CN1048765C - Polyester mixed yarns with fine filaments - Google Patents

Abstract

Polyester mixed fine filament yarns with excellent mechanical quality and uniformity, and preferably with a good balance of dyeability and shrinkage, produced by a simplified direct spin orientation method with choice of polymer and processing conditions.

Description

Method for preparing non-stretched mixed filament polyester spinning oriented yarn and yarn prepared therefrom

The present invention relates to polyester (continuous) blended filament yarns (including thin filaments) of different filament deniers and/or cross-sections and improvements thereto, but preferably relates to polyesters which can provide a variety of different properties from the same raw material. Ester mixed filament yarns of this type; the invention also includes improved manufacturing methods and new products obtained therefrom.

Historically, synthetic fibers for clothing, including polyester fibers, have been supplied to the textile industry for the manufacture of fabrics and garments with the aim of more or less replicating and/or improving on natural fibers. For many years, commercial synthetic textile filaments (such as those made and used for clothing) have a denier per filament (dpf) range similar to that of common natural fibers (ie, cotton and wool). Recently, however, polyester filaments commercially available have dpf ranges similar to those of silk (ie, on the order of 1 dpf), and even subdeniers (ie, less than about 1 dpf), despite their higher cost. Recently, commercial interest in low dpf, eg, about 1 dpf or even lower denier fibers has arisen for various reasons. WO 92/13119, which we hereby refer to as the "parent application", which is hereby incorporated by reference, deals with the novel direct melt spinning/winding process for the manufacture of thin filaments as compared to the existing process of first spraying into thicker filaments , the latter are then further processed in a combined or separate process (including drawing) to obtain the desired filaments of low denier but with properties suitable for textiles. The filaments of the "parent application" were "spin-oriented"; that is, were "undrawn" filaments. Its importance is discussed technically and will be discussed later.

We have found that consumer response to fine filament textile (flat or textured) yarns (all yarns having the same cross-section and the same denier, and especially the denier of the filaments less than about 1 denier) has been tend to limit their application to selected textiles where the "body" and "drape" of the fabric have become unimportant, or by twisting and/or changing the The structure of the fabric to provide the "body" and "drape" of the fabric is too expensive for a particular end use, and/or such alterations have a detrimental effect on other properties (such as appearance and feel) such that such fabrics are not suitable as desired. It is desirable to produce finely woven fabrics having the desired "body" and "drape" directly from filament yarns without having to twist the filament yarns and/or alter the fabric structure. It would also be desirable to provide a spin-oriented non-drawn fine filament yarn which, depending on its combination of properties, can be used as a direct-use yarn or as a drawn feed yarn (e.g. to create drawn flat yarn or textured " Bulk" yarns) that provide the "body" or "drape" of the fabric without, for example, expensive yarn twisting, without altering the fabric structure and sacrificing its appearance and fabric feel.

It is important to maintain uniformity throughout and between the various spin orientation filaments and the drawn filaments therefrom. Lack of uniformity often manifests itself as dyeing imperfections in the final dyed fabric and is therefore undesirable.

For weaving purposes, "spinning yarns" must have certain properties, such as sufficiently high modulus and yield point, and sufficiently low shrinkage, which make common spinning yarns different from common "feed yarns", which Further processing is required to produce the minimum required properties for fabric manufacture and subsequent use. Generally, we refer to non-textured filament yarns as "flat yarns" here, and undrawn flat filament yarns as "feed" or "stretch-feed" yarns, where no further stretching and/or Filament yarns that are heat-treated so that they can be used as textile yarns are called "direct-use yarns".

It is important to realize that the combination of all the properties of a particular yarn (or garment) is important for any particular end use, and that this yarn is sometimes the yarn itself in processing, but sometimes also the final product that has this yarn as a component. fabric or clothing. It is easy to process to reduce shrinkage, but this modification is usually accompanied by other changes, so it is this combination or balance of properties of any garment (or staple fiber) that is important. It is also understood that, according to the present invention, such filaments may be supplied and/or processed in the form of yarns or filament bundles, and such filament bundles need not have true "yarn" cohesion. For convenience, however, many filaments may be referred to as "yarns" or "bundles" without intending to be particularly limiting by this term. It will be appreciated that, where appropriate, this process can also be used for other forms of polyester filaments, such as tow, which can then be converted into staple fibers and used according to their balance of properties . As discussed below, this balance is both desirable and achievable.

The polyester polymer used to make the spin-oriented undrawn mixed filament yarn of the present invention may be the same as that of the "parent application".

The spin-orientation process for making polyester undrawn fine blended filament feed yarn is substantially the same as the "spin-orientation" process of the "parent application" (which is described in the "Background of the parent application" and also in Figures 4A, B and C are discussed), the feed yarn is composed of two or more types of filaments of different cross-sections and/or deniers, wherein at least one of the filament components has a denier is less than about 1; preferably wherein the average yarn filament denier is less than about 1 when stretched to 30% elongation; and particularly wherein the fine mixed filament yarns have an average yarn filament denier of less than about 1 . However, the selection of the spinneret capillary size (L and D) and the shape of the discharge die hole in the two methods are different, so that two or more different filament components can be sprayed together; and if necessary, the spinneret hardware structure The pattern has been modified to quench and cohere the different filament components before interlacing and winding into packages.

From previous efforts to co-spray polyester filament blends of higher dpf, and co-spray polyester filament blends at low speeds of the prior art to produce low-oriented undrawn filaments, we are interested in such a The fact that a mixture of deniers and cross-sections can be co-extruded from one spinnerette and still have uniformity is surprising. There is something unique about this method of master application processing that can create amazing results.

As will be appreciated, a particularly useful mixed filament draw feed yarn has two types of filaments, one having a dpf of less than about 1 and referred to as "(dpf) ₁ ", and the other serving as draw feed Not only is the dpf greater than 1 when the yarn is fed, but even after stretching to a desired degree, eg, to a desired residual draw ratio (RDR), the resulting dpf is greater than 1.

It is generally desired that the RDR values for both types of drawn filaments be in the range of about 1.2X to 1.4X. It is also desirable that the draw feed yarn can be drawn without filament or "neck draw" defects. Of course it is also desirable that the difference in RDR for the two types of filaments be less than about 40%, so that the difference in RDR for the drawn filament type is about 20% or less. Providing higher dpf filaments with profiled (non-circular) cross-sections can be a very effective technique for achieving the desired object.

Mixed filament yarns (which are "flat") of different dpf (one greater than 1, one less than 1) of different cross-sections are desirable in terms of feel and aesthetics. Likewise, mixed filament yarns such as direct use yarns in which all of the filaments are low shrinkage are also useful. In this regard, non-circular cross-sections for higher dpf filaments are expected to provide a useful means to achieve desired objectives.

The yarns made by the method of the invention can be used as: 1) drawing feed yarns (for example in separate or combined processes, in warp drawing, in drawing air texturing, in drawing dummy plus Twisting method, stretching in stretching gear crimping and stretching stuffing box crimping); 2) Can be used as a direct "fabric" mixed filament yarn without further stretching and/or heating non-drawn fine mixed filament yarns; 3) non-drawn direct-use "fabric" yarns that can be used as feed yarns without drawing (such as in air-jet texturing, stuffer box crimping, and gear crimping); 4) Non-drawn direct use "fabric" fine mixed filament yarns that can be partially or fully drawn into uniform fine mixed filament yarns with or without heat and with or without post heat treatment.

The foregoing spin-orientation process provides a spin-orientated polyester non-drawn mixed filament yarn wherein the polyester polymer is characterized by a relative viscosity (LRV) in the range of about 13 to about 23, zero shear Melting point ( _TM °) in the range of about 240°C to about 265°C, glass transition temperature (Tg) in the range of about 40°C to about 80°C; wherein hybrid filaments are composed of two or more filament components Yarns, these filaments differ in cross-section and/or denier, wherein at least one filament component has a filament denier of less than about 1 (preferably average yarn filament denier (dpf)s such as average Drawn yarns have a filament denier (dpf) _D of less than about 1, where (dpf) _D is defined as (dpf)sX[(1.3)/(1+Eb/100)s]; Denier (dpf)s less than about 1), wherein for mixed filament yarn, the ratio of high denier filaments (2) to low denier filaments (1) is from about 2 to about 6; and characterized in that: The maximum dry heat shrinkage tension STmax is _less than about 0.2 g/d when the dry heat peak shrinkage tension temperature T( _STmax ) is about 5°C to about 30°C above the glass transition temperature Tg of the polymer; (1-S/ Sm) value of at least about 1 (preferably at least about 0.25) to provide aging stability shrinkage; elongation at break (E _B ) of about 40% to about 160% (preferably about 90% for stretch feed yarn to about 120%, especially about 40% to about 90%, and the (1-S/Sm) value is at least 0.85 so as to be used as a non-stretched direct-use yarn); the tenacity range at 7% elongation is about 0.5 to about 1.75g/d (the range of about 0.5 to about 1g/d is preferred for stretched feed yarns (especially the strength T ₇ at 7% elongation is less than the strength T ₂₀ at 20% elongation to improve Tensile stability), and especially in the range of about 1 to 1.75 g/d for direct use yarn); and breaking strength (T _B ) _n , normalized to 20.8 polymer RLV, is at least about 5 g /dl is preferably at least about 6 g/d): while the preferred shrinkage difference (DHS-S) is less than +2%.

The non-drawn mixed filament yarns of the present invention provide drawn flat yarns or air-jet texturized mixed filament yarns having a filament shrinkage difference of at least 5%, which is obtained by combining the non-drawn mixed filament yarns at the glass transition of the polymer temperature (Tg) to the main crystallization onset temperature (Tc °), characterized by a residual elongation at break (E _B ) of about 15% to about 45%, 7% elongation The tenacity is at least about 1 g/d; and the shrinkage difference between the non-drawn direct blended filament yarn and the air-jet textured yarn is at least 5%, the cold drawn dissimilar mixed filament yarns described above and herein are further characterized by a residual elongation at break (E _B ) of about 15% to 55% and a tenacity at 7% elongation of at least about 1 g/d .

The present invention provides uniform drawn polyester flat yarns and textured fine mixed filament yarns, made from the non-drawn fine mixed filament feed yarns of the invention described above, having an elongation at break (E _B ) of about 15 to 45%, a (1-S/Sm) value of at least about 0.85, a strength (T ₇ ) of at least 1 g/d at 7% elongation, and a preferred post-flex modulus (Mpy) of about 5 to 25 g/d; Yet preferred drawn oblate mixed filament yarns are further characterized by an over-filament uniformity of less than about 3% (especially less than about 2%) as measured by along-filament denier dispersion (DS).

Other general aspects and specific implementations of the invention will be seen below.

Figure 1A is a representative magnified photograph of a cross-section of a filament whose postcoagulation is incomplete (herein referred to as "open") and which is considered novel, useful and inventive; Figure 1B is a representative enlarged photograph of the cross-section of a round filament (required here) with dense longitudinal voids (holes) according to the present invention; and Fig. 1c is also a representative representation of a textured hollow filament yarn according to the present invention , showing that the voids collapse almost completely when stretched and false twisted.

