MXPA97002077A - Improvements in pillows and other articles with filling and in their rell materials - Google Patents

Abstract

The present invention relates to the improvements in and relating to pillows and other stuffed articles, more generally, in and relating to their filling materials, and more particularly in and relating to the material of filling of polyester synthetic fiber such as the one with "spiral curling", which includes the new polyester synthetic fiber filling material, and the new processes and the new rows to make

Description

IMPROVEMENTS IN PILLOWS AND OTHER ARTICLES WITH FILLING AND IN THEIR FILLING MATERIALS FIELD OF THE INVENTION This invention relates to improvements in and relating to pillows and other stuffed articles, more generally, in and relating to their filling materials, and more particularly in and relating to the material of filling of polyester synthetic fiber such as the one with "spiral curling", which includes the new polyester synthetic fiber filling material, and the new processes and the new rows to make them.

BACKGROUND OF THE INVENTION The filling material of synthetic polyester fibers (sometimes referred to herein as synthetic polyester fibers) has been reasonably well accepted as a cheap insulating and / or filling material especially for pillows, and also for cushions and other REF: 23912 -? - furniture materials, which include other bedding materials, such as sleeping bags, mats, quilts, and blankets and including soft velvety fabrics (duvets), and on the dress, such as coats and other insulating articles of clothing , due to its filling volume power, aesthetic qualities and various advantages over other filling materials, it is now manufactured and used commercially in large quantities. The "curly" is a very important feature. The "curly" provides the volume that is an essential requirement for synthetic fibers. The softeners, referred to in the art and hereinafter, are preferably applied to improve aesthetics. As with any product, it is preferred that the desirable properties do not deteriorate during prolonged use; this is generally referred to as durability. Hollow polyester fibers have been generally preferred over solid filaments, and improvements in our ability to make hollow polyester synthetic fibers with a rounded periphery have been an important reason for the commercial acceptance of synthetic polyester fibers as a material preferred filling. Examples of hollow cross sections are those with a single hole, such as that described by Tolliver, in US Patent No. 3,772, 137, and by Glazoft, in British Patent No. 1, 168,759, 4-cavities. , such as that described in European Patent No. 2 67, 684 (Jones and Kohli), and 7-cavities, described by Broaddus, in US Patent No. 5, 104, 725, all of which have been used in a commercial as filling material of hollow polyester synthetic fibers. The most commercial filler material has been used in the form of staple fibers (often referred to as strands) but some filler material, which includes the filler material of polyester synthetic fibers, has been used in the form of the filament bundle without registration of the filaments with inuos, as described, for example by Watson, in US Pat. No. 3, 952, 134, and 3,328, 850.

In general, for economic reasons, the filling material of synthetic fibers of polyester, especially in the form of strands, has become bulky by mechanical ripple, in the usual way, in a machine for curling the stuffing box, the which mainly provides a 2-dimensional type of zigzag ripple, as described, for example, by Haim et al. in US Patent No. 5, 112, 684. However, a different curly type and 3-dimensional type, it can be provided in synthetic filaments by various means, such as an appropriate asymmetric tempering or by using bicomponent filaments, as reported, for example, by Marcus in US Pat. No. 4, 618, 531, which is directed to provide beads of re-spongeable fiber (sometimes referred to in the middle as "conglomerations") of spirally curled, tangled, randomly arranged polyester synthetic fibers, and in the North American Patent No. 4,794,038, which is directed to provide fiber balls containing the binding fiber (in addition to the synthetic fibers of polyester) so the fiber balls containing the binding fiber could be molded, for example, in useful agglomerated articles activating the binding fibers. Ta-fiber balls of both types has been of great commercial interest, as has the problem of providing improved synthetic polyester fibers having "spiral curl". The term curled spiral is used frequently in the art, but the processes used to provide synthetic filaments with a helical configuration (perhaps a more accurate term than spiral curled) does not involve a "curling" process in a mechanical sense , because the synthetic filaments take on their helical configuration spontaneously during their formation and / or processing, as a result of the differences between the portions of the cross sections of the filaments. For example, asymmetric tempering can provide "spiral curling" in the single-component filaments, and the bicomponent filaments of the eccentric cross-section, preferably side-by-side because also with an offset component, can take a elicoidal configuration in spontaneous form.

The polyester fibers that have the curled and spiral are sold commercially. For example, Hl 8 Y polyester fibers are commercially available from Unitika Ltd. of Japan, and 7-HCS polyester fibers are available commercially from Sam Yang of the Republic of Korea. Both of these commercially available bicomponent polyester fibers are believed to derive their spiral curl due to the difference in viscosities (measured as intrinsic viscosity, IV, or as relative viscosity RV), i.e., a difference in molecular weight of poly (ethylene terephthalate), used as the polymer for both components to make bicomponent fibers. The use of differential viscosity (delta viscosity) to differentiate the 2 components presents problems and limitations, as will be discussed. This is mainly because the spinning of the bicomponent polyester islets of deltas is difficult, that is, it is easier to spin the bicomponent filaments of the same viscosity, and there is a limit to the difference in viscosity that can be tolerated in the practice. Since it is the delta viscosity that provides the desired spiral curl, this limit on the difference that can be tolerated correspondingly limits the amount of spiral curl that can be obtained in a delta iscosity type of the bicomponent filament. Therefore, it has been desired to overcome these problems and limitations.

