US3403070A - Unoriented polyolefin filament with polyurethane foam core - Google Patents

Unoriented polyolefin filament with polyurethane foam core Download PDF

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US3403070A
US3403070A US341704A US34170464A US3403070A US 3403070 A US3403070 A US 3403070A US 341704 A US341704 A US 341704A US 34170464 A US34170464 A US 34170464A US 3403070 A US3403070 A US 3403070A
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polyurethane foam
foam
filaments
unoriented
fibre
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US341704A
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Jr John C Lewis
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Polymers Inc
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Polymers Inc
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Priority to ES0307187A priority patent/ES307187A1/en
Priority to GB3662/65A priority patent/GB1088506A/en
Priority to FR3712A priority patent/FR1443106A/en
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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/16Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
    • AHUMAN NECESSITIES
    • A46BRUSHWARE
    • A46DMANUFACTURE OF BRUSHES
    • A46D1/00Bristles; Selection of materials for bristles
    • AHUMAN NECESSITIES
    • A46BRUSHWARE
    • A46DMANUFACTURE OF BRUSHES
    • A46D1/00Bristles; Selection of materials for bristles
    • A46D1/02Bristles details
    • A46D1/023Bristles with at least a core and at least a partial sheath
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/24Formation of filaments, threads, or the like with a hollow structure; Spinnerette packs therefor
    • D01D5/247Discontinuous hollow structure or microporous structure
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/28Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30Conjugate filaments; Spinnerette packs therefor
    • D01D5/34Core-skin structure; Spinnerette packs therefor
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/26Composite fibers made of two or more materials
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2933Coated or with bond, impregnation or core
    • Y10T428/2935Discontinuous or tubular or cellular core
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2973Particular cross section
    • Y10T428/2975Tubular or cellular
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2973Particular cross section
    • Y10T428/2978Surface characteristic