Figure 1B shows the relationship of (dpf) ₂ /(dpf) ₁ to (L ₁ D ₂ /L ₂ D ₁ ) ⁿ (D ₂ /D ₁ ) ³ for co-spun round filaments 1 and 2, and (L ₁ D ₂ /L ₂ D ₁ ) ⁿ (D ₂ /D ₁ ) ³ is the length (L) and diameter (D) of the nozzle plate capillary (1) and (2) [(L/D) ⁿ D ₃ ] ₁ Simplified representation of /[(L/D) ⁿ /D ₃ ] ₂ , for a Newtonian liquid, "n" has a value of 1; for the range of polymer RLV and processing conditions used here, "n" The economic value of is about 1.1, in other words, n=1 is a useful practical approximation).

Figure 2A is a representative graph of desizing shrinkage (S) versus elongation at break (E _B ), where lines 1, 2, 3, 4, 5 and 6 represent (1-S/Sm) values of 0.85, 0.7, respectively. 0.5, 0.25, 0.1 and 0; while Curve 7 represents the typical relationship between shrinkage and elongation at break for a series of yarns produced, for example increasing the spinneret speed while keeping other processes variable. Other processes that vary intersectingly (such as dpf or polymer viscosity) generate a "family" of similar curves that are virtually parallel to each other. Based on aging stability, the vertical dotted lines represent the approximate range of EB values for the preferred filaments of this invention, i.e. 40% to 90% represent direct use yarns, while 90% to 120% represent drawn feed yarns, and 160% is approximately upper limit. Preferred filaments of the invention suitable for use as draw feed yarns are represented by the "wide spaced" \\\\\\\ region, which has an _EB value of about 90% to 120%, and (1-S/Sm) With a ratio of at least about 0.25 (below line 4), the preferred filaments of this invention suitable for use as textile yarns are represented by the "narrow pitch" \\\\\\\ region with an E _B value of 40% to 90%, and The ratio (1-S/Sm) is at least about 0.85 (below line 1).

Figure 2B is a representative plot of desizing shrinkage (S) versus volume percent crystallinity (X _v ) for a spin-oriented "solid state" filament (not in accordance with the present invention), wherein the filament has an elongation at break, E _B A wide range of about 160%-40%, using a wide range of processing conditions (such as filament denier and cross-section, spinneret speed, polymer LRV, quenching, capillary size (LXD) and polymer temperature) for spraying Silk, while _Xv is measured with floating density and corrected to % pigment. The single relationship between S and density (i.e., a measure of the degree of stress-induced crystallization SIC of amorphous regions during melt spinning) obtained from such yarns with different Eb values supports the view that in determining the degree of S In this range of E _B values, the degree of SIC is the first structural event, while the stress-induced orientation (SIO) of the amorphous region during melt spinning is the second structural event. For stretched feed yarns , when corresponding to the range of X _v value from about 10% to 20%, then the range of S value is from about 50% to about 10% (ab), which is the preferred level of SIC, and for direct use of textile yarn Say, corresponding to X _v greater than about 20%, the range of shrinkage values is less than about 10%, ie line (bc) This is the preferred level for SIC.

Figure 3A is a representative graph of Tcc versus birefringence in the amorphous region. Tcc is the peak temperature of "cold crystallization", measured by differential scanning calorimetry (DSC) at a heating rate of 20°C per minute, and the birefringence is a measure of amorphous orientation (as expressed by Frankfort and Knox), and for filaments whose birefringence is difficult to measure, the Tcc value is a useful measure of amorphous orientation. The Tcc value of the filaments of the present invention is between 90°C and 110°C.

Figure 3B is a representative plot of post-yield secant modulus (Tanβ) (ie, "Mpy") versus birefringence. Mpy here is calculated by (1.20T ₂₀ −1.07T ₇ )/0.13, where T ₂₀ is the strength at 20% elongation, and T ₇ is the strength at 7% elongation. As can be seen, above 2 g/d, the post-yield modulus (Mpy) provides a useful measure of the birefringence of spin oriented, drawn and textured filaments. Preferred drawn filaments of the present invention have an Mpy value of from about 5 to 25 g/d.

。喷丝线温度也对喷丝线距离作图，而且发现它随着距离均匀降低。作为比较，在颈缩处喷丝线速度迅速增大。在拉细时选择加工条件使得在约0.45～0.105g/d范围的表观内喷丝线应力有发展，以制得喷丝-取向长丝，特别是合适作拉伸喂入纱(DFY)，其特征在于7％伸长时的强度(T₇)值为0.5～1g/d的范围；以及使得表观内喷丝线应力为约1.05～0.195g/d范围，以制造喷丝定向长丝，特别是适用于直接用纱(DUY)，其特征在于7％伸长时的强度(T₇)为约1～1.75g/d的范围；其中表观内喷丝线应力在这里用经验分析表达式表示：Figure 4A is a graphical representation of spinneret line speed (V) versus distance (X) from the face of the spinneret, where the spinneret speed is increased from the speed at extrusion (Vo) to the final (coil) after it has been fully attenuated. Take) velocity (typically measured downstream at the converging point, Vc); where the apparent internal spinneret stress is proportional to the spinneret velocity at the necking point (i.e. approximately proportional to the ratio LRV(Tm°/Tp) ⁶ , where the temperature is Celsius) and the product of the velocity gradient (dv/dx) at the necking point, here it is found that dv/dx is approximately proportional to V ² /dpf, especially at a spinning speed of about 2 to 4 km/ Minutes, and at a higher spinning speed, that is, about 4 to 6 km/min, it is proportional to about

. The spinneret temperature was also plotted against spinneret distance, and it was found to decrease uniformly with distance. In comparison, the spinneret line speed increases rapidly at the constriction. The selection of processing conditions during attenuation allows the development of apparent internal spinneret line stress in the range of about 0.45 to 0.105 g/d to produce spinner-oriented filaments, especially suitable for drawing feed yarn (DFY), It is characterized in that the strength (T ₇ ) value at 7% elongation is in the range of 0.5 to 1 g/d; and the apparent inner spinneret stress is in the range of about 1.05 to 0.195 g/d to produce spinneret oriented filaments, Especially suitable for direct-use yarn (DUY), characterized by a tenacity (T ₇ ) at 7% elongation in the range of about 1 to 1.75 g/d; wherein the apparent inner spinneret stress is here expressed by empirical analysis express:

k(LRV/LRV _20.8 )(T _R /T _P ) ⁶ (V ² /dpf)(A _o / ^# C) ^0.7

In the formula, for a filament with a density of about 1.345 to 1.385 g/cm ³ , that is, 1.36 g/cm ³ , the k value is an approximate value of (0.01/SOC), and SOC is the "stress optics" of the polyester polymer. coefficient" (for example, it is about 0.7 (g/d) ^-1 for 2GT homopolymer); TR is the polymer reference temperature defined as (T _M ° + 40 ° C), where T _M ° is zero shear ( DSC) polymer melting point; Tp is polymer melt spinning temperature, ℃: V is the take-up speed expressed as km/min; ^# C is the number of filaments (i.e. capillary) of given extrusion area; A ₀ is expressed as #C/cm ² ; LRV is the measured polymer (lab) viscosity; and LRV _20.8 is the corresponding reference LRV value for a polyester polymer having the same zero-shear "Newtonian" melt viscosity at 295°C (see here for the definition of LRV ), as the 2GT homopolymer has an LRV value of 20.8 (e.g., the melt viscosity of a 15LRV cationic dyeable polyester has been found to be within the range of about 20LRV 2GT homopolymer as indicated by the reduction in capillary pressure , thus a preferred reference LRV for such modified polymers is about 15.5 and is experimentally determined using standard capillary pressure drop assays.)

Figure 4B is a graphical representation of the birefringence of the spinneret oriented filaments versus the apparent inner spinneret line stress, the slope of which is referred to as the "stress optics coefficient (SOC)", with SOC values of 0.75, 0.71 and 0.71 for lines 1, 2 and 3, respectively. 0.645(g/d) ^-1 , and is a typical relationship for 2GT polymers found in ref. The average value of SOC is therefore about 0.7.

Figure 4C is a graphical representation of Tenacity at 7% elongation versus apparent inner spinline stress for spin oriented filaments. The nearly linear relationship between birefringence and _T7 (each of which is in turn relative to the apparent internal spinneret stress) makes _T7 a useful measure of the average molecular orientation of the filaments. Birefringence is a difficult structural parameter to measure for deniers less than 1, especially for shaped cross-sections (including hollow fibers).

Figure 5 is a representative plot of elongation at break (E _B ) versus spin speed for spin oriented non-stretched nylon (I) and polyester (II). Between about 3.5 km/min and 6.5 km/min (expressed in the ABCD region), especially between about 4 and 6 km/min, the elongation of non-stretched polyester and nylon filaments is of the same order. The elongation of non-stretched nylon can be increased by increasing the polymer RV (see U.S. Patents 4,583,357 and 4,646,514 to Chamberlin), as can the use of chain branching agents (see U.S. Patent 4,721,650 to Nunning), or by using selected copolyamides and relatively High RVs are also possible (see EP _A1 0411774 by Knox). The elongation of non-stretched polyesters can be improved by using low intrinsic viscosity and using copolyesters (see U.S. Patent 4,156,071 to Knox, U.S. Patents 4,134,882 and 4,195,051 to Frankfort and Knox), or by adding small amounts of chain branching agents (see US Patent 4,092,229 to MacLean, US Patent 4,156,051 to Knox, and US Patents 4,883,032, 4,996,740, 5,034,174 to Reese). The elongation of polyester filaments is particularly sensitive to the denier and shape of the filaments, and increasing the area-to-volume ratio of the filaments (i.e., is related to either or both the denier and non-circular shape of the filaments) ), the elongation can be reduced.

Figure 6 shows the relationship between the relaxation/heat-setting temperature TR (Celsius °C) and the residual draw ratio (RDR) _D of nylon 66 stretched yarn, plotting [1000/TR+273)] against (RDR) _D , As described by Boles et al. in US Patent 5,219,503. Selection of processing conditions in regions I (ABCD) and II (ADEF) can produce non-drawn filaments suitable for stringent dyeing as end use. Acceptable uniformity of dyeing along the monofilament is obtained if the degree of stretching and heat setting is balanced by the relationship 1000/(TR+273)>/=[4.95-1.75(RDR) _D ]. This relaxation temperature vs. (RDR) _D correlation can also be used for co-drawing and thermal relaxation of mixed filament yarns, or thermal relaxation of mixed filament yarns that have been drawn and blended, e.g. co-drawn mixed filament Thermal relaxation of yarns such as nylon/polyester filament yarns.

According to the method of "parent application", the non-stretched fine mixed filament yarn of the present invention can be produced, the difference is to make changes so that two or more different types of filaments can be co-spun, quenched , and converged into fine mixed filament bundles. For example, combining filament bundles of different filament deniers and/or cross-section extrudates from the same or different spinneret assemblies prior to interlacing and winding, but preferably prior to bundling and collation, can produce mixed denier Count filament yarn. If desired, yarns may be advantageously prepared according to the present invention from non-drawn feed yarns which have been treated with caustic in a spin finish (as described in U.S. Patent No. 5,069,844 by Grindstaff and Reese), To improve their hydrophilicity and provide good moisture absorption and comfort.