The curly composite filaments have been described by Shima et al., In US Pat. No. 3,520,770, by arranging two different eccentric polyester components of polymeric ethylene glycol terephthalate and in intimate adhesion to each over the entire length of the polymer. the filaments, at least one of the components which is a polyester of the branched chemically modified branched ethylene glycol terephthalate with at least one branching agent having from 3 to 6 functional groups which form the ester and at least one of the components which is a polyester of the polymeric ethylene glycol terephthalate without branching. Shima taught the use of such filaments in woven fabrics made of filaments of cut strands. Shima did not teach the use of its bicomponent filaments as filler material. Shima did not provide any teaching regarding the pillows, nor about stuffed items, nor about stuffing materials.

BRIEF DESCRIPTION OF THE INVENTION We have found, in accordance with the present invention, that a difference between the contents in the branched chain of the polyester components can provide entajas in the polyester bicomponent fibers to be used as polyester synthetic fiber filling materials in the stuffed articles , especially in the pillows, and in the new hollow polyester bicomponent fibers for such use. We use here both terms "fiber" and "filament" even without pretending to use one term to exclude the other. Therefore, in accordance with one aspect of the invention, we provide a pillow filled with filler material which includes the synthetic fibers of the polyester, the polyester synthetic fiber filler material comprising at least 10%, preferably the less 25%, and in particular at least 50% by weight of the synthetic fibers of the polyester b components of helical configuration resulting from a difference between the contents of the branched chain of the polyester components of the synthetic fibers of the bicomponent poiiéster. Preferably 100% of the filler material is bicomponent fibers but, as will be understood, the blends of the fillers can be used in practice by some operators, eg, 10/90 or more, 25/75 or more , 50/50 or whatever may be considered desirable for any reason.

As indicated, pillows are a very significant part of the stuffed goods market, but this invention is not restricted only to pillows, and, accordingly, we provide, more generally, articles filled with filler material, filler material comprising at least preferentially at least 2 in form At least 50% by weight of bicomponent synthetic fibers of helical configuration resulting from a difference between the branched chain content of the polyester components of the synthetic fibers of the bicomponent polyester. In particular, such padded articles are preferred, in accordance with the invention, includes articles of clothing, such as coats with caps and other insulated or insulating articles of clothing, bedding materials (sometimes referred to as sleeping products) other than the pillows, which include blankets and quilts that include soft velvety fabrics (duvets), and sleeping bags and other stuffed items suitable for camping purposes, for example, furniture items, such as cushions, "light pillows or travel "(which is not necessarily intended to be used as bedding materials), and furniture with fillers, toys and, in reality, any item that can be filled with the synthetic fibers of the polyester. The rest of the filling material can be another filling material of the polyester, which has the advantage of being washable, and is preferred, but if desired another material can be used.

Such articles may be filled (at least in part) with fiberballs (conglomerates), in which the synthetic fibers of the bicomponent poiyher of helical configuration are randomly entangled in such fiberballs. The fiberballs may be molded, cause of the presence of the binding beast, as described by Marcus in US Patent No. 4, 794, 038, for example, and Halm et al. in US Patent No. 5, 112, 684, or re-sponge, as described, for example by Marcus in U.S. Patent No. 4, 618,531 and also by Halm et al., Also provided, in accordance with the invention, are the fiberballs, wherein the synthetic fibers of the bicomponent polyester. of helical configuration are randomly entangled to form the 1? fiber balls The articles co filled according to the invention also include articles characterized in that (ai any of) the filling material is in the form of wadding, which can be bonded, if desired, or left unbonded. Preferably, (at least some of) such synthetic fibers of the bicomponent polyester are hollow in filled articles, in accordance with the invention, in special form with multiple voids, that is, they contain more than one continuous gap along the length of the fibers, as described in the art. Particularly preferred are fibers having three continuous voids, for example, as described below, with a round peripheral cross section. We believe that nobody has described how to spin round filaments with 3 cavities. In other words, we believe that this is a new cross section for any fiber. They also provide themselves, in accordance with other aspects of the invention, the new synthetic fibers of the bicomponent polyester hollow, and the new processes and the new rows to make them. Preferably, at least some of the synthetic fibers of the bicomponent polyester are softened in the stuffed articles, according to the invention, that is, they are coated with a durable softener, as is written in the art. As described below, a mixture of fibers Synthetic 1C polyester bicomponents softened and un-smoothed according to the invention may have processing advantages. They also provide themselves, from In accordance with another aspect of the invention, the new synthetic fibers of the softened bicomponent polyester.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an enlarged photograph of several cross sections of the bicomponent 3-cavity filament of the preferred embodiments of the invention. Or FIG. 2 is an enlarged view of a capillary row according to the invention of the lower surface of the row, for spinning a filament of 3 cavities. Fig. 3 is an enlarged photograph of another cross-section of the bicomponent 3-cavity filament, which is dyed to show a dividing line between the two components.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES As indicated, an important aspect of the invention is a new use for the bicomponent polyester fibers of helical configuration resulting from a difference between the branched chain content of the polyester components of the bicomponent polyester fibers. The idea of using a difference (between a component that is polyester of the unbranched polymeric ethylene glycol terephthalate and another component that is branched with at least one branching agent having from 3 to 6 functional groups that form the ester) in a polyester filament Two-component for use on woven fabrics was already by Shima (and will collaborate on 1? North American No. 3, 520, 770) more than 20 years ago. The branching chain for the purposes of the synthetic fibers of the polyester has also been described in the published application of European Patent No. 0., 294, 912 (DP-4210) in a completely different context. Examples of the technology for making the polyester polymer of the branched chain have already been described in accordance with this technique (the description incorporated herein by reference), and it would be slow to repeat such technology here. In practice, it will be generally preferred to use the unbranched polyester polymer as a component, and a branched chain polymer as the other component, as Shima did, and it will generally be preferred to use the unbranched polyester polymer as the major component, since the unbranched polymer is cheaper. However, none of these is necessary, and this can sometimes be, for example, desirable for both components to be branched chain, with differences between the ration chain in order to provide the desired helical configuration, as shows, for example, in Example 4 below. Similarly, it may be desired to make the bicomponent filament of more than two components, but, in practice, only two components are preferably preferred. Shima was not related to the field of the present invention, specifically with articles with fillers, such as and in special pillows, and their filler materials, and did not describe how to make such articles.

