A method to make bicomponent fibers and articles comprising the same

Abstract

The disclosure generally relates to bicomponent fibers, and more particularly, methods to make bicomponent fibers and articles comprising them, wherein a first extruded component has a moisture level less than a second extruded component. The bicomponent fibers may comprise polyesters and are useful in articles such as carpets and fabrics.

What is claimed is: 
     
         1 . A method to make bicomponent fibers comprising:
 a) extruding a first and second component on a spinning machine capable of producing two or more independent melt streams;   b) combining the melt streams in a spinneret suited for making bicomponent fibers;   c) quenching in air the bicomponent fibers produced in step (b);   d) drawing and heat setting the quenched bicomponent fibers; and   e) winding up the bicomponent fibers in step (d) by any suitable means; 
 wherein the first extruded component has a moisture level less than the second extruded component. 
     
     
         2 . The method according to  claim 1 , wherein the first and second component is independently selected from the group consisting of: polyesters, nylons, and combinations thereof. 
     
     
         3 . The method according to any one of  claims 1-2 , wherein the first and second component is a polyester independently selected from the group consisting of: poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof and the second component is a polyester selected from the group consisting of: poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof. 
     
     
         4 . The method according to any one of  claims 1-3 , wherein the first component is poly(ethylene terephthalate) and the second component is poly(trimethylene terephthalate). 
     
     
         5 . The method according to any one of  claims 1-4 , wherein the first component has moisture level in a range from about 10% to about 20% and the second component has a moisture level in a range from about 90% to about 80. 
     
     
         6 . The method according to any one of  claims 1-5 , wherein the first component has a moisture level of about 50 ppm or less and the second component has a moisture level greater than about 50 ppm. 
     
     
         7 . The method according to  claim 1 , wherein a stretch measurement of the bicomponent fibers produced in step (e) increased in a range from about 10% to about 85% as compared to bicomponent fibers made by steps (a) to (e) wherein the first extruded component did not have a moisture level less than the moisture level of the second extruded component. 
     
     
         8 . The method according to  claim 7 , wherein the stretch measurement increase is selected from the group consisting of: 12%, 17%, and 40%. 
     
     
         9 . The method according to  claim 1 , wherein the first and second components of the bicomponent fiber are present in a weight percent ratio ranging from 20:80 to 80:20. 
     
     
         10 . The method according to  claim 1 , wherein the bicomponent fiber is in a configuration selected from the group consisting of: side-by-side, eccentric sheath core configuration, and trilobal. 
     
     
         11 . The method according to  claim 11 , wherein the crimp contraction after heating of the bicomponent fiber, of step (e), is in a range from about 10% to about 85% as determined according to the Crimp Contraction Method. 
     
     
         12 . The method of  claim 1 , wherein an extruder temperature of one of the components in step (a) is in a range from about 240° C. to about 320° C. 
     
     
         13 . The method according to  claim 12 , wherein an extruder temperature of one of the two extruded components in step (a) is selected from the group consisting of: 260° C., 270° C., 280° C., 290° C., 300° C., 310° C., and 320° C. 
     
     
         14 . An article of clothing comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         15 . A fabric comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         16 . A fully drawn yarn comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         17 . A partially oriented yarn comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         18 . A staple fiber comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         19 . A carpet whose face fiber comprises bicomponent fibers made from the method of  claim 1 . 
     
     
         20 . The carpet of  claim 19 , wherein the bicomponent fiber is in a configuration selected from the group consisting of: side-by-side, eccentric sheath core configuration, and trilobal. 
     
     
         21 . The carpet of  claim 20 , wherein the face fiber further comprises at least one additional fiber selected from the group consisting of: bulked continuous filament, synthetic staple fiber, and natural fiber. 
     
     
         22 . The carpet of  claim 21 , wherein the at least one additional fiber is bulked continuous filament, and the bulked continuous filament comprises nylon, polypropylene, or polyester. 
     
     
         23 . The carpet of  claim 21 , wherein the at least one additional fiber is synthetic staple fiber, and the synthetic staple fiber comprises nylon or polyester. 
     
     
         24 . The carpet of  claim 21 , wherein the at least one additional fiber is natural fiber, and the natural fiber comprises wool, silk, or cotton. 
     
     
         25 . A non-woven fiber comprising bicomponent fibers made by the method of  claim 1 . 
     
     
         26 . A non-woven fabric comprising bicomponent fibers made by the method of  claim 1 .