The degree of (amorphous) orientation (SIO) induced by the stress imparted to these non-drawn filaments during melt attenuation reduces the peak temperature of cold crystallization (Tcc), here, for amorphous non-oriented filaments , Tcc values are typically around 135°C, and reducing the stress-induced orientation (SIO) of the non-crystalline (amorphous) polymer chains can lower the Tcc to less than 100°C. This is illustrated in Figure 3A as the peak temperature Tcc of cold crystallization plotted against the amorphous birefringence (as defined by Frankfort and Knox). Amorphous birefringence is known to increase with increasing spinneret speed, therefore, amorphous birefringence increases with decreasing elongation at break (E _B ) of undrawn filaments. For preferred non-drawn spin-oriented filaments having an elongation (E _B ) in the range of 40 to about 120%, with a measured Tcc value in the range of about 90°C to 110°C, this is believed to be such that even at The reason for further crystallization also starting under mild drawing conditions is also considered in part to be important in producing uniformly drawn polyester fine mixed filament yarns even when cold drawn.

The degree of stress-induced crystallization (SIC), a consequence of the degree of SIO in the amorphous region, is usually defined in terms of the density of the polymer material. It is difficult to measure experimentally for thin filament yarns because of the air traps between the filaments and on the large surface of the filaments; therefore a relative measure of stress-induced crystallization is used here, the The method is based on the degree of desizing shrinkage (S) for a given yarn elongation at break (E _B ), and for a given fiber polymer crystallinity, it is expected that desizing shrinkage (S) increases with molecular expansion (i.e., as the elongation at break E _B decreases); therefore, stress-induced crystallization (SIC) is defined by the following formula: (1-S/Sm), where Sm is given when there is no crystallization Maximum shrinkage expected for a filament of given molecular expansion (E _B ); here Sm is defined as: Sm (%)=([(E _B ) _max - _EB ]/[( _EB ) _max +100]) 100%, where (E _B ) _max is the maximum elongation at break (E _B ) expected for a fully amorphous "isotropic" filament. For polyester filament extrudates derived from polymers having a typical textile intrinsic viscosity of about 0.56 to about 0.68 (corresponding to an LRV of about 16 to about 23), _{the maximum} normal value of (E _B ) was experimentally It is found to be about 550%, assuming that the maximum residual stretch ratio is 6.5 ("High Speed Fiber Spinning", edited by A.Ziabicki and H.Kawaj, Wiley Interscience Press (1985), p.409), so, here, Sm(%) can be defined by the following simple formula: Sm,%=[(550-E _B )/650]×100% (shown graphically in FIG. 2A ). The filaments of the present invention are described as having a (1-S/Sm) value greater than about 0.1 (preferably greater than about 0.25 to provide sufficient SIC for aging stability) and an elongation (E _B ) of about 40 to 160%.

The spin-oriented mixed filament yarns of the present invention are characterized by a peak shrinkage tension temperature T( _STmax ) occurring at 5°C to 30°C higher than the polymer Tg (e.g., for a homopolymer with a polymer Tg of about 65°C 2GT, this temperature is 70-100 ℃) when the maximum shrinkage tension (ST _max ) is less than about 0.2 g/d; while the preferred non-drawn fine mixed filament feed yarn is further characterized by elongation at break (E _B ) in In the range of about 90% to about 120%, the strength (T ₇ ) at 7% elongation is in the range of about 0.5 to about 1 g/d; and the (1-S/ _Smax ) value is at least about 0.25; suitably used Particularly preferred non-drawn filament yarns for direct use yarns are further characterized by an elongation at break (E _B ) in the range of about 40% to about 90% and a tenacity at 7% elongation (T ₇ ) of about The range of 1 to 1.75 g/d, and the (1-S/Sm) value is at least about 0.85.

The denier of each filament of mixed filament yarn obtained from the same spinneret is measured by the capillary mass flow rate W=(Vs*dpf)/9000 when passing through the spinneret capillary. The W value is inversely proportional to the capillary pressure drop (here it is approximately proportional to (L/D) ⁿ /D ³ ), where, for Newtonian liquids, the n value is 1, L is the capillary length, D is the capillary diameter, for For the usual short-length non-circular cross-section capillary, the (L/D) ⁿ //D ³ value is taken from the metering capillary, which feeds the polymer into a shape determined by the exit orifice; thus, (dpf) ₁ ×[(L/D) ⁿ /D ³ ] ₁ ＝(dpf) ₂ ×[(L/D) ⁿ D ³ ] ₂ , so the ratio (dpf) ₂ /(dpf) ₁ ]=(L/D) ⁿ /D ³ ] ₂ For example, for n values of about 1 and for the range of processing conditions employed here, using spinnerets with 15 x 72 mil and 8 x 32 mil metering capillaries for co-spraying, Filaments of mixed dpf will be produced with a ratio (dpf) ₂ /(dpf) ₁ of about 476.7 mm ³ /86.5 mm ² (=5.5). If spinning filaments with different cross-sections but the same dpf, the metering capillary may need to be of slightly different diameter (i.e. a different value of [(L/D) ⁿ /D ³ ]) to overcome any small but significant gap in the shaped exit orifice. different pressure drops. However, if, for example, different filament components are sprayed from separate spinneret packs and are combined into a simple blended bundle of filaments, the dpf of the filaments obtained from a given spinneret pack will depend on the pack The pressure and the size of the spinneret are simply given by the following formula: dpf=9000w/(Vs#F), where W is the total spinneret assembly mass flow rate (g/min), and #F is each The number (#) of filaments (F) of the spinneret pack and Vs is the take-up speed expressed in meters per minute.

Specifically, the present invention includes, but is not limited to, the following preparation methods (and products made therefrom):

(1) The spin-orientation method of the present invention produces a class of spin-oriented polyester non-drawn mixed filament yarns wherein the polyester polymer is characterized by a relative viscosity (LRV) of about 13 to about 23, zero shear The melting point (T _M °) is about 240°C to about 265°C, and the glass transition temperature (Tg) is about 40°C to about 80°C; and two or more filaments of different cross-sections and/or deniers Mixed filament yarns of components having at least one filament component having a filament denier of less than 1 (preferably having an average yarn spun filament denier (dpf) _s such that the average drawn yarn filament denier The number (dpf) _D is less than about 1, and (dpf) _D is defined as {(dpf) _s × [(1.3)/(1+Eb/100) _s ); in particular, here, the average filament denier of the undrawn yarn The number (dpf) _s is less than 1, whereby the ratio of high denier filaments (2) to low denier filaments (1) is from about 2 to about 6 for mixed denier yarns; and it is further characterized by: At a dry heat shrinkage peak temperature T ( _STmax ) that is about 5°C to 30°C higher than the glass transition temperature (Tg) of the polymer, its maximum dry heat shrinkage tension STmax _is less than about 0.2g/d; its (1-S / _STmax ) value of at least about 0.1 (preferably at least about 0.25) to produce aging stability shrinkage; its elongation at break (E _B ) is about 40% to 160% (preferably about 90% for stretched feed yarn ~120%, in which there is no practical loss of void volume when stretching), especially the (1-S/Sm) value is at least 0.85, and E _B is about 40% ~ 90% for stretching feed yarn or used as non-drawn direct-use yarn); the tenacity (T ₇ ) at 7% elongation is about 0.5-1.75 g/d (preferably about 0.5-1 g/d for drawn-feed yarn, and about 0.5-1 g/d for As a direct-use yarn, especially about 1 to 1.75); and the breaking strength (T _B ) _n normalized to 20.8LRV is at least 5g/d (preferably at least 6g/d); the difference (DHS-S) is preferably for less than +2%.

The spin orientation method is characterized by:

(i) The polyester polymer is selected to have a relative viscosity of about 13-23, a zero-shear melting point ( _TM °) of about 240°C to 265°C, and a glass transition temperature (Tg) of 40°C to 80°C : The mixture is melted and heated to about 25°C to 55°C above the apparent polymer melting point ( _TM )a, filtered rapidly enough to minimize degradation; it is then extruded through the capillaries of a spinneret, the latter being chosen The cross section (Ac) is about 125×10 ^-6 cm ² to about 1250×10 ^-6 cm ² , and the length (L) and diameter (D _RND ) are chosen such that the ratio (L/D _RND ) is at least 1.25 and Less than 6 (preferably less than 4), and the shape of the exit hole and/or the L and D values of the capillary are selected to produce filaments of different cross-sections and/or different deniers (as previously described)

时，使其避免直接冷却；然后将其冷至低于聚合物转变温度(Tg)，并拉细这较细的长丝至表观喷丝线应变为约5.7～7.6，其中(dpf)₁是混合长丝纱中的较细长丝的。(ii) When the exit distance (L _QD ) of the extruded melt through the spinneret capillary is at least about 2 cm and less than about

, avoid direct cooling; then cool it below the polymer transition temperature (Tg), and attenuate the finer filaments to an apparent spinneret strain of about 5.7 to 7.6, where (dpf) ₁ is Of the thinner filaments in mixed filament yarns.

的距离内，将混合长纱集束成为混合长丝捆；进行交织以获得长丝捆的集积性，然后以约2～6公里/分钟的卷绕速度把混合长丝纱进行缠绕。(iii) then use a low friction surface at a distance (Lc) of about 50 cm to about [90

Within a distance, the mixed filament yarn is bundled into a mixed filament bundle; interweaving is performed to obtain the accumulation of the filament bundle, and then the mixed filament yarn is wound at a winding speed of about 2 to 6 km/min.

(2) As described in Knox and Noe in U.S. Pat. jet thinning) to prepare:

(i) drawn flat yarns or drawn air-textured mixed filament yarns having a differential filament shrinkage of at least 5% obtained from undrawn mixed filament yarns at the glass transition temperature (Tg) of the polyester polymer and the main crystallization initiation temperature (Tc°) are stretched and are also characterized by a residual elongation at break (E _B ) of about 15% to 45%, and a strength at 7% elongation (T ₇ ) at least about 1 g/d; and in particular drawn mixed filament flat yarns and air-jet textured yarns, the differential shrinkage when cold drawn as described above but not post heat set directly with mixed filament yarns for non-drawing is at least Here, the cold drawn dissimilar mixed filament yarn is also characterized by a residual elongation at break (E _B ) of about 15% to 55% and a tenacity at 7% elongation of at least about 1 g/d.

(ii) drawn polyester flat yarns and textured fine mixed filament yarns, as previously described, made from the non-drawn fine mixed filament feed yarns of the present invention, characterized by an elongation at break of about 15 to 45%, a (1-S/Sm) value of at least 0.85, a strength at 7% elongation of at least about 1 g/d, and a preferred post-yield modulus (Mpy) of about 5 to 25 g/d; preferred Yes, the drawn oblate mixed filament yarns herein are also characterized by an along-filament uniformity of less than about 3% (especially less than about 2%) as measured by along-filament denier dispersion (DS).