Although Shima described his own preferred techniques for making the branched-chain polymers and the bicomponent polyester fibers, we prefer to use different techniques in some way, as described below, especially in our Examples. Shima described the formulas for calculating the upper and lower limits (mol%) for the amounts of their branching (chain) agents; this means that it should be used for a trifunctional agent, such as trimethylolethane (or tricyclic tri-ethate, which we have successfully used), 0.267 to 3.2 mol%; for pentaerythritol having 4 functional groups, its limits were 0.1 to 1.2 mol%; Shima taught that smaller quantities will be used, the bicomponent filaments that have satisfactory rizability could not be obtained. In contrast to the negative teaching of Shima against the use of smaller amounts of branching chain agents, we prefer to use 0.14% in mol of trimethyl trimellitate (a trifunctional branching chain agent), as can be seen in our Examples (in combination with the unbranched polymers, ie, 2G-T). 0.14 mol% of a trifunctional branching chain is only about half as much as the minimum amount that Shima indicated would be used to obtain satisfactory curling; we doubt (from incomplete experimentation) that 0.07% in mole provides the adequate spontaneous ripple; therefore we prefer to use more, at least 0.09% in mol, or about 0.1% in mol; We believe that we can use as much as around 0.25% in mole; Shima was successful with larger quantities, as he indicated. Shima preferred to use a terminal agent: or control of the final production with its branching agent, in order to be able to exceed its upper limit of the branching agent; We found this unnecessary, at least in our preferred operation, as you can see, and we prefer to avoid this.

Shima did not describe the relative proportions of modified 2G-T (branched chain) to 2G-T unmodified in his Examples or elsewhere. We assume that he used a 50:50 ratio. We find that useful bicomponent synthetic fibers can result from as little as 8% by weight of branched chain 2G-T (using 0.14% mol), ie, a weight ratio of 8:92 in bicomponent synthetic fibers. We have also found it possible to spin filaments of useful synthetic fibers with voids, as indicated herein, and also filaments of non-round cross section. This was not taught by Shima, and we doubt that it would have been possible to use expressly the technology taught by Shima.

Returning to the field of the invention, specifically for the articles with filling and their filling with the synthetic fibers of the polyester, the synthetic fibers of the bicomponent polyester of the present invention have important advantages over the bicomponents available in commercial form to date as it follows: 1. - Our selection of the polymer allows us to spin in continuous form, cross sections of 1-cavity or of multi-cavities like the self-crimping fibers. We can thus adjust the cross section to several different needs of particular end use. We have demonstrated the continuity of the fibers of 1 cavity, 3 cavities and 7 cavities in a peripheral shape with a round cross section. Indeed, we believe that, if a capillary can be used to spin a convectional fiber, we can spin a self-crimping bicomponent with that capillary. 2. - I can vary and have the variety of the polymer ratio to obtain the ZU curl levels from non-curled to micro-curly. With other technologies such as the RV delta, there is not enough difference between the polymers to allow them to deviate too far from 50/50 (equal amounts of each co-driver of different RV). 3. - We can use and we have used a single row to spin a variety of ripple levels by changing the polymer ratio. Other technologies would require changing the geometry of the capillary if the polymer ratio were changed in a significant way. We have shown that polymer ratios vary from 10/90 to 50/50. 4.- We believe that the use of these two polymers of higher viscosity (both components that are of higher viscosity.) Versus delta RV results in a more durable curl 5.- We can elaborate hollow content up to 40% in a "curly spiral" fiber, since the fibers of such high hollow content could collapse in the knots if it will be mechanically curled. 6. - We were surprised to find that the development of the ripple did not depend on the selected stretch ratio, but on the ratio of the selected polymer. Thus, we were surprised to find that we had the same ripple level even when the stretch ratio was varied from 2.5X to 5X. This is an important and surprising processing advantage, since it allows the manufacturer to maintain a constant level of curling despite fluctuations in the stretching conditions. The deniers of the suitable filaments will generally fluctuate from 1.5 to 20 dtex for the final stretched synthetic fibers, 2-16 dtex which are preferred in most cases and 4-10 dtex which are more preferred in general form, it was understood that mixtures of different deniers can often be desirable, especially with the current interest in low deniers (ie microdeniers), in a special way for purposes of aesthetics and / or isolation.