Definitions

  • synthetic filaments have been produced in various cross-sectional shapes such as circular, square, tapered, X and Y and three-square from therrrnoplastic resins like polystyrene, polystyrene-acrylonitrile, polyvinylchloride, polyethylene, polypropylene and polyamides.
  • these filaments are comprised of a single polymer composition and are highly oriented to irnpart to the particular filament the maximum physical properties; such properties being stiffness, recovery, abrasion resistance, wet and dry wear, heat distortion and the like.
  • Many attempts have been made to create the perfect synthetic filament, the closest being an oriented polyamide.
  • the polyamides, better known as nylons, are described in United States Patent 2,130,523 to W.
  • nylon filaments of this type have all the aforementioned physical properties and also display excellent chemical properties.
  • the one great disadvantage of nylon filaments is cost, and even through nylon vfilaments made in different cross-sectional shapes seem to help the bulk density/ cost ratio, th'e cost per pound is still not advantageous.
  • Polypropylene filaments fall into the low-cost category but have the tendency to suffer matting and permanent deformation. Also, polypropylene filaments lack good recovery. Certain attempts have been made to overcome this deformation, for instance, by controlling the degree of orientation, but oftentimes one good characteristic such as abrasion resistance is forfeited for tensile strength and elongation or vice versa. It also has been found true that polypropylene filaments having various cross-sectional shapes are no good from the recovery standpoint since any protruding webs or fins split and tear when the oriented filaments are bent through 180. It is therefore apparent that the only oriented filament possessing all the physical and chemical properties desired of a brush fibre is nylon, i.e., nylon 6-10.
  • unoriented filaments of the polyolefin type have been made such as those set forth in co-pending patent application 231,799, filed Oct. 19, 1962 now U.S. Patent No. 3,121,040 issued Feb. 11, 1964. Such filaments exhibit essentially complete recovery after deformation.
  • the physical and chemical properties of such unoriented polyolefin filaments are directly comparable to nylon 6-10 filaments and markedly superior to nylon 6-10 filaments in maintaining their stiffness (wet and dry ratio) when exposed to wet or high humid conditions.
  • Unoriented polyolefin filaments can be produced in various cross-sectional shapes and in hollow tubes down to diameters of 0.010" having wall thickness in the range of 3,403,070 Patented Sept. 24, 1968 ICC 0.001". Such filaments have excellent recovery and are low-cost fibres.
  • a light weight unoriented polyole- .tin fibre could retain all its dry stiffness in a wet application and also discharge during operating a constant amount of abrasive material, i.e., as it wears, it would eliminate the necessity for adding large quantities of water slurries. This would also eliminate high cost of maintenance and excessive wear of lmachine parts, as high concentrations of abrasive slurries tend to spill over onto machinery in such applications.
  • hollow fibres are used in connection with applications where liquids ⁇ are present and the hollow void has an effect of capillary action. While immersed in such liquid, the hollow fibre retains liquid, but when removed, it discontinues to hold the liquid.
  • Another area where light weight fibres .are used is in insulating and filling materials where the hollow void is supposed to act like a moisture barrier or in the case of filling materials, act like a resilient cushion.
  • the hollow sections tend to collapse and deform and never return to their original shape, thus rendering the fibre useless.
  • Another object of this invention is to provide a lowcost synthetic filament having excellent recovery, a high stiffness ratio (wet or dry) and superior wearing qualities.
  • Still another object of this invention is to provide novel filaments which have insulating properties.
  • Yet another object of this invention is to provide synthetic filaments which can be used to absorb liquids.
  • FIGURE 1 is a longitudinal sectional view of one embodiment of my invention consisting of an unoriented high pressure polyethylene shell with a core consisting of a polyester based-polyurethane foam.
  • FIGURE 2 is a transverse section of the filament of FIGURE 1.
  • FIGURE 3 is a longitudinal sectional View of a second embodiment of my invention consisting of an unoriented polypropylene shell with a core consisting of a polyester-based polyurethane foam in which an abrasive particle is held by the foam.
  • FIGURE 4 is a transverse section of the filament of FIGURE 3.
  • FIGURE 5 is a longitudinal sectional view of a third embodiment of my invention consisting of an unoriented polyallomer shell with a core consisting of a polyether based-polyurethane foam and having running longitudinally along its entire length a slice cutting into the annular wall and foam core.
  • FIGURE 6 is a transverse section of the filament of FIGURE 5.
  • the objects of my invention may be realized by forming a fibre comprising an unoriented polyolefin outer shell of the type described hereinafter and an inner core of polyurethane foam, More particularly, the outer shell of the fibre of the present invention is an unoriented polyolefin hollow fibre of the type described in the aforementioned co-pending application Ser. No. 231,779, filed Oct. 19, 1962, and consists of annular walls Whose radius to annular wall thickness ratio is in the order of at least 4 to 1.
  • the outer shell is of a polyolen composition, such, for example, as high pressure polyethylene, polypropylene, polyallomer or physical and/ or chemical mixtures thereof.