(iii) preferred polyester blended filament yarns having an average yarn filament denier of less than about 1, a residual elongation at break (E _B ) of about 15% to 55%, and a (1-S/Sm) value of at least 0.85 , the strength (T ₇ ) at 7% elongation is at least 1 g/d, and the preferred post-yield modulus (Mpy) is about 5 to 25 g/d, and is made in a separate or composite method of monofilament or Non-drawn mixed filament yarn obtained by cold-drawing or hot-drawing in the shape of warp sheets without weft, with or without post-heat treatment, as non-drawn direct-use yarn, having a residual elongation of about 40 ~90%, (1-S/Sm) value of at least about 0.85; by selecting the spin orientation mixed filament feed yarn of the present invention, its tenacity at 7% elongation (T ₇ ) is about 1 to 1.75 g /d, wherein all filaments are characterized by the non-stretched direct-use mixed filament yarn of the present invention as previously described; preferably, the stretched flat thin mixed filament yarn is further characterized by less than about 3% (especially less than about 2%) along-filament uniformity as measured by number dispersion (DS)

(iv) Uniformly drawn air-jet textured fine mixed filament yarn and uniformly drawn textured fine mixed filament yarn; wherein the method comprises subjecting a non-drawn mixed filament feed yarn obtained by the aforementioned spin orientation method to uniformly drawn stretch air texturing or stretch false twist texturing to produce uniformly stretched bulked mixed filament yarns, the latter being characterized by a residual elongation at break (E _B ) of about 15% to 45%, (1-S/Sm ) value of at least 0.85, the strength at 7% elongation (T ₇ ) of at least about 1 g/d, and the preferred post-yield modulus (Mpy) of about 5 to 25 g/d.

(v) stretched bulked mixed filament yarn, which shrinks the different filaments by at least 5% when the flat mixed filament yarn or drawn air-jet texturized mixed filament yarn of the present invention is stretched by heat relaxation, which is determined by the foregoing The non-stretched hybrid filaments of the present invention are produced directly from yarns that are cold-drawn without post-heat treatment, thereby producing uniformly stretched bulked hybrid filament yarns characterized by their residual elongation at break (E _B ) is about 15-55%, (1-S/Sm) value is at least about 0.85, the strength at 7% elongation (T ₇ ) is at least about 1g/d, and the preferred post-yield modulus (Mpy) It is about 5~25g/d.

(vi) Stretched bulked mixed filament yarn, which shrinks the different filaments by at least 5% when the flat mixed filament yarn or drawn air-jet texturized mixed filament yarn of the present invention is stretched by heat relaxation, is obtained by the present invention Non-drawn blended filament yarns are produced by stretching without post-heat treatment, as previously described, at a draw ratio ranging from Tg to Tc° to produce uniform stretched bulked blended filament yarns. Silk yarns, the latter characterized by a residual elongation at break (E _B ) of about 15% to 45%, a (1-S/Sm) value of at least 0.85, and a tenacity at 7% elongation (T ₇ ) of at least 1 g /d, and then the yield modulus (Mpy) is about 5-25g/d.

(vii) Drawn yarns with a shrinkage tension ( _STmax ) greater than about 0.25 g/d for compact construction fabrics. In order to enable the yarn to overcome the yarn-yarn tube bundles in the fabric during dyeing and finishing, the method is to treat the non-drawn mixed filament yarn at a temperature above the glass transition temperature (Tg) and at a low main crystallization onset temperature (Tc°). Stretching is performed with post heat treatment adjusted to produce the desired balance between shrinkage S and shrinkage tension ST.

The fine denier flat filament of the present invention is also characterized in that the denier variation along the yarn (herein called denier dispersion, DS) is less than about 4% (preferably less than 3%, particularly preferably less than 2%); Silk yarn is suitable for fabrics that require strict dyeing (configuration) uniformity; the shape factor (SF) of non-round filaments (added to improve touch, appearance and comfort) is at least 1.25, here, for a considerable cross-section For round filaments, the shape factor is defined as the ratio of the measured filament roundness (P _M ) to the calculated roundness (P _RND ). The filaments of the invention are also characterized by good mechanical properties, having a breaking strength of at least 5 g/d normalized to a polymer LRV of 20.8.

Detection method

Many of the polyester parameters and assay methods mentioned herein are fully discussed and described in USP 4,156,071 to Knox, USP 5,066,447 to Knox and Noe, and 4,434,882 to Frankfort and Knox, all of which are incorporated herein by reference , so further detailed discussion here will be superfluous. Here, for clarity, the desizing shrinkage is written as "S" (sometimes as _S1 , or as S1 in the tables); in all examples, the differential shrinkage (DHS-S) of the cospun yarn is always less than + 2; T _B (sometimes Tb in the table) is based on the strength of the denier at break (that is, based on the tensile denier, written as Mpy), and Tb is defined as the usual textile strength and residual elongation RDR (=1+E _B /100), and the normalized (T _B ) _n is defined as [(T _B )(20.8/LRV) ^0.75 (1-% delustering agent/100) ^-4 ], the hybrid filament yarn of the present invention is characterized by a _TB value of at least about 5 g/d, preferably at least about 6 g/d, normalized to a polymer LRV of 20.8.

The polymer glass transition temperature Tg, the main crystallization onset temperature (Tc°), and the temperature _Tcmax of the crystallization maximum rate can be determined by usual DSG analysis; however, for a given group of compounds such as polyesters, These values can also be estimated from the zero-shear melting point T _M ° of the polymer (expressed in degrees Kelvin), using the method of RF Boyer [see "Ordering in the Amorphous Form of Polymers", edited by SE Reinath, RLMiller, JK Riecke, Plenum Press Company (New York), 1987]; where Tg = 0.65T _M °: Tc° = 0.75T _M °; and _Tcmax = 0.85T _M °; all temperatures in the formula are expressed in degrees Kelvin.

The preparations and products of the invention are illustrated, but not limited, by the following examples and are summarized in detail in the tables.

Example A

In Example A, lower denier filaments and higher denier filaments are co-spun to produce mixed filament yarns (such as the low shrinkage (crystalline) spin-oriented filaments of U.S. Patent 4,156,071 to Knox, and / or U.S. Patent 3,772,872 of Piazza and Reese for high-shrinkage (amorphous) spin-oriented POY filaments, so that mixed shrinkage (such as post-bulking in fabrics) may occur, such as when low-shrinkage filaments are combined with high-shrinkage long when mixing).

Such high and low dpf filaments can be ejected from separate spin pack cavities and then combined to form simple mixed dpf filament bundles, but are preferably ejected from a single-spin pack cavity where The dimensions of the capillaries (L and D) and the number of capillaries are chosen to produce different mass flow velocities; for example, the capillaries are chosen such that the ratio of spinneret filament denier [(dpf) ₂ /(dpf) ₁ ] is approximately equal to [(L ₁ D ₂ /L ₂ D ₁ ] ⁿ ×[(D ₂ /D ₁ ) ³ ], where 1 and 2 represent filaments of different deniers; for Newtonian polymer melt n=I (and here, for the used polymer and processing conditions, the average value of "n" was found experimentally to be 1.1); while the measured average yarn filament denier is defined as (dpf) average = [( ^# 1dpf ₁ + ^# 2dpf ₂ )/( ^# 1 + ^# 2) ].

Examples 1-6 The yarns were prepared by spinning a 2GT homopolymer of nominal 21.2 LRV at a polymer temperature (Tp) of about 290°C; and quenching with room temperature air at a speed of 40-50 mpm; then use a metered oil pan guide to make the yarn appear at a distance of 109 cm from the spinneret surface, and then proceed at the speed indicated in Table I, II, and III Coiled to produce 200 filament yarns ranging in nominal denier from about 127 to about 239 as indicated. "Spray DPF Average" is the nominal denier divided by 200 and "DPF Ratio" is the ratio of the measured high dpf to the measured low dpf (which is fairly close to the nominal dpf ratio of 3.54 as described below). The 200 filaments are spun yarns containing 24 high dpf filaments (2) and 176 low dpf filaments (1). For Examples 1-3, the normal (dpf) ₂ /(dpf) ₁ ratio is about 3.54 respectively, which is the result of using different size spinneret capillaries; mm) and a diameter (D) of 39 mils (0.975 mm), and 176 capillaries of a length (L) of 36 mils (0.914 mm) and a diameter (D) of 9 mils (0.229 mm), such that This results in a pressure drop ratio of 3.54; i.e., (dpf) ₂ /(dpf) ₁ = [(L ₁ D ₂ /L ₂ D ₁ ] ⁿ X [D ₂ /D ₁ ) ³ ], where "n" , which is 1 for Newtonian liquids and 1.1 for polymer LRV and processing conditions used in experiments. Measured average yarn denier = ^# 1(dpf) ₁ + ^# 2(dpf) ₂ = ^# 1(dpf) ₁ + ^# 2{[(dpf) ₂ /(dpf) ₁ ](dpf) ₂ )= ^# 1(dpf) ₁ +3.54[ ^# 2(dpf) ₁ ]＝[ ^# 1+3.54( ^# 2)](dpf) ₁ ＝[24+3.54(176)(dpf) ₁ , where (dpf) ₁ ＝ Measured average yarn denier/[24+3.54(176)], and (dpf) ₂ =3.54(dpf) ₁ .

In Example 1, the high dpf filaments (2) are ejected from the outer ring located in the multi-ring capillary arrangement (since earlier prophesied that more quenched high dpf filaments are more beneficial than low dpf filaments ). In Figure 2, the capillary (2) that makes the high dpf filaments is located in the middle of the arrangement, where the filaments (2) ejected here will naturally tend to "move" and converge when quenched. In Example 3, the capillaries for preparing high dpf filaments (2) are symmetrically arranged by capillaries arranged in multiple rings. The data for Examples 1-3 are in Tables I-III and include a column "Average DPF Tensile", which is derived from the "Stretched Denier" divided by 200 to calculate.

In practice we have surprisingly found that the symmetrical arrangement in Example 3 yields the best quantity uniformity, whereas the outer layer arrangement in Example 1 is the worst. The breaking strengths (T _B ) of the symmetrical arrangement (3) and the outer ring arrangement (1) are practically equal, while the inner ring arrangement (2) is clearly the worst.

In Examples 4-6, the extruded yarns of Examples 1-3 were carefully stretched to a residual elongation of 25% to 45% at 400 mpm using a stretching and setting temperature of 180°C. And its nominal average yarn filament (dpf) _D is less than 1dpf. The same relative levels of uniformity and breaking tenacity were observed for drawn yarns such as the spin feed yarns in Examples 1-3, the optimum filament arrangement will depend on the number of filaments, the dpf ratio, and The desired balance of denier uniformity (DS) along the filament and tensile strength (as measured here in _TB ).

In the next series, instead of blending filaments, separate bales of high and low dpf yarns are fabricated and stretched to obtain data on the properties and behavior of the filaments, and it will be understood that such filaments can be blended together.

Example 7

Individual bundles of 50 high dpf and 200 low dpf filaments were ejected from separate spinneret packs, using 15 x 60 and 9 x 36 mil capillaries, respectively; and wound separately (data summarized in Table VII). The resulting low dpf filaments have higher tensile properties (modulus T ₇ , T _B ) and lower elongation at break (E _B ) than high dpf filaments. Based on experience with stretching and stretch texturing, we choose a dpf ratio of 4 to 1 in order to produce higher dpf filaments with a stretched dpf of about 2 for fine fabrics to avoid different sizes from different bends Different reflections on the surface of the filaments create a "glitter". A dpf ratio of 4 to 1 produces a difference in _EB values of about 20% to 40%, but smaller differences in _EB values will generally be preferred to produce optimal drawn yarn mechanical properties and uniformity.