As indicated, we believe that the bicomponent "spirally curled" polyester fibers that are commercially available (H18Y and 7-HCS) use both components of the ethylene terephthalate homopolymer (2G -T), but with different viscosities (RV for relative viscosity). We have found that a delta (difference) of about 6RV units is the only delta that is easy to turn and that gives good curling in a two-component spiral, that a smaller delta of around 6 RV can be spun but gives a low "spiral curling", since it is difficult to spin filaments with a delta greater than around 6RV units. We believe that the H-18Y has an RV average of 17.9 LRV (LRV is measured as described in Example 1 of Broaddus in US Patent No. 5, 104, 725) which means that we believe that the H-18 is probably a 50/50 side-by-side bicomponent of the 2G-T polymers of 15 LRV and 21 LRV. We believe that 7-HCS has an average LRV of 15, which means that we believe that 7-HCS is probably a 50/50 side-by-side bicomponent of the 2G-T polymers of 12 LRV and 13 LRV. In contrast, with a combination of the unbranched and branched 2G-T polymers we can spin filaments in accordance with the invention of equivalent LRVs, and actually the LRV of the polymer blend used in our Examples was measured in 22.7.

Of particular interest, as indicated, are round multi-hollow bicomponent filaments according to the invention and softened bicomponent filaments according to the invention, both of which are believed to be new. A preferred round multi-hole filament is now described and illustrated in the accompanying Drawings. Referring to the accompanying Drawings, Fig. 1 is a photograph showing several cross-sections of bicomponent filaments of 3 spun cavities of a capillary row as shown in Fig. 2. Three recesses (cavities) can be clearly seen in each one of the filaments shown in Fig. 1, but the dividing line between the two components is not thus visible, thus, an amplified photograph of another cross-section of the 3-cavity filament (proportions of the two components 82/18) is provided dyed for this purpose in Fig. 3. Referring to Fig. 3, the filament is generally indicated by ummer reference I 1, and contains three holes 12. The two polymeric components 13 and 14 are shown in Fig. 3 , with a clearly defined boundary line between these different components. This line was visible after the cross section of the filament was stained with osmium tetroxide, which stains the components differently, therefore the dividing line is better shown in Fig. 3 than in Fig. 1. In this For example, the three complete holes 11 are shown to be located in most of the polymeric components 13. It will be understood that this will not necessarily happen, especially when more than one second component is present than that shown in Fig. 3 for component 14. filaments have round peripheral (circular) cross section, which is carrier and is preferred for synthetic fiber materials.

Fig. 2 shows a capillary row for spinning filaments with three holes. It will be noted that the capillary is segmented, with three segments 21 arranged symmetrically about an axis or point. central C_. Each segment 21 consists of two grooves, ie a peripheral arched groove 22 (width E_) and a radial groove 23 (width G_)? the middle of the inner edge of the peripheral arched groove 22 which is joined to the outer end of the radial groove 23, thus each segment forms a "T-shaped" type with the upper part of the T that is convexly curved to form a arc of a circle. Each peripheral arcuate groove 22 extends almost 120 ° around the circumference of the circle. Each radial slot 23 reaches a point 24 at its inner end. Points 24 are spaced from the center point C_. The outer diameter H_ of the capillary is defined by the distance between the outer edges of the peripheral arcuate grooves 22. Each peripheral arcuate groove 22 is separated from its neighbor by a distance F_, which is referred to as a "tongue".

The short fronts of the neighboring peripheral arcuate grooves 22 on either side of each tongue are parallel to each other and parallel to the radius bisecting said tongue. In many respects, the capillary design shown in FIG. 2 is typical of art-delineated designs for providing hollow filaments by post-coalescing threading through the segmented orifices. A segmented design is shown for post-coalescing 4-cavity filament spinning, for example, by Champaneria et al. In U.S. Patent No. 3,745,061. The dots 24 on the inner ends of the radial slots 23 are provided in FIG. The capillary design of the row shown in FIG. 2, however, to improve the coalescence of the polymers in the center of the filaments, that is, to ensure that the three holes do not become connected.

TEST METHODS The parameters mentioned here are standard parameters and are mentioned in the technique referred to here, as are the methods for measuring them. Since the methods of measuring the volume of the pillows can vary, the method we use to test the pillows in our Examples is summarized briefly: The oysters made of a filling material that have the most effective volume or filling power will have the largest center height. The Initial Height the center of a sub-zero load pillow is determined by crushing the opposite corners of the pillow several times (re-fluffing) and placing the pillow on the sensitive load table of an Instron tester and measuring and recording its Height (Initial ) at zero load. The Instron tester is equipped with a metal disc press that is 4 inches (10.2 cm.) In diameter. The press-fabric is then operated to compress the pillow by continuously increasing and applying the load to 20 pounds (9.08 kg). The load required to compress the center section of the pillow to 50% of the Initial Height below zero load is measured and this height at half load is recorded as the "Consistency" of the pillow.

Before the current compression cycle in which Initial Height and Consistency are measured and recorded, the pillow undergoes a complete compression cycle of 20 pounds (9.08 kg) and frees up the load for accommodation. Pillows that have higher half-load height values are the most resistant to deformation and thus provide the largest support volume.

