Water-dispersible and multicomponent fibers from sulfopolyesters

Abstract

Disclosed are multicomponent fibers derived from a blend of a sulfopolyester with a water non-dispersible polymer wherein the as-spun denier is less than about 6 and wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than 12,000 poise measured at 240° C. at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues. The multicomponent fiber is capable of being drawn at a relatively high fiber speed, particularly at least about 2000 m/min, and may be used to produce microdenier fibers. Fibrous articles may be produced from the multicomponent fibers and microdenier fibers. Also disclosed is a process for multicomponent fibers, nonwoven fabrics, and microdenier webs.

1 . A process for making at least one woven fabric comprising:
 (A) spinning at least one water dispersible sulfopolyester and at least one water non-dispersible polymers immiscible with said sulfopolyester to produce a multicomponent fiber; wherein said water dispersible sulfopolyester exhibits a melt viscosity of less than about 12,000 poise measured at 240° C. at a strain rate of 1 rad/sec, and wherein said sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues; and   (B) knitting or weaving said multicomponent fibers to produce said woven fabric.   
     
     
         2 . The process according to  claim 1  wherein said multicomponent fiber has a plurality of domains comprising said water non-dispersible polymer and said domains are substantially isolated from each other by said sulfopolyester intervening between said domains. 
     
     
         3 . The process according to  claim 1  wherein said shaped cross section is an islands-in-the-sea, segmented pie, side by side or sheath-core configuration. 
     
     
         4 . The process according to  claim 1  wherein said sulfopolyester exhibits a melt viscosity of less than about 6000 poise measured at 240° C. at a strain rate of 1 rad/sec. 
     
     
         5 . The process according to  claim 1  wherein said sulfopolyester exhibits a melt viscosity of less than about 4500 poise measured at 240° C. at a strain rate of 1 rad/sec and comprises less than about 20 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues. 
     
     
         6 . The process according to  claim 1  wherein said sulfopolyester comprises:
 (A) residues of one or more dicarboxylic acids; 
 (B) about 5 to about 20 mole %, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof; 
 (C) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure
   H—(OCH 2 —CH 2 ) n —OH
 
 
 wherein n is an integer in the range of 2 to about 500; and 
 (D) 0 to about 20 mole %, based on the total repeating units, of residues of at least one branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof. 
 
     
     
         7 . The process according to  claim 1  wherein said multicomponent fiber contains less than 10 weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber. 
     
     
         8 . A process according to  claim 1  further comprising contacting said woven fabric with water to remove said water dispersible sulfopolyester to produce a woven microdenier fabric. 
     
     
         9 . The process according to  claim 8  wherein contacting said water is at a temperature of at least about 45° C. 
     
     
         10 . The process according to  claim 1  wherein said water non-dispersible polymer is selected from polyolefins, polyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, polyvinyl chlorides, cellulose esters, and combinations thereof. 
     
     
         11 . The process according to  claim 10  wherein said water non-dispersible polymer is biodistintegratable as determined by DIN Standard 54900 or biodegradable as determined by ASTM Standard Method, D6340-98. 
     
     
         12 . The process according to  claim 10  wherein said water non-dispersible polymer is an aliphatic-aromatic polyester.