Example 8

Stretching was performed at a stretching temperature of about 180°C and a set temperature of about 180°C at 400 m/min to obtain a stretch ratio series of 1.4X, 1.5X and 1.6X. The difference in tensile elongation is typically about 10-20%, with higher dpf filaments having higher elongation. Drawn yarns are summarized in Table VIII.

Example 9

The 172 denier 200 filaments and the 172 denier 50 filament bundles of Example 7 are drawn at 400 mpm and 1.64 draw ratio, using a fixed plate whose starting temperature is room temperature (25° C., items 1 and 2), and stretched. The stretching temperature rises from room temperature (cold stretching) to 180°C (i.e. the maximum crystallization rate temperature Tc of 2GT polyester, _maximum ). As indicated in Table IX, the shrinkage decreases with increasing, especially above about 120°C That is, the main crystallization start temperature Tc°, so the differential shrinkage drops to about 2% at 130°C. This demonstrates that stretched mixed denier filament yarns can be produced at higher stretching temperatures from the same mixed denier feedstock as flat yarns (i.e. non-bulked because mixed dpf filaments have similar shrinkage) . We often produce hybrid shrinkage stretch yarns that self-expand when stretched at lower stretch temperatures.

Example 10

For items 1-11 in Example 10, the temperature of the heat-set plate is room temperature (25° C.), with a stretch rate of 400 mpm and 1.64X, for 24 filaments with an average dpf of 2.45 and 176 filaments with an average dpf of Ordinary 200-200 spun yarns composed of 0.78 filaments are stretched, and the stretching temperature is raised from 25°C to 180°C. The shrinkage _S1 decreased from 47.2% to 5.8% as the stretching temperature increased, and the decrease in shrinkage _S1 decreased after the stretching temperature was 114°C, which supports the results of Example 9. In items 12-13, a 127 denier feed yarn consisting of 24 filaments of 1.65 dpf and 176 filaments of 0.5 dpf was drawn at 1.4X draw ratio. Item 12 was cold drawn with no post heat treatment (ie the fixed plate was maintained at room temperature of 25°C). In entry 13, a 127 denier yarn was drawn at 180°C and set at 180°C, resulting in a shrinkage S ₁ of 5.9 compared to 28.4 in entry 12 . This illustrates the degree of shrinkage that can be controlled by choice of stretch setting temperature. The data for Example 10 are summarized in Table X.

Example 11

The 127-200 and 159-200 (denier filament) yarns of Example 3 (24 high denier and 174 low denier) were drawn with 1.4X and 1.6X stretching rates at 200 m/min. The temperature of deformation, stretching and setting is changed from room temperature (i.e. the heater is turned on) to 180°C, and stretched air-jet textured yarns whose shrinkage is less than 2% and as high as about 40% can be prepared, which provides a Possibility of mixing shrinkage yarns from raw materials. Data are summarized in Table XI.

Example 12

Using 1/7/1BB disc mixing chamber (PU disc type), the usual 200 denier-200 filaments (items 5-8 in Table III) will be used as spun yarn, with 1.506 elongation and 1.707D /Y rate, stretch false twist texturing at 180°C on a Barmag FK6-900K at 450 m/min. The tensile yarn denier was 136.7 (0.68 dpf) at 40.6% elongation, its tenacity was 3.66 g/d, and its modulus was 20.7 g/d. With a desizing shrinkage of 5.6% and a Leesona skein shrinkage (a measure of textured yarn bulk) of 23.7%, this hybrid dpf filament yarn yields higher bulk than 100% microdenier filament yarn and depends on the final Elongation at break can make good melange yarn.

Example 13

The stretched feed yarn of Example 12 is stretched at 4000 m/min at a stretching temperature of 115°C (about the cold crystallization temperature Tcc), using a pre-stretching temperature of 75°C and a stretching ratio of 1.64X. Produces 10% desizing shrinkage. This drawn yarn has a denier of 124.8 (average filament (dpf) _D of 0.62) at 37.5% elongation, a tenacity of 3.98 g/d, a modulus of 66.8 g/d, and a _T7 of 2.47 g/d. d. The fine denier yarn has a denier spread of 2.2% and a slow Uster of 0.6%, which makes these yarns suitable for strictly dyed end uses.

Example 14

50 filaments of 1.83 denier with a shrinkage S ₁ of 21% and thus a (1-S ₁ /Sm) ratio of 0.67, and 200 filaments of 0.46 with a shrinkage S ₁ of 5.2% and a (1-S ₁ /Sm) ratio of 0.92 Denier filaments (see items 17 and 18 of Table VIII) were co-jetted at 2473 mpm to produce post-texturable hybrid shrinkage yarns. 50 x 2.28 denier filaments and 200 0.57 denier filaments (items 13 and 14 in Table VII) were co-jetted at 2473 mpm to produce similar post-texturable yarns with shrinkage of 7.8% and 39.4%. Shrinkage of low dpf filaments increases at low spin speeds, which reduces the difference in shrinkage between low and high dpf filaments and creates excessive spin loss. Preferably, the low shrinkage filaments have a shrinkage of less than about 10%, that is, a (1-S ₁ /Sm) value of at least about 0.85, which produces mixed shrinkage and Fabric loss is reduced, at most equal to the shrinkage of the high shrinkage component if the shrinkage component has sufficient shrink tension to overcome the tube bundles in the fabric. To reduce fabric loss in the fabric body during post-bulking, bulking can occur by overfeeding at a temperature sufficient to expand shrinkage and bulking during warp drawing; but it is preferable to leave some residual shrinkage This allows bulking to be amplified during fabric formation, which helps to randomize differences in seam tightness and improves conformation uniformity. A residual shrinkage of about 3-4% is sufficient for knitted and light weight fabrics.

Example 15

A 20D (mixed) filament yarn was jetted from a nominal 21.2 LRY 2GT homopolymer at a polymer temperature (Tg) of about 290°C, using a radial shock equipped with a 1.7 inch (4.32 cm) delay tube. The cooler and room temperature air at a speed of about 30-50mpm are quenched, and then the filaments are converged at a distance of about 109cm from the surface of the spinneret with a metered oil pan guide, and then stretched to produce a nominal denier of 124 Denier changed to 220 denier 200 filament yarn, wherein the 200 filament yarn is composed of 24 high dpf non-circular cross-section filaments and 176 low dpf circular cross-section filaments. The spinneret capillary used to generate 176 low dpf long wires had a capillary length (L) of 36 mils (0.914 mm) and a diameter (D) of 9 mils (0.229 mm). The spinneret capillaries used to produce 24 high dpf filaments were selected to form the desired fiber cross-section; yarns were produced in which the high dpf component was the following cross-sections: 1) triangular ribbons, 2) octagonal ribbons, 3) polygonal tape, 4) hollow yarn. To obtain a dpf ratio of 3.5:1, a metering plate with 24 capillaries of 56 mil (1.42 mm) in length (L) and 90 mil (2.29 mm) in diameter (D) was used to control polymer formation non-circular capillary. For low dpf components, use a low pressure drop metering plate with a capillary length (L) of 90 mils (2.29 mm) and a diameter (D) of 40 mils (1.02 mm), such that the low dpf polymer flow rate is virtually Spinneret capillary controlled.

This process is used to produce yarns composed of mixed denier filaments and mixed cross-sectional shape filaments, which reduces the difference between the elongation of low denier and high denier filaments, thereby improving co-drawing Stretch (that is, components that can be co-stretched to an elongation of about 20% to 40% can be produced to improve mechanical properties and denier uniformity), and produce low-shrinkage high-denier filaments, so it is made suitable for making Mixed filament yarns for direct use with flat yarns.

It will become apparent that the invention allows itself many variations and further improvements, especially as these or other processes advance, for example, any type of stretch winder may be used; feeding yarn and/or stretching If the yarn needs post-heat treatment, any heating device can be used (such as thermal guide wire, hot air and/or steam injection, through heat pipe, microwave heating, etc.); Object manipulator and finishing can be done in several steps, e.g. finishing before stretching during spinning or finishing after stretching but before winding; interweaving can be enhanced using hot or non-thermal entanglement air jets , and the reinforcement of the interweaving can be carried out in several steps such as during spinning and drawing, and other devices such as entanglement reeds on the weft sheets of yarn can be used. In addition, if desired, from the capillary holes of the fan-shaped spinneret, hollow filaments can be added through post-coalescence as one (or more) filament components of the mixed filament yarn of the present invention to generate to improve fabric drapability, and co-pending Application No. as filed by Aneja et al. _____ (DD-4555H), also at least produces a different cross-section, the disclosure of which application is also incorporated herein by reference.

                                                  Item No.

Denier Speed Average Value Ratio (%) (g/d) (%) (g/d) (%) DPF Average

(mpm)1      239    2195     1.20     3.44   0.93    3.21  1.67   2.36    145.5  5.79   62.23    0.682      239    2195     1.20     3.62   0.92    3.33  3.84   2.37    156.9  6.09   60.48    0.603      239    2195     1.20     3.55   0.92    3.28  1.45   2.35    146.5  5.79   62.07    0.634      212    2469     1.06     3.70   0.81    2.99  2.07   2.38    129.7  5.47 64.66    0.605      199    2195     1.00     3.43   0.78    2.67  1.83   2.53    139.1  6.05   63.21    0.546      199    2195     1.00     3.77   0.75    2.84  1.45   2.60    150.3  6.51   61.49    0.527      199    2195     1.00     3.27   0.79    2.58  1.88   2.11    132.7  4.91   64.20    0.568      199    2195     1.00     3.43   0.78    2.67  1.59   2.51    139.9  6.02   63.10    0.549 191    2743     0.96     3.41   0.75    2.55  2.12   2.75    125.2  6.19   65.35    0.5510      180    2195     0.90     3.51   0.70    2.45  1.82   2.58    134.6  6.05   63.90    0.5011      177    2469     0.89     3.40   0.69    2.36  2.11   2.62    123.7  5.86   65.58    0.5112      159    2743     0.80                          1.91   2.45    113.0  5.22   67.23    0.4913      159    2195     0.80     3.30   0.63 2.08  1.43   2.76    134.1  6.46   63.99    0.4414      159    2195     0.80     3.36   0.63    2.10  1.91   2.58    126.7  5.85   65.12    0.4615      159    2195     0.80     3.46   0.62    2.15  1.86   2.58    122.1  5.73   65.83    0.4716      142    2469     0.71     3.27   0.56    1.84  1.42   2.70    124.9  6.09   65.40    0.4117      127    2743     0.64     3.55   0.49    1.74  2.23 2.71 101.4 5.46 69.02 0.41

                                                               