The durability of the volume and of the Consistency are determined by subjecting the filling material in the pillow to repeated cycles of compression and release of load, followed by a washing and drying cycle. Repeated cycles, or contractions, of the pillows are performed by placing a pillow on a turntable associated with 2 pairs of 4 x 12 inch (10.2 X 30.5 cm) air operated work presses that are mounted on top of the turntable at so that, during a revolution, in essential form all the contents are subjected to compression and liberation. Compression is performed by operating the work presses with 80 pounds per square inch (5.62 kg / cm2) of air pressure so that a static load of approximately 125 pounds (56.6 kg) is exerted when in contact with the Rotary table. The rotating table rotates at a speed of one revolution for 110 seconds and each of the work presses compresses and releases the filling material 17 times per minute. After it is repeatedly compressed and released for a specific period of time, the pillow is refoamed by crushing at the opposite corners several times. As before, the pillow is subjected to a conditioning cycle and the Initial Height and Consistency (height at half load) are determined. The pillow is then subjected to a normal washing and drying house cycle. After drying it is again re-sponged by crushing on the opposite corners several times and allowed to rest overnight. After this conditioning period, the pillow is remeasured for Initial Height and Consistency (average loading height) using the aforementioned Instron meter technique, and recording the measurements after a full cycle.

The properties of the fibers are measured mostly in essential form as described by Tolliver in US Patent No. 3,772, 137, the volume measurements of the fibers referred to herein as "Initial Volume" and "Support Volume" (to avoid the confusion with the heights edited for the pillows). However, friction is measured by the SPF method (Friction of the Thread Bearing), as described below, and for example, in the North American Application assigned No. 08 / 406,355. As used herein, a strand bearing of the fibers whose friction is measured, is sandwiched between a weight on the top of the thread bearing and a base that is below the thread bearing and is mounted on the lower transverse head of an Instron 1122 machine (product of Instron Engineering Corp., Canton, Mass). The thread bearing is prepared by cardaging the fibers of the strands (using a SACO-Lowell roller) to form a sheet of fibrous material that is cut into sections, which are 4.0 inches (10.16 cm) in length. and 2.5 inches (6.35 cm) of a cho, with the fibers oriented in the longitudinal dimension of the sheet of fibrous material. Sufficient sections are stacked in such a way that the thread bearing weighs 1.5 g. The weight is 1.88 inches (4.78 cm.) In length (L), 1.52 inches (3.86 cm) wide (W), and 1.46 inches (3.71 cm.) In height (H), and weighs 496 g. of the weight and of the base that makes contact with the thread bearing, they are covered with a cloth of Emery (the grain that is in the line of 220-240), in such a way that it is the Emery cloth that makes contact with the surfaces of the thread bearing The thread bearing is placed on the base The weight is placed on the middle of the bearing A nylon monofilament line joins one of the smaller vertical fronts (WxH) of the weigh and pass around a small pulley to the upper transverse head of the Instron machine, operating a 90 degree angle around the pulley.

A computer interconnected to the Instron machine emits a signal to co-test. The lower transverse head of the Instron machine moves downward at a speed of 12.5 inches / min (31.75 cm / min.). The thread bearing, the weight and the pulley also move downward with the base, which mounts on the lower transverse head. The tension increases in the monofilament of ylon as it stretches between the weight, which moves down, and the upper transverse head, which remains in a stationary form. The tension is applied to the weight in a horizontal direction, which is the direction of orientation of the fibers in the thread bearing. Initially, there is little or no movement in the thread bearing. The force applied to the upper transverse head of the Instron machine is monitored by a load cell and is increased to a minimum level, when the fibers in the bearing initiate the movement passing one to the other. (Because of the emery cloth in the interconnections with the thread bearing, there is little relative movement in these interconnections, essentially any movement results from the fibers of the bearing of the threads that move past each other). The minimum level of force indicates that it is required to overcome static friction from fiber to fiber and is recorded.

The coefficient of friction is determined by dividing the minimum force measured by the 496 gm weight. Eight values are used to compute the average SPF. These eight values are obtained by making four determinations of each of the two samples of the thread bearing. The invention is further illustrated in the following Examples; all parts and percentages are by weight, unless otherwise indicated. The capillary row used to spin the fiber of the 3-cavity polyester in the Examples is as illustrated in Fig. 2, with the following dimensions in inches: H (outer diameter) 0.060 inches (0.15 cm.); E (width of slot 22), F (tab) and G (width of slot 23) all of 0.004 inches (0.01 cm.); the points 24 were defined by the fronts at the inner end of each radial groove 23 on either side of the points 2_ _, each front which is aligned with a short front at the end of the corresponding peripheral arched groove 22, i.e. on one side of a tongue of width F_, so as to provide the corresponding distances also of the width F_ (0.004 inches) (0.01 cm.) between each pair of parallel fronts at the inner ends of each pair of radial grooves 23. capillary grooves were 0.010 inches (0.025 cm.) deep, and were fed from a reservoir as shown in Fig. 6A of U.S. Patent No. 5,356, 582 (Aneja et al.) and with a registered metering plate for spinning bicomponent filaments side by side, as described in the art.