  • the inner core of the fibre of this invention is made of a polyurethane foam.
  • polyurethane foam as used herein, includes both polyester based-polyurethane foam and polyether based-polyurethane foam. Any conventional polyester based-polyurethane foam or polyether basedpolyurethane foam may be used as the core material.
  • polyester based-polyurethane foams are conventionally made by reaching an organic polyisocyanate, e.g., toluene diisocyanate, with a polyester containing free hydroxyl and/or carboxyl groups, e.g., the polyester resin reaction product of ethylene glycol and adipic acid.
  • an organic polyisocyanate e.g., toluene diisocyanate
  • a polyester containing free hydroxyl and/or carboxyl groups e.g., the polyester resin reaction product of ethylene glycol and adipic acid.
  • catalysts e.g., a tertiary amine catalyst such as triethylamine and N-methylmorphaline.
  • Polyether based-polyurethane foams are conventionally made in a manner similar to that described above except that in place of a polyester, a polyether, eg., is employed for reaction with the organic polyisocyanate.
  • U.S. Patents 2,726,219, 2,814,606 and 3,029,209 disclose polyurethane foam compositions that may be used as the core material in accordance with this invention.
  • the polyurethane foam core material is generally of the flexible or semi-rigid foam type so that the fibre exhibits the desired flexural characteristics.
  • FIGURES 1-6 illustrate preferred forms of the fibres in accordance with the invention, although such forms are given by way of example only, and other forms may be used.
  • the fibre of this invention is comprised of an unoriented high pressure polyethylene shell 1 and a polyester based-polyurethane foam core 2.
  • the outer shell or wall of the fibre consists of an annular wall as shown in FIGURE 2 ⁇ whose radius R to annular wall thickness S ratio is in the order of at least 4 to 1.
  • FIGURES 3 and 4 there is shown another embodiment yof my fibre comprising an unoriented polypropylene shell 3 and a polyester based-polyurethane foam core 4, containing foreign compounds or substances 5.
  • Any foreign material can be incorporated physically or chemically to the foam as long as the material does not interfere with the processing of the foam.
  • Such material can be fire retardant compounds, abrasive compounds, Watersoluble compounds, colorants or any organic or inorganic compound which allows for foam processing.
  • the amount of the additive is not important as long as consistent cellstructure is maintained throughout the foam.
  • FIGURES 5 and 6 there is shown another embodiment of my fibre comprising an unoriented polyallomer shell 6 and a polyether based-polyurethane foam core 7, said fibre having slit 8i running longitudinally along its annular Wall, cutting into the core and terminating at the center.
  • This opening actually cuts into the cell-structure of the foam, thus allowing air or liquids to enter into the hollow voids of the foam.
  • the amount of void per Kcell, or absorbency per cell unit is controlled by the chemical composition formula and/or method of processing.
  • any convenient processing technique may be used ⁇ for -filling the unoriented polyolefin outer shell with polyurethane foam.
  • a procedure which may be used is as follows:
  • a polyurethane premix is formed by blending an appropriate amount of polyester (or polyether) resin with appropriate amounts of catalyst and water. If the desired foam is to include a foreign substance, it may be incorporated in the premix. To this premix is added an appropriate amount of organic polyisocyanate and the resulting composition is mixed thoroughly to form a foam-producing mix. Immediately after, samples of hollow unoriented polyolefin fibres are immersed in the aforementioned foam-producing composition to a sufficient depth and suction is applied to the projecting ends of the fibres to cause the foam-producing mix to travel up into the hollow portion of the fibre. In a matter of seconds, the foaming reaction starts and the cell structure begins to foam. Within a relatively short period of time, e.g., 30 seconds, the hollow portion of the fibers are completely filled with polyurethane foam.
  • a batch of 2 pounds per cubic foot flexible polyurethane foam was made by the following recipe (all reactants Were at room temperature):
  • Formez-50 a polyester-resin
  • N-ethyl morpholine a polyester-resin
  • distilled water a distilled water
  • Nacconate 80:20 mixture of 2.4 and 2.6-toluene diiocyanate
  • the laments of this invention may be made in long continuous lengths or cut into shorter lengths and used for bristles, fibres and the like. They may be tapered if so desired.
  • the filament can be made in the Wide Variety of sizes.
  • the filament can have an overall cross-sectional dimension from about 0.010 to 0.500 of an inch, and the cross-section area of the core portion comprising at least 60% of the total cross-sectional dimension.
  • the fibre can be made to wear down at different rates, and exposing to the wearing surface at all times definite amounts of abrasive material.
  • the core for liquid retention, by selection of proper cell-size, the fibre will retain its maximum quantity of liquid.
  • the filaments of this invention may be used to prepare improved products such as: mops, polishing brushes, abrasive strip-brushes, rotary brushes, liquid retention brushes, fabrics, insulating mats, etc.
  • Colorants, extenders, plasticizer, catalysts and modifiers may be added to these materials as practice dictates.
  • a synthetic filament comprising an unoriented polyolefin shell whose radius to annular wall thickness ratio is in the order of at least 4 to 1, and an inner core of a polyurethane foam composition.