Denier Speed Average Ratio (%) (g/d) (g/d) (g/d) (%) DPF Average

(mpm)1      239    2195   1.20       3.82  0.87    3.34   2.19  2.15    157.6   5.54   60.37    0.602      239    2195   1.20       3.23  0.93    2.99   3.08  2.09    153.2   5.29   61.05    0.613      239    2195   1.20       3.49  0.90    3.15   1.97  2.09    151.2   5.25   61.35    0.624      212    2469   1.06       3.83  0.77    2.97   2.20  2.14    137.7   5.09 63.43    0.585      199    2195   1.00       3.62  0.74    2.69   1.81  2.01    136.8   4.76   63.57    0.556      199    2195   1.00       3.63  0.74    2.69   2.54  1.91    141.7   4.62   62.82    0.547      199    2195   1.00       3.15  0.78    2.45   1.84  2.24    133.8   5.24   64.02    0.558      199    2195   1.00       3.27  0.77    2.51   2.22  1.97    126.2   4.46   65.21    0.579 191    2743   0.96       3.52  0.72    2.53   3.07  2.41    122.6   5.36   65.76    0.5610      180    2195   0.90       3.50  0.68    2.38   2.14  2.08    125.7   4.69   65.28    0.5211      177    2469   0.89       3.11  0.69    2.16   2.19  2.18    124.6   4.90   65.45    0.5112      159    2743   0.80       3.85  0.58    2.23   1.60  2.72    117.4   5.91   66.56    0.4813      159    2195 0.80       3.29  0.61    2.01   2.07  2.47    135.4   5.81   63.79    0.4414      159    2195   0.80       3.72  0.59    2.19   2.33  2.22    125.5   5.01   65.31    0.4615      159    2195   0.80       3.75  0.59    2.19   1.45  2.30    121.2   5.09   65.97    0.4716      142    2469   0.71       3.63  0.53    1.92   2.15  2.19    105.8   4.51   68.34    0.4517      127    2743   0.64       0.64 0.47 1.72 1.85 2.09 89.9 3.97 70.78 0.43

Table III Item No. Extrusion Spinning Extrusion DPF DPF Low DPF High DPF DS Ten. Eb Tb T ₇ T ₂₀ S ₁ Sm 1-S ₁ /Sm Stretched

Denier Speed Average Ratio (%) (g/d) (g/d) (g/d) (g/d) (g/d) (%) (%) (%) DPF average

(mpm)

239    2195   1.20      3.91  0.89    3.46    1.62   2.48  154.4   6.31  0.61   0.57     58.2   60.87    0.04      0.612      239    2195   1.20      3.35  0.93    3.12    2.10   2.41  156.9   6.19  0.62   0.56     56.8   60.48    0.06      0.603      239    2195   1.20      3.85  0.89    3.43    1.58   2.35  148.6   5.84  0.61   0.56     57.4   61.75    0.07      0.624      212    2469 1.06      3.47  0.82    2.84    1.57   2.54  134.6   5.96  0.64   0.60     55.6   63.91    0.13      0.595      199    2195   1.00      3.55  0.76    2.70    1.56   2.56  144.9   6.27  0.63   0.61     52.1   62.33    0.16      0.536      199    2195   1.00      3.74  0.75    2.80    1.59   2.61  149.5   6.51  0.59   0.53     55.3   61.62    0.10      0.527      199    2195   1.00      3.31 0.78    2.58    1.58   2.55  140.3   6.13  0.62   0.61     54.5   63.03    0.14      0.548      199    2195   1.00      3.49  0.77    2.67    1.75   2.47  138.6   5.89  0.62   0.61     51.6   63.30    0.18      0.549      191    2743   0.96      3.40  0.74    2.52    1.72   2.71  123.9   6.07  0.68   0.69     45.3   65.55    0.31      0.5510      180    2195   0.90      3.67  0.68    2.50 1.88   2.46  128.8   5.63  0.59   0.61     52.8   64.80    0.21      0.5111      177    2469   0.89      3.22  0.70    2.25    1.40   2.61  123.7   5.84  0.66   0.65     46.6   65.58    0.29      0.5112      159    2743   0.80      3.83  0.59    2.27    2.09   2.44  115.0   5.25  0.79   0.86     53.1   66.93    0.21      0.4813      159    2195   0.80      3.19  0.63    2.01    1.52   2.72 133.4   6.35  0.63   0.64     50.7   64.09    0.21      0.4414      159    2195   0.80      3.72  0.60    2.23    1.65   2.62  137.0   6.21  0.63   0.63     53.4   63.54    0.16      0.4415      159    2195   0.80      3.45  0.61    2.12    1.60   2.60  127.2   5.91  0.66   0.65     50.5   65.04    0.22      0.4516      142    2469   0.71      3.40  0.55    1.87    1.64   2.42  111.1   5.11 0.73 0.77 34.0 67.52 0.50 0.4417 127 2743 0.64 3.32 0.50 1.28 2.68 101.4 5.85 0.87 11.7 69.01 0.83 0.41

Table IV Item No. Feed Stretched Tensile Modulus T ₇ Ten. Eb Tb WTB S ₁ DS

Denier Denier Rate (g/d) (g/d) (g/d) (%) (g/d) (g/d) (%) (%)1 199 126.6 1.60 79.1 2.45 4.17 34.70 3.70 5 5.30    2.222       199    125.4   1.62  80.2    2.59  4.11   31.21  5.39  120.6    4.95    2.233       199    124.0   1.64  79.7    2.71  4.23   31.50  5.56  125.0    5.10    1.924       199    126.9   1.60  69.5    2.39  4.11   34.68  5.54  132.25       199    127.1   1.60  70.6    2.53  4.14   33.68  5.53  131.96       177    120.6   1.50  78.0    2.52  4.15   37.52  5.71 141.07       159    115.8   1.40  77.1    2.27  4.07   45.74  5.93  158.78       239    151.9   1.60  72.5    2.13  3.83   36.10  5.21  152.6    5.60    2.679       239    150.5   1.62  74.3    2.22  3.86   34.50  5.19  146.9    5.30    2.3510       239    148.8   1.64  72.4    2.28  3.79   30.60  4.95  127.0    5.30    2.5011       239    152.4   1.60  60.4    1.93  3.54   36.18 4.82  140.612       239    152.8   1.60  63.4    2.09  3.72   34.49  5.00  141.513       212    144.9   1.50  72.6    2.11  3.95   43.50  5.67  180.914       191    139.8   1.40  70.2    2.07  3.73   42.48  5.31  161.815       159    101.5   1.60  73.6    3.00  4.56   35.04  6.16  124.416       159    101.7   1.60  72.7    2.86  4.45   34.61  5.99  118.817       159    101.7   1.60 76.8    3.03  4.42   31.41  5.81  108.818       142    96.3    1.50  88.0    2.94  4.27   34.42  5.74  109.819       127    93.0    1.40  88.5    2.79  3.71   31.11  4.86  87.120       180    114.1   1.60  82.8    2.76  4.28   33.40  5.71  124.0    5.90    1.3321       180    113.0   1.62  83.6    2.86  4.34   32.03  5.73  119.4    6.10    1.6222       180    111.6   1.64  85.0 3.01 4.40 31.10 5.77 117.5 5.75 1.74

Table V Item No. Feed Stretched Tensile Modulus T ₇ Ten. Eb Tb WTB

Dan Dian Dan Number (G/D) (G/D) (G/D) ( %) (G/D) (G/D) 1 199 127.0 1.6 56.3 2.25 3.42 31.78 4.51 104.32 199 126.8 1.6 60.1 2.21 3.42 34.61  4.60   114.33       199    126.8    1.6    57.3    2.30     3.45   32.24  4.56   107.44       177    120.3    1.5    62.3    2.27     3.48   36.37  4.75   116.95       159    115.9    1.4    72.3    2.40     3.85   40.01  5.39   135.86       239    152.4    1.6    54.5    2.01     3.11   33.11  4.14   118.97       239    152.2    1.6    54.1    1.91     2.95   31.71  3.89   107.68       239    152.4 1.6    57.1    2.00     3.19   24.51  3.97   126.09       212    144.7    1.5    59.9    1.98     3.12   34.71  4.20   117.610       191    139.5    1.4    59.8    1.92     3.12   39.25  4.34   127.011       159    101.5    1.6    60.9    2.65     3.81   31.33  5.00   93.112       159    101.3    1.6    57.7    2.52     3.72   32.20  4.92   92.513       159    101.5    1.6    61.7    2.66     3.73   29.38 4.83 85.714 142 96.3 1.5 59.5 2.57 3.78 34.48 5.08 96.315 127 92.7 1.4 60.7 2.53 36.27 4.81 93.3

Table VI Item No. Feed Stretched Tensile Modulus T ₇ Ten. Eb Tb WTB S ₁ DS

Denier Denier Rate (g/d) (g/d) (g/d) (%) (g/d) (g/d) (%) (%)1 199 127.2 1.60 77.6 2.46 5 .5 3 9 3 5.70    1.742       199    126.1   1.62    76.3  2.50    4.11    34.01  5.51    131.1    7.85    1.883       199    124.4   1.64    73.5  2.62    4.17    32.07  5.51    124.6    5.55    1.654       199    126.7   1.60    65.7  2.31    4.01    35.65  5.44    132.85       199    126.9   1.60    68.1  2.49    3.95    31.27  5.19    116.46       177    120.3   1.50    71.4  2.51    4.16    39.28  5.79 148.17       159    116.2   1.40    64.4  2.19    3.35    37.45  4.60    111.68       239    152.7   1.60    68.0  2.07    3.69    36.90  5.05    151.6    5.65    2.199       239    151.2   1.62    68.7  2.18    3.72    34.20  4.99    140.7    5.85    2.2110       239    149.5   1.64    70.5  2.24    3.82    33.50  5.10    141.2    5.60    2.3011       239    152.4   1.60    61.9  1.98    3.59    37.56 4.94    149.812       239    152.6   1.60    60.1  2.01    3.70    38.90  5.14    159.213       212    144.6   1.50    62.7  2.11    3.87    41.66  5.48    168.714       191    139.4   1.40    69.7  2.12    3.93    45.19  5.71    177.815       159    101.2   1.60    68.9  2.97    4.43    34.31  5.95    118.616       159    101.3   1.60    68.4  2.81    4.45    37.06  6.10    127.017       159    101.2   1.60 80.1  3.05    4.33    30.20  5.64    102.018       142    96.0    1.50    76.9  2.91    4.24    36.00  5.77    114.219       127    92.6    1.40    84.6  2.78    3.84    34.87  5.18    98.320       180    114.6   1.60    80.0  2.69    4.19    33.14  5.58    120.4    5.80    1.7121       180    113.5   1.62    76.9  2.78    4.23    32.40  5.60    118.3    4.30    1.5322       180    112.2   1.64    77.5 2.93 4.33 31.50 5.69 117.0 5.70 1.54

Table VII Item No. Spray #fils DPF Spindle DS Ten. Eb Tb T ₇ T ₂₀ S ₁ Sm 1-S ₁ /Sm

Denier Speed (%) (g/d) (%) (g/d) (g/d) (g/d) (%) (%)

