of  claim 17 , wherein in the second treating step, the yarn is heated by passing the wet fibers over a second plurality of hot rolls heated and the time the yarn contacts the rolls is the second heating time. 
     
     
         21 . The process of  claim 20 , wherein the second plurality of hot rolls are electrically heated.

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