Description

Sept. 24, 968 J. c. I EwIs, IR 3,403,070
UNORENTED POLYOLEFIN FILAMENT WITH POLYURETHANE FOAM CRE Filed Jan. 3l, 1964 INVENTOR JOHN C. LEWIS, JR.
MORGAN,FINNEGAN,DURHAM a PINE ATTORNEYS United States Patent() 3,403,070 UNORIENTED POLYOLEFIN FILAMENT WITH POLYURETHANE FOAM CORE `Iohn C. Lewis, Jr., Middlebury, Vt., assigner to Polymers, Inc., Middlebury, Vt., a corporation of Vermont Filed Jan. 31, 1964, Ser. No. 341,704 5 Claims. (Cl. 161-175) ABSTRACT OF THE DISCLOSURE This invention relates to artificial filaments and more specifically to large hollow filaments made from unoriented polyolefin resins filled with a cellular-type foam useful as bristles and mop fibres. The cellular type foam forming the core of the filaments of this invention is a polyurethane foam composition.
For many years synthetic filaments have been produced in various cross-sectional shapes such as circular, square, tapered, X and Y and three-square from therrrnoplastic resins like polystyrene, polystyrene-acrylonitrile, polyvinylchloride, polyethylene, polypropylene and polyamides. Normally, these filaments are comprised of a single polymer composition and are highly oriented to irnpart to the particular filament the maximum physical properties; such properties being stiffness, recovery, abrasion resistance, wet and dry wear, heat distortion and the like. Many attempts have been made to create the perfect synthetic filament, the closest being an oriented polyamide. The polyamides, better known as nylons, are described in United States Patent 2,130,523 to W. H. Carothers. Of all the nylons, the condensation product from hexamethylene-diamine and sebacic acid proves to be the superior, and nylon filaments of this type have all the aforementioned physical properties and also display excellent chemical properties. However, the one great disadvantage of nylon filaments is cost, and even through nylon vfilaments made in different cross-sectional shapes seem to help the bulk density/ cost ratio, th'e cost per pound is still not advantageous.
Polypropylene filaments, on the other hand, fall into the low-cost category but have the tendency to suffer matting and permanent deformation. Also, polypropylene filaments lack good recovery. Certain attempts have been made to overcome this deformation, for instance, by controlling the degree of orientation, but oftentimes one good characteristic such as abrasion resistance is forfeited for tensile strength and elongation or vice versa. It also has been found true that polypropylene filaments having various cross-sectional shapes are no good from the recovery standpoint since any protruding webs or fins split and tear when the oriented filaments are bent through 180. It is therefore apparent that the only oriented filament possessing all the physical and chemical properties desired of a brush fibre is nylon, i.e., nylon 6-10.
Prior to this invention, unoriented filaments of the polyolefin type have been made such as those set forth in co-pending patent application 231,799, filed Oct. 19, 1962 now U.S. Patent No. 3,121,040 issued Feb. 11, 1964. Such filaments exhibit essentially complete recovery after deformation. The physical and chemical properties of such unoriented polyolefin filaments are directly comparable to nylon 6-10 filaments and markedly superior to nylon 6-10 filaments in maintaining their stiffness (wet and dry ratio) when exposed to wet or high humid conditions. Unoriented polyolefin filaments can be produced in various cross-sectional shapes and in hollow tubes down to diameters of 0.010" having wall thickness in the range of 3,403,070 Patented Sept. 24, 1968 ICC 0.001". Such filaments have excellent recovery and are low-cost fibres.
It has ybeen found that when using hollow fibres for certain applications such as applying abrasive slurries to surfaces, the hollow void tends to fill up with the slurry, but if the applicator rotates or moves too rapidly, the centrifugal force tends to eject the slurry rather than hold it. Also the slurry must be continually added to the operation as the slurry is always being discarded. When nylon type fibres are used in the presence of water slurries, they absorb a given amount of moisture and lose their stiffness. Therefore, if a light weight unoriented polyole- .tin fibre could retain all its dry stiffness in a wet application and also discharge during operating a constant amount of abrasive material, i.e., as it wears, it would eliminate the necessity for adding large quantities of water slurries. This would also eliminate high cost of maintenance and excessive wear of lmachine parts, as high concentrations of abrasive slurries tend to spill over onto machinery in such applications.
Another important area where hollow fibres are used is in connection with applications where liquids `are present and the hollow void has an effect of capillary action. While immersed in such liquid, the hollow fibre retains liquid, but when removed, it discontinues to hold the liquid.