(mpm)1      172.0      200    0.86   2195    1.86    2.51    143.4  6.11   0.64    0.59  49.9    62.6    0.202      172.0      50     3.44   2195    1.64    2.10    186.7  6.02   0.57    0.52  56.4    55.9    -0.013      153.0      200    0.77   2469    1.74    2.81    128.2  6.41   0.68    0.64  32.7    64.9    0.504      153.0      50     3.06   2469    1.80    2.51 166.8  6.70   0.59    0.56  56.3    58.9    0.045      143.0      200    0.72   2195    1.70    2.52    121.0  5.57   0.64    0.62  43.3    66.0    0.346      143.0      50     2.86   2195    1.43    2.18    169.2  5.87   0.57    0.54  55.1    58.6    0.067      138.0      200    0.69   2743    1.61    2.67    114.0  5.71   0.75    0.80  14.4    67.1    0.798      138.0      50     2.76   2743 1.58    2.52    142.4  6.11   0.63    0.59  50.2    62.7    0.209      127.0      200    0.64   2469    2.06    2.86    121.1  6.32   0.72    0.74  22.6    66.0    0.6610      127.0      50     2.54   2469    1.34    2.59    153.6  6.57   0.63    0.59  51.1    61.0    0.1611      115.0      200    0.58   2195    2.24    2.72    121.9  6.04   0.71    0.69  31.8    65.9    0.5212      115.0      50 2.30   2195    1.34    2.49    162.9  6.54   0.60    0.57  56.1    59.6    0.0613      114.0      200    0.57   2743    1.35    2.86    107.9  5.95   0.83    0.93  7.8     68.0    0.8914      114.0      50     2.28   2743    1.50    2.78    140.4  6.68   0.63    0.59  39.4    63.0    0.3715      102.0      200    0.51   2469    1.55    2.57    103.3  5.22   0.80    0.86  12.5    68.7    0.8216 102.0      50     2.04   2469    1.24    2.35    133.3  5.19   0.64    0.59  44.9    64.1    0.3017      91.7       200    0.46   2743    1.79    2.76    104.9  5.66   0.95    1.10  5.2     68.5    0.9218      91.7       50     1.83   2743    1.18    2.85    135.2  6.70   0.69    0.65  21.0    63.8    0.67

Table VIII Item No. Spray Filament No. Stretched Elongation Modulus T ₇ Ten. Eb Tb WTB

Dan number (g/d) (g/d) (g/d) ( %) ( %) (g/d) (g/d) 1 172.0 2008.1 1.6 85.1 2.73 4.40 34.51 5.92 127.192 172.0 50 108.1 1.6 59.7 1.31 2.60     42.50    3.71      84.713      153.0     200    102.5    1.5    88.4    2.77    4.24     34.55    5.70      114.854      153.0     50     102.8    1.5            1.49    3.53     55.81    5.50      137.945      143.0     200    89.8     1.6    88.2    3.19    4.59     28.03    5.88      87.726      143.0     50     89.8     1.6    57.8    1.60    3.39     45.62    4.94      96.287      138.0     200    98.9     1.4    81.0    2.58    4.10 40.41    5.76      124.208      138.0     50     99.2     1.4    62.6    1.51    3.68     57.60    5.80      141.169      127.0     200    85.3     1.5    91.8    3.08    4.20     27.42    5.35      76.8210      127.0     50     85.5     1.5    66.3    1.76    3.95     52.36    6.02      122.1611      115.0     200    72.1     1.6    101.4   3.66    4.62     23.81    5.72      62.5612      115.0     50     72.0     1.6    67.8    2.04    3.99 41.66    5.65      84.7013      114.0     200    82.3     1.4    91.1    2.90    4.01     33.79    5.36      88.5314      114.0     50     82.5     1.4    69.0    1.74    3.84     53.20    5.88      116.0215      102.0     200    68.5     1.5    96.4    3.48    4.36     27.35    5.55      66.9016      102.0     50     68.5     1.5    73.1    2.12    3.93     41.03    5.54      79.3217      91.7      200    66.1     1.4    97.0    3.26    3.95 26.09 4.98 56.3518 91.7 50 66.1 1.4 75.2 2.02 3.81 44.87 5.52 81.40

Table IX Item No. Ejection Filament No. Elongation Ratio Elongation S1 D.S. %U

Denier Temperature (%) (%)

(℃)1       172      200     1.64      25    48.1    1.92   0.492       172      50      1.64      25    60.8    16.58  4.893       172      200     1.64      100   18.2    3.95   0.904       172      50      1.64      100   46.8    12.41  5.045       172      200     1.64      110   11.7    1.72   0.496       172      50      1.64      110   32.5    11.47  3.017       172      200     1.64      115 10.38       172      50      1.64      115   20.59       172      200     1.64      120   9.8      3.48   0.7410       172      50      1.64      120   18.1     7.68   1.8411       172      200     1.64      130   8.3      2.86   0.7612       172      50      1.64      130   10.3     5.03   1.3813       172      200     1.64      140   7.4      2.78   0.7014       172      50      1.64      140   8.5      4.02   1.1115       172      200 1.64      150   6.6      2.99   0.7716       172      50      1.64      150   7.4      3.48   0.9617       172      200     1.64      160   6.2      2.90   0.7518       172      50      1.64      160   6.7      3.64   1.0419       172      200     1.64      170   5.6      2.47   0.7320       172      50      1.64      170   6.5      3.31   1.0621       172      200     1.64      180   5.4      5.29   1.2822       172      50      1.64 180 6.1 3.37 1.08

                                      Table X Item No. Feed Material   Low DGP   High DPF   Elongation Ratio   Stretch   Set   S1   D.S. %U

Quantity Temperature (%) (%)

(C) (c) 1 1999 0.78 1.64 25 27.2 2.89 0.5.78 2.58 1.64 100 222.1 2.67 0.77 0.78, 8, 120, 12, 0.73 0.7, 12, 12, 12, 07, 07, 07, 07, 07, 07, 07, 07, 07, 07, 07, 07, 07, 07. 10.8    2.07    0.606       199     0.78    2.58    1.64     130      25    9.0     1.59    0.607       199     0.78    2.58    1.64     140      25    7.9     2.03    0.758       199     0.78    2.58    1.64     150      25    7.3     2.49    0.859       199     0.78    2.58    1.64     160      25    6.6     2.15    0.8510       199     0.78    2.58    1.64     170      25    6.2     2.50    0.8811       199     0.78 2.58 1.64 180 25 5.8 2.44 0.9212 127 0.50 1.65 1.40 25 28.4 1.58 0.4813 127 0.50 1.65 140 180 5.9 1.82 0.54

Table XI Item No. Feed Stretch Ratio Stretch Temperature Overfeed Set Stretched Modulus T ₇ T ₂₀ Ten. Eb Tb S1

Denier (g/d) (g/d) (g/d) (g/d) (%) (g/d) (%)

(C) ( %) (C) 1 127 1.4 25 16 25 104.5 23.9 1.05 1.95 2.57 37.5 3.53 21.27 1.4 25 16 180.8 46.3 0.97 1.83 2.26 31.0 2.96 1.4 115 103.8 20.0.0.09 2.5 1.4     115      16    180   108.2   36.2   1.10    2.07   2.58  33.5    3.44   1.65       127     1.4     180      16    25    103.8   18.9   1.27    2.44   2.54  22.3    3.11   3.86       127     1.4     180      16    180   104.2   37.7   1.42    2.43   2.74  27.5    3.49   1.97       159     1.6     25       16    25    116.3   28.0   1.06    1.84   2.66  37.2    3.65 40.38       159     1.6     25       16    180   138.1   34.3   0.76    1.23   2.37  49.6    3.55   1.79       159     1.6     115      16    25    114.4   21.1   1.27    2.37   2.66  26.0    3.35   8.710       159     1.6     115      16    180   120.6   29.8   0.94    2.07   2.76  34.0    3.70   1.911       159     1.6     180      16    25    114.4   18.4   1.23    2.63   2.91 24.8 3.63 4.412 159 1.6 180 16 180 115.1 24.7 1.24 2.58 2.85 24.7 3.55 2.6

Claims (32)

1. the method for preparing non-stretching mixed filament polyester spray silk orientated yarns, described yarn peak contraction tension force temperature T (ST _Maximum) in high about 5～30 ℃ scope than glass transition temperature of polymer Tg, this yarn is made up of the long filament that its cross section of two classes and/or dawn number differ from one another at least, the at least a of this filament types is fine filament, and every rhizoid dawn number of this fine filament is called (dpf) here less than about 1 ₁, said filament types has identical polyester polymers, and this method for making comprises:

(i) selecting polyester polymers to make it relative viscosity LRV is about 13～23, zero shearing fusing point T _M° be about 240～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃; This polymer melted and be heated to than melting point polymer T _M° high about 25 ℃～55 ℃ temperature Tp; Filter this polymer melt rapidly to reduce degraded; This melt by different outlet opening shapes spinneret capillary and/or have difference (L/D _RND ⁴) capillary of value to be to generate its cross section and/or the different filament types of dawn number; Wherein concerning this fine filament type, the cross-sectional area A c of spinneret capillary is about 125 * 10 ^-6Cm ²～1250 * 10 ^-6Cm ², select length L and diameter D _RND, make its ratio (L/D _RND ⁴) be at least about 1.25 and less than about 6;

(ii) when the melt of newly extruding from spinneret capillary at least about 2cm and less than about 12 (dpf) ₁ ^1/2The distance L of cm _DQProtect it to make it not be subjected to direct cooling during discharge; Drawing-down and the gained long filament is chilled to be lower than glass transition temperature of polymer Tg then; Wherein this fine filament type is about 5.7～7.6 by drawing-down to the scope of apparent spray silk thread strain; At the extremely about [50+90 (dpf) of about 50cm ₁ ^1/2] using low-friction surface in the distance L c of cm, long filament is assembled becomes endless tow; With about 2～6 kilometers/minute speed endless tow is batched; The long filament generation combined filament yarn that interweaves; The extension at break E of this combined filament yarn wherein _BIntensity T for about 40%～160%, 7% when elongation ₇Be about 0.5～1.75g/d, shrinkage value is for can make (1-S/Sm) value be at least about 0.05, and differential is shunk (DHS-S) less than making an appointment with+2%, and wherein S is that destarch is shunk, and Sm is maximum potential minification, and DHS is 180 ℃ of xeothermic contractions that record.

2. according to the method for making of claim 1, the wherein said combined filament yarn that do not stretch is stretched to generate mixed filament stretch yarn, the latter's remaining extension at break E _BIntensity T for about 15%～45%, 7% when elongation ₇Be at least about 1g/d, and (1-S/Sm) value is at least approximately 0.85, wherein this yarn also can be out of shape to generate draw-textured yarn.

3. according to the method for making of claim 1, wherein should select processing conditions, make the extension at break E of non-stretching polyester yarn _BFor the intensity in about 40%～90%, 7% when elongation is about 1～1.75g/d, shrink S for can make (1-S/Sm) value be at least about 0.85.

4. according to the method for making of claim 3, wherein this non-stretching combined filament yarn is stretched and generates the combined filament yarn that stretches, the latter's remaining extension at break E _BIntensity T for about 15%～55%, 7% when elongation ₇Be at least about 1g/d, and keep (1-S/Sm) value to be at least about 0.85.

5. according to the method for making of claim 4, wherein this yarn also can be deformed and generate the varicosity combined filament yarn that stretches.

6. according to the method for making of claim 3, wherein this non-stretching combined filament yarn is generated the combined filament yarn that stretches, the latter's remaining extension at break E by cold stretch _BIntensity T for about 15%～55%, 7% when elongation ₇Scope for about 1～1.75g/d.

7. according to the method for making of claim 3, wherein this non-stretching combined filament yarn is generated the bulk yarn with the described yarn performance of claim 6 by air jet texturing.

8. according to each method for making of claim 1～7, wherein should select processing conditions to generate the non-stretching combined filament yarn of belt length silk, the difference that the long filament of this long filament shrinks S is at least 5%.