E j ampio 1 The icomponent fibers according to the invention were produced from two different component polymers, both 0.66 IV. One component polymer (A) was 2G-T, homopoly (ethylene terephthalate), while the other component polymer (B) contained 0.14% mol, 3500 ppm, of trimellitate branching chain (analyzed as trimethyl trimellitate, but added as trihydroxyethyl trimellitate). Each was processed simultaneously through a separate screw crucible or melter at a combined polymer yield of 190 pounds per hour (86 g / hour). The use of a measuring plate with holes just above each of the 1176 capillary rows allowed these molten polymers to be combined side by side in a ratio of 80% (A) and 20% (B) and spun in filaments at 0.162 pounds / hour / capillary (0.074 kg / hour / capillary) and 500 ypm (457 m / min). The post-coalescent capillaries (Fig. 2) were designed to give fibers with three equidistant and equidistant gaps parallel to the fiber axis. The resulting hollow fibers (from denier spinning 25 and hollow content of 12.5%) were tempered in a cross flow manner with air at 55 ° F (18 ° C). The spun fibers were grouped together to form a string (loose bundle denier of 360,000). This fall was stretched in a hot humid spray stretch zone, maintained at 95 ° C using a 3.5X stretch ratio. The stretched filaments were coated with a softening agent containing a polyaminosiloxane and laid with a jet of air on a conveyor. It was now observed that the filaments in the rope on the conveyor have a helical ripple. The (curly) rope was loosened in an oven at 175 ° C, after which it was cooled, and an unsightly finish of about 0.5% by weight was applied, after which the cloth was cut in a conventional manner. to 3 inches (76 mm). The finished product has a denier per filament of 8.9. The fibers had a cross section similar to that shown in Figure 3 (said fiber which in current form contained slightly different proportions (82/18) of polymer A / B), which contain three continuous holes that were parallel and substantially equal in size and substantially equidistant from each other. The periphery of the fibers was round and smooth Several properties of the fibers were measured and compared in Table 1A with commercial bi-component fibers of the delta-RV type commercialized by Unitika (Japan) and Sam Yang (South Korea).

The almonds were prepared from bicomponent strands cut from the previous Example and also from the commercially available 6-H18Y (Unitika) and 7-HCS (Sam Yang), were opened by passing them through an impeller and then processed on a garnett opener. (such as a simple double cylinder cylinder model manufactured by James Hunter Machine Co. of North Adams, MA). Two tissues of open fibers were combined and rolled to form the wadding of the pillow. The weight of each pillow was adjusted to 18 ounces (509 gm) and each one was then carried within 20 inches (51 cm) X 26 inches (66 cm) of 100% cotton weave with the count of 200 , using a Bemíss pillow filler. The pillows (after a reshoot) were measured for the Initial Height and Consistency, which are shown in Table IB.

The 18-ounce (509 gm) pillows of the invention provided by this Example have a very good filling power, much more than the typical smoothed and mechanically curled fibers, to the extent that we believe that a pillow filled with 18 ounces of Our new hollow two-component spiral curly fiber can provide as much filling power as in a pillow filled with the prior art with 20 ounces of commercially curled fiber mechanically, which is a significant saving, there is also an economic advantage in avoiding need to use a filler box (for the mechanical rizamiento) that can also risk the damage of the fibers. These to the ohad have an Initial Height superior to the 7-HCS and around the equivalent to the H-18 Y. In contrast to the 18-ounce (509 gm) pillows with good filling power of the technique, these pillows of Example 1 were consistent. Its consistency was greater than for any competitive fiber.

An important advantage of the pillows of the invention (and our new filler fiber in that respect) on the pillows filled with spirally curled fibers commercially available before is also the versatility and flexibility provided by the use of our technology. , as will be shown in Example 2.

Table ÍA Physical Properties of Bicomponent Fibers Article Example 1 H18Y 7-HCS DPF 8.9 6.0 7.0 Curl / inch (/ cm) 6.1 (15.5) 5.0 (12.7) 5.4 (11.9 Hollow% 11.4 25.1 3.8 TBRM Initial Volume, In (cm) 5.56 (14.1) 5.81 (14.8) 5.76 (14.6) Support Volume, In (cm) 0.66 (1.68) 0.56 (1.42) 0.36 (0.91) Friction of the Thread Bearing 0.353 0.262 0.246% silicon 0.324 0.210 0.215 Table IB Properties of 18 oz laminated wadding pillows Article Example 1 H18Y 7-HCS Initial Height in. (cm) 8.98 (19.8) 9.13 (23.3) 7.69 (19.5) Consistency, Ibs (kg) 7.97 (3.62) 7.04 (3.20) 3.29 (1.50) EXAMPLE 2 A series of bicomponent fibers according to the invention with different ripple frequencies were prepared by varying the ratio of the two polymer components, A and B, of Example 1. The proportion of polymer A was varied from 70% to 84% when the proportion of polymer B was varied from 30% to 16% as shown in Table 3. Using the same spinning process as in Example 1, the different polymer combinations were spun into a series of bicomponent fibers having visually different ripple frequencies. Its physical properties are given in Table 2. Each of these fibers were converted into standard laminated batt pillows as in the first axis 1. The properties of the pillows are given in Table 2. In general, an increase in consistency of the pillow was noted when the content of polymer B in the fiber increased from 16% to 22%, which: corresponds to the increase in the ripple frequency obtained for the bicomponent fibers, a content of polymer B of 22% q. that gives a ripple frequency of about 7 cpi and a pillow consistency of about 10 pounds (4.54 kg.), which are even better than those pillows of Example 1 which, in turn, had better values than those of the products available in commercial form (as shown in Table 1), while a content of polymer B of 30% gives an even higher hollow content and good values of ripple frequency and consistency.