Another area where light weight fibres .are used is in insulating and filling materials where the hollow void is supposed to act like a moisture barrier or in the case of filling materials, act like a resilient cushion. The hollow sections tend to collapse and deform and never return to their original shape, thus rendering the fibre useless.
Other objects yand advantages of this invention will be set forth in part hereinafter and in part will be obvious herefrom, or may be learned by practice with the invention, the same being realized and attained by means of the improvements pointed out in the :appended claims.
It is therefore an object of this invention to create a light weight synthetic filament having a highly desirable overall balance of properties.
Another object of this invention is to provide a lowcost synthetic filament having excellent recovery, a high stiffness ratio (wet or dry) and superior wearing qualities.
Still another object of this invention is to provide novel filaments which have insulating properties.
Yet another object of this invention is to provide synthetic filaments which can be used to absorb liquids.
In the drawings:
FIGURE 1 is a longitudinal sectional view of one embodiment of my invention consisting of an unoriented high pressure polyethylene shell with a core consisting of a polyester based-polyurethane foam.
FIGURE 2 is a transverse section of the filament of FIGURE 1.
FIGURE 3 is a longitudinal sectional View of a second embodiment of my invention consisting of an unoriented polypropylene shell with a core consisting of a polyester-based polyurethane foam in which an abrasive particle is held by the foam.
FIGURE 4 is a transverse section of the filament of FIGURE 3.
FIGURE 5 is a longitudinal sectional view of a third embodiment of my invention consisting of an unoriented polyallomer shell with a core consisting of a polyether based-polyurethane foam and having running longitudinally along its entire length a slice cutting into the annular wall and foam core.
FIGURE 6 is a transverse section of the filament of FIGURE 5.
It has been found that the objects of my invention may be realized by forming a fibre comprising an unoriented polyolefin outer shell of the type described hereinafter and an inner core of polyurethane foam, More particularly, the outer shell of the fibre of the present invention is an unoriented polyolefin hollow fibre of the type described in the aforementioned co-pending application Ser. No. 231,779, filed Oct. 19, 1962, and consists of annular walls Whose radius to annular wall thickness ratio is in the order of at least 4 to 1.
As indicated above, the outer shell is of a polyolen composition, such, for example, as high pressure polyethylene, polypropylene, polyallomer or physical and/ or chemical mixtures thereof. As indicated hereinabove, the inner core of the fibre of this invention is made of a polyurethane foam. The term polyurethane foam as used herein, includes both polyester based-polyurethane foam and polyether based-polyurethane foam. Any conventional polyester based-polyurethane foam or polyether basedpolyurethane foam may be used as the core material. As is Well known, polyester based-polyurethane foams are conventionally made by reaching an organic polyisocyanate, e.g., toluene diisocyanate, with a polyester containing free hydroxyl and/or carboxyl groups, e.g., the polyester resin reaction product of ethylene glycol and adipic acid. When reacting a polyisocyanate with an hydroxypolyester, a small amount of water is added to bring about carbon dioxide formation with polyisocyanate and the reaction is accelerated in known manner by the addition of catalysts, e.g., a tertiary amine catalyst such as triethylamine and N-methylmorphaline.
Polyether based-polyurethane foams are conventionally made in a manner similar to that described above except that in place of a polyester, a polyether, eg., is employed for reaction with the organic polyisocyanate. U.S. Patents 2,726,219, 2,814,606 and 3,029,209 disclose polyurethane foam compositions that may be used as the core material in accordance with this invention. The polyurethane foam core material is generally of the flexible or semi-rigid foam type so that the fibre exhibits the desired flexural characteristics.
In order to describe the invention more fully, specific reference will now be made to the drawings. FIGURES 1-6 illustrate preferred forms of the fibres in accordance with the invention, although such forms are given by way of example only, and other forms may be used. As shown in FIGURE 1, the fibre of this invention is comprised of an unoriented high pressure polyethylene shell 1 and a polyester based-polyurethane foam core 2. The outer shell or wall of the fibre consists of an annular wall as shown in FIGURE 2` whose radius R to annular wall thickness S ratio is in the order of at least 4 to 1.