9. method for making according to Claim 8, wherein this non-stretching combined filament yarn is stretched, and draft temperature is at least glass transition temperature of polymer Tg approximately and is lower than crystallization start temperature Tc ° to generate varicosity mixed filament stretch yarn, the latter's remaining extension at break E _BFor about 15%～45%, and the intensity T during 7% elongation ₇Be at least about 1g/d.

10. according to the method for making of claim 9, wherein this yarn also can be deformed the generation draw-textured yarn.

11. according to the method for making of claim 9, wherein this non-stretching combined filament yarn is stretched and is at least 0.85 varicosity mixed filament stretch yarn to generate (1-S/Sm) value.

12. method for making according to Claim 8, wherein this non-stretching mixed filament polyester yarn is sprayed cold air distortion and is generated the bulk yarn that mixes shrinkage continuous yarn, this bulk yarn anti-open and shrinkage in as claim 1 and the described scope of claim 8.

13. according to the method for making of claim 1, wherein should select processing conditions, make its extension at break E to generate non-stretching combined filament yarn _BBe about 40%～90%, intensity during 7% elongation is about 1～1.75g/d, it is differed by shrinkage S and is at least about at least two kinds of dissimilar long filaments of 5% and forms, wherein at least a filament types have such contraction S so that (1-S/Sm) value be about 0.85 at least, and the contraction S of another filament types is about 0.25～0.85 for making (1-S/Sm) value at least.

14. according to the method for making of claim 13, wherein this non-stretching combined filament yarn is generated varicosity mixed filament stretch yarn, its remaining extension at break E by jet stretcher strain _BIntensity T for about 15%～55%, 7% when elongation ₇Be about 1～1.75g/d.

15., wherein select processing conditions to generate non-stretching combined filament yarn, its extension at break E according to the method for making of claim 1 _BFor the intensity in about 90%～120%, 7% when elongation is about 0.5～1g/d, shrinks S and can make that (1-S/Sm) value is about 0.25～0.85.

16. according to the method for making of claim 15, wherein this non-stretching combined filament yarn is carried out stretcher strain with air jet texturing method or false add sth. made by twisting deformation method, generates stretch yarn, the latter's extension at break E _BIntensity T for about 15%～45%, 7% when elongation ₇Be at least about 1g/d, and (1-S/Sm) value is at least about 0.85.

17. according to each method for making of claim 1～16, wherein select processing conditions, make its average filament dawn number and [1.3/ (1+E to generate long filament _B/ 100)] product is about 1 or less than 1.

18., wherein select processing conditions to generate such long filament, the dawn number (dpf) of this fine filament according to each method for making of claim 1～17 ₁Filament denier ratio to the dawn number of high Denier long filament is about 1: 2 to about 1: 6.

19. mixed filament spray silk oriented polyester yarn of forming by at least two kinds of filament types, this two types long filament is difference aspect cross section and/or dawn number, but all have identical polyester polymers, wherein the relative viscosity LRV of polyester polymers is about 13～23, zero shearing fusing point T _M° be about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, wherein the extension at break E of this yarn _BIntensity T for about 40%～160%, 7% when elongation ₇Be about 0.5～1.75g/d, at peak contraction tension force temperature T (ST _Maximum) its maximum collapse tension force (ST when being about (Tg+5 ℃) to about (Tg+30 ℃) _Maximum) less than about 0.2g/d, and its shrinkage value is for making differential shrink (DHS-S) less than about+2%, value is at least about 0.1 and (1-S/Sm), S is that destarch is shunk in the formula, Sm is maximum potential minification, and DHS is xeothermic contraction (measuring at 180 ℃), and wherein at least a filament types is that filament denier is about 1 or less than 1 fine filament.

20. according to the yarn of claim 19, its extension at break E _BIntensity T for about 90%～120%, 7% when elongation ₇Be about 0.5～1g/d, and (1-S/Sm) value is at least about 0.25.

21. according to the yarn of claim 20, this yarn particularly suitable is made the stretching feeding yarn.

22. according to the yarn of claim 19, its extension at break E _RIntensity T for about 40%～90%, 7% when elongation ₇Be about 1～1.75g/d, and (1-S/Sm) value is at least about 0.85.

23. according to the yarn of claim 22, this yarn is specially adapted to directly use yarn.

24. a jet modification mixed filament spray silk oriented polyester yarn, different by its cross section of two classes and/or dawn number at least but long filament that all have an identical polyester polymers is formed, and the relative viscosity LRV of polyester polymers wherein is about 13～23, zero shearing fusing point T _M° be about 240～265 ℃, and glass transition temperature Tg is about 40 ℃～80 ℃, and the extension at break E of this yarn wherein _BIntensity T when being about 40%～90%, 7% elongation ₇Be about 1～1.75g/d, at peak contraction tension force temperature T (ST _Maximum) its maximum collapse tension force (ST when being about (Tg+5 ℃) to about (Tg+30 ℃) _Maximum) be less than about 0.2g/d, it is about 0.85 for making that (1-S/Sm) value is at least that it shrinks S, and S is destarch contraction and Sm is maximum potential minification here, and wherein at least one class long filament is that its filament denier is about 1 or less than 1 fine filament.

25. one kind can a back varicosity mixed filament spray silk oriented polyester yarn, it counts difference by its cross section of at least two classes and/or dawn, but the long filament that all has an identical polyester polymers forms, and wherein the relative viscosity LRV of polyester polymers about 13～23, zero shears fusing point T _M° be about 240 ℃～265 ℃, and glass transition temperature Tg is about 40 ℃～80 ℃, and the extension at break E of this yarn _BIntensity T for about 40%～90%, 7% when elongation ₇Be about 1～1.75g/d, at peak contraction tension force temperature T (ST _Maximum) be the maximum collapse tension force (ST under about (Tg+5 ℃) to about (Tg+30 ℃) _Maximum) be less than about 0.2g/d, the contraction S of wherein at least a this class long filament is for can make (1-S/Sm) value be at least about 0.85, and the contraction S of another kind of at least this class long filament can make that (1-S/Sm) value is about 0.25～0.85, wherein the difference of the long filament of this class long filament contraction S is at least 5%, here S is that destarch is shunk, and Sm is maximum potential minification, and wherein at least one class long filament is that its filament denier is about 1 or less than 1 fine filament.

26. one kind can spray silk oriented polyester yarn by back varicosity air jet texturing mixed filament, its long filament different by its cross section of at least two classes and/or dawn number but that all have an identical polyester polymers is formed, here the relative viscosity LRV of polyester polymers is about 13～23, zero shearing fusing point T _M° about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, wherein the extension at break E of this yarn _BIntensity T for about 40%～90%, 7% when elongation ₇Be about 1～1.75g/d, and at peak contraction tension force temperature T (ST _Maximum) be the maximum collapse tension force (ST when making an appointment with (Tg+5 ℃) to about (Tg+30 ℃) _Maximum) be less than about 0.2g/d, the contraction S of at least a here this class long filament can make (1-S/S _Maximum) value is at least about 0.85, and the contraction S of another kind of at least this class long filament is for can make (1-S/Sm) value be at least about 0.25～0.85, and the difference of the contraction S of such long filament is at least 5%, here S is that destarch is shunk and Sm is maximum potential minification, and wherein at least one class long filament is that its filament denier approximates 1 or less than 1 fine filament.

27. a stretching can back varicosity mixed filament polyester yarn, its long filament different by its cross section of at least two classes and/or dawn number but that all have an identical polyester polymers is formed, and wherein the relative viscosity LRV of polyester polymers is about 13～23, zero shearing fusing point T _M° it is about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, wherein the difference of the contraction S of this class long filament is at least 5%, and the contraction S of at least a this class long filament is for can make (1-S/Sm) value be at least about 0.85, and the contraction S of another kind of at least this class long filament can make that (1-S/Sm) value is about 0.25～0.85, and the extension at break E of this yarn wherein _BIntensity T for about 15%～45%, 7% when elongation ₇Be at least about 1g/d, then surrendering modulus Mpy is about 5～25g/d, and wherein at least a this class long filament is that its filament denier approximates 1 or less than 1 fine filament.

28. air jet texturing mixed filament polyester yarn of varicosityization afterwards that stretches, its long filament different by its cross section of at least two classes and/or dawn number but that all have an identical polyester polymers is formed, wherein the relative viscosity LRV of polyester polymers is about 13～23, zero shearing fusing point T _M° be about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, wherein the difference of the long filament of these type long filaments contraction S is at least 5%, and the contraction S of at least a this class long filament is for can make (1-S/Sm) value be at least about 0.85, and the contraction S of another kind of at least this class long filament is for can make (1-S/Sm) value be about 0.25～0.85, here S is that destarch is shunk and Sm is maximum potential minification, and the extension at break E of this yarn here _BFor the intensity in about 15%～45%, 7% when elongation is at least about 1g/d, back surrender modulus Mpy is about 5～25g/d, and wherein at least a type long filament is that its filament denier is about 1 or less than 1 fine filament.

29. a stretching mixed filament polyester yarn, it counts difference by its cross section of at least two classes and/or dawn, but all has the long filament composition of identical polyester polymers, and wherein the relative viscosity LRV of this polyester polymers is about 13～23, and zero shears fusing point T _M° be about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, wherein the extension at break E of this yarn _BIntensity T for about 15%～45%, 7% when elongation ₇Be 1d/g at least, back surrender modulus Mpy is about 5～25g/d, and (1-S/Sm) value is at least about 0.85, and S is the destarch contraction here, and Sm is maximum potential minification, and wherein at least a long filament is that its filament denier is about 1 or less than 1 fine filament.

30. a stretching false add is twisted with the fingers distortion mixed filament polyester yarn, it by its cross section of at least two classes and/or dawn number different but the long filament that all has an identical polyester polymers formed, wherein the relative viscosity LRV of polyester polymers is about 13～23, zero shearing fusing point T _M° be about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, and the extension at break E of this yarn wherein _BIntensity T for about 15%～45%, 7% when elongation ₇Be at least about 1g/d, then surrendering modulus Mpy is 5～25g/d, and (1-S/Sm) value is at least about 0.85, and S is that destarch is shunk here, and Sm is maximum potential minification, and wherein at least one class long filament is that its filament denier is about 1 or less than 1 fine filament.

31. a stretching air jet texturing mixed filament polyester yarn, it counts difference by its cross section of at least two classes and/or dawn, but the long filament that all has an identical polyester polymers forms, and wherein the relative viscosity LRV of polyester polymers about 13～23, zero shears fusing point T _M° be about 240 ℃～265 ℃, glass transition temperature Tg is about 40 ℃～80 ℃, and the extension at break E of this yarn wherein _BIntensity T for about 15～45%, 7% when elongation ₇Be at least about 1g/d, back surrender modulus Mpy is about 5～25g/d, and (1-S/Sm) value is at least about 0.85, and S is the destarch contraction here, and Sm is maximum potential minification, and wherein at least one class long filament is that its filament denier is about 1 or less than 1 fine filament.

32. according to each yarn of claim 19～31, wherein this average filament dawn number and [1.3/ (1+E _B/ 100) product] is about 1 or less than 1.

33. according to each yarn of claim 19～32, it comprises the high dawn of a class and counts long filament, its dawn number is for making that average filament dawn number that this high dawn counts filament types is about 2～6 to the ratio of the average filament dawn number of described fine filament type.

Images