T A B L A 2 PROPERTIES OF FIBERS AND PILLOWS IN CURING SERIES Article A B C D% of polymer A 70 78 80 84% of polymer B 30 22 20 16 DPF 8.7 8.8 8.9 9.6 Ripple / in. (/ cm) 6.8 (17.3) 7.1 (18.0) 5.7 (14.5) 3.9 (9.90)% gap 14.6 11.4 11.5 9.4 TBRM Initial Volume, In. (cm) 4.52 (11.5) 5.24 (13.3) 5.54 (14.1) 5.64 (14.3) Support Volume, In. (cm) 00..9955 ((22..44)) 0.82 (2.1) 0.65 (1.7) 0.50 (1.3) SPF 0.558 0.405 0.355 0.294% silicon 0.313 0.317 0.324 0.303 Pillow Initial Height, in. (cm) 9.40 (23.9) 9.14 (23.2) 8.98 (22.8) 9.16 (23.3) - O Consistency, lbs (kg) 9.20 (4.18) 10.02 (4.55) 7.97 (3.62) 6.33 (2.87) The preferred proportions of the different polymers in the bicomponent fibers according to our The invention fluctuates upwards from about 8/92, for example, from about 10/90 to 30/70. In Example 2, one component branched at 3500 ppm (measured as described above) from a branching chain ? 5 which is preferred for reasons discussed in the published application of the European Patent), 294, 312, but other branching chains as described in this respect and by Shima can be used, if desired, and, with this preferred branching chain, such ratios correspond to the ripple frequencies of about 2-8. CPI, respectively. . Even the 50/50 bicomponent ratios would be useful if the modifications were made to several aspects, such as the amount of the branching chain, for example using about 700 ppm, considering that the proportions of 10/90 could give useful results, both as 17, 500 ppm (the branching chain which is measured as described above). The contents of preferred voids in the bicomponent hollow fibers according to our invention range from 5% to 40%, especially to 10-30%.

EXAMPLE 3 Because the softened open bicomponent fibers give weak cohesion to the fabric that some find it difficult to combine the fabrics into batts and to maneuver the glands in a filling operation from the coti to the oad, we combine a smaller proration of the fibers without softening with a majority of fibers softened in the cutting operation. A blend of 75 251 smoothed / unsharpened was prepared by cutting three 390,000 denier ropes from the softened fiber of article B in Example 2 combined with an equivalent rope of the same bicomponent fiber to which no softening silicon was applied. The resulting strand mixture (cut off from 3 inches, 7.6 cm) had a remarkable increase in fiber to fiber friction as measured by an SPF increase of 0.391 to 0.412. This blend was easily processed on a garnett opener with much improved operability against the all softened product of article B of Example 2 in an 18-ounce (510.29 g) weight batting and on a pillow for comparison with the product's pillow completely soft in Example 2, of article B. A comparison of the properties of the pillow in Table 3 before and after 1 shake / wash / dry cycle shows that addition of the undamped fiber did not affect. adversely the convenient properties of the pillow.

Table 3 Properties of Mixed Bicomponent Pillows 75/25 mixture smoothed without softening completely smoothed height consistency height consistency in. (cm) lbs (kg) in. (cm) lbs (kg) Before the cycle 9.16 (23 3) 9.68 (440) 9 14 (23.2) 10.02 (4.55) After 1 cycle 9.06 (23.0) 6.70 (3.05) 901 (22.9) 7.00 (3.18) The proportions of synthetic fibers of bicomponent polyester smoothed to non-smoothed may vary if desired for the purposes of aesthetics and / or as the need or desirable for processing, for example as much as 5 or 10% of a type of polyester. fiber, or more, and the 25/75 mixture used in Example 3 is not intended to be a limitation and may not even be the optimum one for some purposes.

EXAMPLE 4 The bicomponent fibers in accordance with the invention were produced from two different component polymers, (B) and (C), and were used to show that the useful b-component fibers can be prepared and used as synthetic fibers in accordance with the invention. -when both component polymers contain the branching agent, the amounts of the branching agent qu3 are different. A polymer (C) (0.66 IV) with 175 ppm of the trimellitate branching chain was prepared by mixing the two polymers of Example 1 in a ratio of 95% of the component polymer (A), hourglass (ethylene terephthalate), 5% of the component polymer (B) (which contained 3500 ppm of the branching chain of trimellitate). The polymer (C) and the polymer (B) of Example 1 were then processed simultaneously into bicomponent filaments side by side having three recesses, essentially following the procedure described in Example 1, except as indicated, through of crucibles o - i 1.0 inch (2.54 cm) separate screw smelters in a polymer performance com. binder of 22.3 pounds / hour (10.1 kg / hour), and a measuring plate above a post-coalescent hair row 144 to combine polymer (C) and polymer (B) in a ratio of 78/22, respectively, for spinning (three bicomponents side by side hollows) filaments at 0.155 pounds / hour / capillary (0.070 kg / hour / capillary), at a spinning speed of 500 yds / min (457 m / min). The resulting filaments had a single filament denier of 23 (25.2 dtex) and 20.8% hollow. These filaments were then combined to form a string (loosened bundle denier of 51,800) which was stretched in a wet hot spray stretch zone at 95 ° C using a 3.5X stretch ratio. The stretched filaments were coated with a polyaminosilicon softener (the same as used in Example 1), laid on a conveyor, and loosened in an oven, heated to 170 ° C, after an antistatic finish was applied. The resulting fibers have a denier per filament of 8.4 (9.2 atex), Curly Frequency of 2.8 curled / inch (7.1 curled / cm), Curly Wears 30%, Initial Volume TBRM of 5.99 inches (15.2 cm) and the TBRM Support Volume of 0.32 inches (0.81 cm), and the friction fiber to fiber SPF of 0.265. A sample of this fiber was cut - * 1.5 inches (38 mm), processed on a Rando opener of 36 inches (91 cm) (Rando / CMC, Gastonia, NC), and 18 ounces (509 gm) of the open strand The resultant was blown into a 20 x 26 inch (51 x 66 cm) coti of 80/20 polyester / cotton. The initial height of the pillow was 7.7 inches (19.25 cm) and the consistency was 3.9 kg.