In FIGURES 3 and 4 there is shown another embodiment yof my fibre comprising an unoriented polypropylene shell 3 and a polyester based-polyurethane foam core 4, containing foreign compounds or substances 5. Any foreign material can be incorporated physically or chemically to the foam as long as the material does not interfere with the processing of the foam. Such material can be fire retardant compounds, abrasive compounds, Watersoluble compounds, colorants or any organic or inorganic compound which allows for foam processing. The amount of the additive is not important as long as consistent cellstructure is maintained throughout the foam.
In FIGURES 5 and 6 there is shown another embodiment of my fibre comprising an unoriented polyallomer shell 6 and a polyether based-polyurethane foam core 7, said fibre having slit 8i running longitudinally along its annular Wall, cutting into the core and terminating at the center. This opening actually cuts into the cell-structure of the foam, thus allowing air or liquids to enter into the hollow voids of the foam. The amount of void per Kcell, or absorbency per cell unit is controlled by the chemical composition formula and/or method of processing.
In the specific embodiments of filaments described hereinbefore, any convenient processing technique may be used` for -filling the unoriented polyolefin outer shell with polyurethane foam. A procedure which may be used is as follows:
First, a polyurethane premix is formed by blending an appropriate amount of polyester (or polyether) resin with appropriate amounts of catalyst and water. If the desired foam is to include a foreign substance, it may be incorporated in the premix. To this premix is added an appropriate amount of organic polyisocyanate and the resulting composition is mixed thoroughly to form a foam-producing mix. Immediately after, samples of hollow unoriented polyolefin fibres are immersed in the aforementioned foam-producing composition to a sufficient depth and suction is applied to the projecting ends of the fibres to cause the foam-producing mix to travel up into the hollow portion of the fibre. In a matter of seconds, the foaming reaction starts and the cell structure begins to foam. Within a relatively short period of time, e.g., 30 seconds, the hollow portion of the fibers are completely filled with polyurethane foam.
In order to illustrate the aforedescribed procedure more specifically, the following specific example is now given:
A batch of 2 pounds per cubic foot flexible polyurethane foam was made by the following recipe (all reactants Were at room temperature):
100 grams of Formez-50 (a polyester-resin) was blended with 2 grams of N-ethyl morpholine in an electric mixer for 45 seconds and then 3.6 grams of distilled water was added and the mixture allowed to mix for another 30 seconds. To this resin premix, 105 grams of Nacconate (80:20 mixture of 2.4 and 2.6-toluene diiocyanate) was added and mixed for approximately 10 seconds and then poured intoV a paper cup.
Immediately after, 10 inch samples of polypropylene fibres, (hollow) measuring 0.050" in diameter and having a 0.003 annular wall thickness, were immersed in the foam mixture to a depth of 1/2 inch and a slight vacuum was applied to the projecting ends of the fibres, which allowed the foam mix to travel up into the hollow portion of the fibre. Soon after, that is, 5-10 seconds, the foaming reaction started and the cell structure began to form. Within 30 seconds the hollow portion of the fibres were completely filled with polyurethane foam.
The laments of this invention may be made in long continuous lengths or cut into shorter lengths and used for bristles, fibres and the like. They may be tapered if so desired.
Likewise, the filament can be made in the Wide Variety of sizes. The filament can have an overall cross-sectional dimension from about 0.010 to 0.500 of an inch, and the cross-section area of the core portion comprising at least 60% of the total cross-sectional dimension.
By proper core design, the fibre can be made to wear down at different rates, and exposing to the wearing surface at all times definite amounts of abrasive material. In a like manner, if the core is designed =for liquid retention, by selection of proper cell-size, the fibre will retain its maximum quantity of liquid.
The filaments of this invention may be used to prepare improved products such as: mops, polishing brushes, abrasive strip-brushes, rotary brushes, liquid retention brushes, fabrics, insulating mats, etc.
Colorants, extenders, plasticizer, catalysts and modifiers may be added to these materials as practice dictates.
What is claimed is:
I. A synthetic filament comprising an unoriented polyolefin shell whose radius to annular wall thickness ratio is in the order of at least 4 to 1, and an inner core of a polyurethane foam composition.
2. A synthetic filament according to claim 1 in which the outer shell is made of high pressure polyethylene.
6 References Cited UNITED STATES PATENTS 3,121,040 2/1964 Shaw et al. 16l-18l 5 ROBERT F. BURNETT, Primary Examiner.
L. M. CARLIN, Assistant Examiner.
US341704A 1964-01-31 1964-01-31 Unoriented polyolefin filament with polyurethane foam core Expired - Lifetime US3403070A (en)