EXAMPLE 5 To show the achievable improvement by mixing some bicomponent fibers within the mechanically curled synthetic fibers, even at low blending levels, two-inch (51 mm) strand fibers of the softened bicomponent fibers of 9 dpf (10 dtex) of Example 1 were mixed in quantities of both 15% and 30%, with 85% and 70%, respectively, of the DACRON T-233A from DuPont, which is a mixture of 2G-T, softened fibers of 1.6"dpf 55%, the non-softened 2G-T fibers of 1.65 dpf of 27%, and the core wrapper fiber of 4 dpf of 18%, the core which is 2G-T, and the one of olcool that is of the copolyester The mixture of the bicomponents and the T-233A fibers was processed on an aarnett opener in a 3.3 2 2 ounce / yard (113 g / m) wadding, which was bent transversely and atomized with the 18% of an acrylic resin (Rohm &Haas 3267) The resin was cured and the wadding stuck roasting it through a heated oven at 150 ° C. The resulting batts were measured for the thickness under a load of 0.C02 psi using a "MEASURE-MATIC" thickness measuring device (Certain Forced Corp., Valley Forge, PA) and for the CLO insulation value using a Rapid tester. K (Dynatech R / D Co. Cambridge, MA). The measured thickness and the CLO values are shown in the following table after being normalized to the weight equivalent of the batting, in order to compare the CLO values. Those wadding containing the bicomponent fiber were more v.uminous (somewhat thicker), and in signified form had higher CLO insulation values than the wadding containing only T-233A.

Weight of Wadding Wadding thickness CLO g / m2 cm / g / m2 CLO / g / m2 T-233A 115 0.0113 0.0151 Mix of 85/15 115 0.0119 0.0176 Mix of 70/30 113 0.0135 0.0189 EXAMPLE 6 The component polymers (A) and (B) of Example 1 were combined in a ratio of 82/18 (A / B) to spin bicomponent filaments side by side having three gaps, and from 14.8 dpf (16.3 dtex) to a yield total of 140 pounds / hour (63.6 kg / hour), using a row with 1176 capillaries and a spinning speed of 600 yards / minute (548 m / min), and otherwise in essential form as described in Example 1 These filaments had a gap of 11.4%, and were combined to form a loosened denier cord of 400,000, and were stretched 3.5X, shot in an air jet, coated with 0.7% of a softener of aminosilicon, loosened to 165 ° C and coated with an antistatic finish. The rope was cut into 0.75 inch (19 mm) strands, and the strand was processed to make fiberballs as described by Kirkbride in US Patent No. 5,429,783, at 800 pounds / hour (364 kg / hour). As when characterized as described by Marcus in U.S. Patent No. 4, 618, 531, the fiberballs were round in essential shape, and their volume values at the loads of 0, 5, 88.5, and 121.5 Newtons were of 33.7, 28.8, 9.6, and 7.1 cm, respectively. These fiber balls were then blown into the cotis to produce the pillows and cushions.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is the conventional one for the maufacturing of the objects that it refers to.

Having described the invention as above, property is claimed as contained in the following

Claims (4)

1. CLAIMS 1. Stuffed articles filled with filling material, characterized in that the filling material comprises at least 10% by weight of the synthetic, polyester, bicomponent, helical-configuration fibers that have resulted from a difference between the contents of the Branched chain of polyester components of bicomponent polyester synthetic fibers.
2. 2. An article according to claim 1, characterized in that it is a pillow.
3. 3. An article according to claim 1, characterized in that it is a clothing item, a bedding material, a furniture article or a toy.
4. 4. An article according to any of claims 1 to 3, characterized in that the synthetic beasts of the polyester helically shaped components are entangled at random in balls of or r a. 2 . n article according to any of claims 1 to 3, characterized in that the filling material is in the form of batting. A a r t i in accordance with 1 a 10 claim 5, characterized in that the batting is agglomerated. 7. The synthetic fibers of the bicomponent polyester, characterized by having one i ", or more continuous gaps through the length of its fiber and which are helical in shape, resulting from a difference between the contents of the branched chain of the polyester components of the fibers 20 synthetic bicomponent polyester. 8. The fibers according to claim 7, characterized in that they are smoothed. 25 9. The synthetic fibers of the bicomponent polyester, characterized in that they are softened and that they are helical in shape, have resulted from a difference between the contents of the branched chain of the polyester components of the synthetic fibers of the bicomponent polyester. 10. The fiber balls that have a random distribution and a tangle of fibers within each of the balls, and that have an average diameter of 2-20 mm, the individual fibers that have a length of 10-100 mm, characterized because at least 10% of the fibers are synthetic bicomponent polyester fibers of helical configuration which have resulted in a difference between the branched chain contents of the polyester components of the synthetic fibers of the bicomponent polyester.