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US341704A US3403070A (en) 1964-01-31 1964-01-31 Unoriented polyolefin filament with polyurethane foam core
ES0307187A ES307187A1 (en) 1964-01-31 1964-12-16 Unoriented polyolefin filament with polyurethane foam core
GB3662/65A GB1088506A (en) 1964-01-31 1965-01-27 Synthetic composite filaments and fibres
FR3712A FR1443106A (en) 1964-01-31 1965-01-29 Artificial filament

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Cited By (22)

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US3641610A (en) * 1970-02-11 1972-02-15 Tucel Industries Artificial tufted sponges
US3765360A (en) * 1972-03-31 1973-10-16 P Monfort Reinforced mast construction
US3874021A (en) * 1973-03-05 1975-04-01 Herbert V Jacobs Disposable paintbrushes
US3990437A (en) * 1974-09-26 1976-11-09 Boyden Jr John S Article and method of forming a support structure
US4055702A (en) * 1974-03-29 1977-10-25 M & T Chemicals Inc. Additive-containing fibers
DE2650974A1 (en) * 1976-11-08 1978-05-11 Boyden Jun Support structure for an orthopaedic cast etc. - is pliable during installation and becomes rigid subsequently in situ
US4367564A (en) * 1981-04-14 1983-01-11 Holley John D Sweeper bristle and method of making
USRE31619E (en) * 1981-04-14 1984-07-03 Holley Engineering Company, Inc. Sweeper bristle and method of making
US5011275A (en) * 1988-07-05 1991-04-30 Ciba-Geigy Corporation Dimethylacrylamide-copolymer hydrogels with high oxygen permeability
WO1994010539A1 (en) * 1992-11-05 1994-05-11 The Gillette Company Improved brush filaments
WO1998034514A1 (en) 1997-02-07 1998-08-13 Smithkline Beecham Consumer Healthcare Gmbh Toothbrush bristles
US6058883A (en) * 1998-06-26 2000-05-09 Robins; Anna Washable/reusable animal bedding element
US6151745A (en) * 1995-11-09 2000-11-28 Gillette Canada, Inc. Gum-massaging oral brush
US6772467B1 (en) * 1999-07-13 2004-08-10 Coronet-Werkc Gmbh Brush bristle, method of making same and brush comprising such brush bristles
US20050112965A1 (en) * 2003-11-20 2005-05-26 Jone Chang Resilient and colored bath sponge
US20090282628A1 (en) * 2003-02-11 2009-11-19 The Gillette Company Toothbrushes
US7707676B2 (en) 1999-06-14 2010-05-04 The Procter & Gamble Company Toothbrush
US7941886B2 (en) 2003-09-19 2011-05-17 Braun Gmbh Toothbrushes
US7975344B2 (en) 2003-03-14 2011-07-12 The Gillette Company Toothbrush head
US8332982B2 (en) 2004-04-23 2012-12-18 The Gillette Company Vibrating toothbrush
US8584299B2 (en) 2003-04-23 2013-11-19 The Procter & Gamble Company Electric toothbrushes
USRE44819E1 (en) 2000-03-16 2014-04-01 Procter & Gamble Business Services Canada Company Toothbrush

Citations (1)

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US3121040A (en) * 1962-10-19 1964-02-11 Polymers Inc Unoriented polyolefin filaments

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3121040A (en) * 1962-10-19 1964-02-11 Polymers Inc Unoriented polyolefin filaments

Cited By (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3641610A (en) * 1970-02-11 1972-02-15 Tucel Industries Artificial tufted sponges
US3765360A (en) * 1972-03-31 1973-10-16 P Monfort Reinforced mast construction
US3874021A (en) * 1973-03-05 1975-04-01 Herbert V Jacobs Disposable paintbrushes
US4055702A (en) * 1974-03-29 1977-10-25 M & T Chemicals Inc. Additive-containing fibers
US3990437A (en) * 1974-09-26 1976-11-09 Boyden Jr John S Article and method of forming a support structure
DE2650974A1 (en) * 1976-11-08 1978-05-11 Boyden Jun Support structure for an orthopaedic cast etc. - is pliable during installation and becomes rigid subsequently in situ
US4367564A (en) * 1981-04-14 1983-01-11 Holley John D Sweeper bristle and method of making
USRE31619E (en) * 1981-04-14 1984-07-03 Holley Engineering Company, Inc. Sweeper bristle and method of making
US5011275A (en) * 1988-07-05 1991-04-30 Ciba-Geigy Corporation Dimethylacrylamide-copolymer hydrogels with high oxygen permeability
WO1994010539A1 (en) * 1992-11-05 1994-05-11 The Gillette Company Improved brush filaments
US5313909A (en) * 1992-11-05 1994-05-24 Gillette Canada Inc. Brush filaments
US20060085931A1 (en) * 1995-11-09 2006-04-27 The Gillette Company, A Delaware Corporation Gum-massaging oral brush
US6151745A (en) * 1995-11-09 2000-11-28 Gillette Canada, Inc. Gum-massaging oral brush
US20040087882A1 (en) * 1995-11-09 2004-05-06 Gillette Canada Company, A Canadian Corporation Gum massaging oral brush
US20050086753A1 (en) * 1995-11-09 2005-04-28 Gillette Canada, A Canadian Corporation Gum massaging oral brush
US20070234496A1 (en) * 1995-11-09 2007-10-11 Gillette Canada Inc., A Canadian Corporation Gum massaging oral brush
US8156600B2 (en) 1995-11-09 2012-04-17 The Gillette Company Gum massaging oral brush
WO1998034514A1 (en) 1997-02-07 1998-08-13 Smithkline Beecham Consumer Healthcare Gmbh Toothbrush bristles
US6058883A (en) * 1998-06-26 2000-05-09 Robins; Anna Washable/reusable animal bedding element
US7707676B2 (en) 1999-06-14 2010-05-04 The Procter & Gamble Company Toothbrush
US6772467B1 (en) * 1999-07-13 2004-08-10 Coronet-Werkc Gmbh Brush bristle, method of making same and brush comprising such brush bristles
USRE44819E1 (en) 2000-03-16 2014-04-01 Procter & Gamble Business Services Canada Company Toothbrush
US7958589B2 (en) 2003-02-11 2011-06-14 The Gillette Company Toothbrushes
US8695149B2 (en) 2003-02-11 2014-04-15 Braun Gmbh Toothbrushes
US7934284B2 (en) 2003-02-11 2011-05-03 Braun Gmbh Toothbrushes
US20090282628A1 (en) * 2003-02-11 2009-11-19 The Gillette Company Toothbrushes
US7975344B2 (en) 2003-03-14 2011-07-12 The Gillette Company Toothbrush head
US8528148B2 (en) 2003-03-14 2013-09-10 The Gillette Company Toothbrush head
US9220335B2 (en) 2003-03-14 2015-12-29 The Gillette Company Toothbrush head
US8584299B2 (en) 2003-04-23 2013-11-19 The Procter & Gamble Company Electric toothbrushes
US8955186B2 (en) 2003-04-23 2015-02-17 The Procter & Gamble Company Electric toothbrushes
US8621698B2 (en) 2003-09-19 2014-01-07 Braun Gmbh Toothbrushes
US7941886B2 (en) 2003-09-19 2011-05-17 Braun Gmbh Toothbrushes
US9204949B2 (en) 2003-09-19 2015-12-08 The Gillettte Company Toothbrushes
US20050112965A1 (en) * 2003-11-20 2005-05-26 Jone Chang Resilient and colored bath sponge
US8332982B2 (en) 2004-04-23 2012-12-18 The Gillette Company Vibrating toothbrush

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ES307187A1 (en) 1965-02-16

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