Cellulose yarn package, and its manufacturing method and processing method.

Abstract

A cellulosic yarn package comprising a core and a plurality of individually entangled cellulosic yarns wound around the core. The yarns can be wound around different sections of the core or around at least one common section of the core. The yarns do not entangle or twist with each other on the core, thereby allowing the yarns to be wound individually from the core.

Description

Background Art

[0001] Technical Field

[0002] This application generally relates to cellulose-based yarns, and more particularly, to systems and methods for use in increasing the production of cellulose-based yarns. Description of Related Art

[0003] Description of Related Art Fiber fabrics made of yarn are widely used in various applications. These fabrics can be formed by weaving, knitting, crocheting, knotting, or felting yarns made of materials such as polyester, polyamide, acrylic, polyurethane, glass, polypropylene, silk, and various cellulose-based materials. Cellulose acetate fibers are one type of cellulose-based material known for their sustainability, biodegradability, and recyclability.

[0004] Conventionally, cellulose acetate fibers are formed by extruding a dope from a spinneret to produce a plurality of filaments, and then joining the filaments to produce a multifilament yarn. As the market for cellulose-based fibers grows, the potential for increasing fiber production is being explored. However, there is a limit to the number of spinnerets that can be accommodated in the cabinet of an existing spinning machine. Also, adding additional spinning machines to a production facility or adding additional winding machines to an existing spinning machine is a time-consuming and costly endeavor.

[0005] Therefore, it is desirable to increase the production of cellulose acetate fibers using existing equipment and processes without investing in additional expensive equipment.

Summary of the Invention

[0006] In one embodiment of the present invention, a core, A cellulose yarn package is provided, comprising cellulose yarns, 2 to 4 individually entangled cellulose yarns wound around a core, wherein each yarn is not permanently entangled with the others on the core.

[0007] In another embodiment of the present invention, The core and It comprises multiple individually entangled cellulose fibers wrapped around a core, The threads are not permanently entangled with each other on the core. Each yarn is provided in a cellulose yarn package, with a density of approximately less than 300 denier.

[0008] In another embodiment of the present invention, The core and It comprises multiple individually entangled cellulose fibers wrapped around a core, The thread is wrapped around separate sections of the core. The yarn is provided in a cellulose yarn package, in which the yarn is wound around a core in a spiral pattern.

[0009] In yet another embodiment of the present invention, The core and It includes 2 to 4 individually entangled cellulosophical threads wrapped around the core, A cellulose yarn package is provided in which at least two threads are wound around at least one common section of a core. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram of an exemplary yarn production system. [Figure 2] Figure 1 shows one embodiment of the thread guide and winding subassembly. [Figure 3A] Figure 2 is a side view of an exemplary yarn package that may be produced. [Figure 3B] Figure 2 is a side view of an exemplary yarn package that may be produced. [Figure 4A] Figure 2 is a side view of another exemplary yarn package that may be produced. [Figure 4B] Figure 2 is a side view of another exemplary yarn package that may be produced. [Figure 5] Another embodiment of the thread guide and winding subassembly shown in Figure 1 is presented. [Figure 6A] Figure 5 is a side view of an embodiment of a yarn package that may be produced. [Figure 6B] Figure 5 is a side view of an embodiment of a yarn package that may be produced. [Figure 7] Another embodiment of the thread guide and winding subassembly shown in Figure 1 is presented. [Figure 8] Figure 7 is a side view of an exemplary yarn package that may be produced. [Figure 9] Another embodiment of the thread guide and winding subassembly shown in Figure 1 is presented. [Figure 10A] Figure 9 is a side view of an exemplary yarn package that may be produced. [Figure 10B] Figure 9 is a side view of an exemplary yarn package that may be produced. [Modes for carrying out the invention]

[0011] This application generally relates to systems and methods for use in increasing the production of cellulosic yarns, and yarn packages produced therefrom. Yarn production is increased by expanding the production capacity of existing fiber spinning machines and / or by switching other assets (e.g., corn production assets) to yarn production assets. Such yarns can be utilized, for example, in expanded application opportunities in downstream fiber replacement applications and end-use clothing applications. The yarn can be manufactured by any type of dry spinning process or wet spinning process known in the art. In one embodiment, wet spinning is defined as a process of dissolving at least one polymer in at least one solvent to create a liquid solution. The solution is passed through a spinneret and then contacted with a coagulation bath, whereby the liquid solidifies into fibers. In another embodiment, dry spinning is defined as a process in which at least one polymer is dissolved in at least one solvent and then extruded. As the fiber exits through the spinneret, the solvent evaporates.

[0012] Fiber spinning machines often include multiple spinnerets per cabinet, each of which generates a yarn end, which is then wound around a respective separate core. As disclosed herein, by varying various sub-assemblies (i.e., spinning, finish application, texturing, yarn guiding, and / or winding) of an exemplary production system, an increase in the yarn output of the production system is facilitated. Specifically, in one embodiment, at least one of the spinnerets used to form filaments is modified to output two or more separate filament groups, each of which manufactures individual textured yarns therefrom. Next, the multiple yarns are wound in a winding configuration around the same core, with each yarn end being individually wound from the core. By winding two or more yarns around the same core, the winding capacity of an existing spinning machine is increased without changing the winding system, such as by increasing the number of winding machines, to accommodate the additional cores required to accept any yarn end.

[0013] Therefore, the yarn package configuration disclosed herein makes it possible to increase yarn output per cabinet while producing separate yarn end packages that can be easily separated from each other when wound from a common core. The yarn packages disclosed herein also offer high versatility to meet customer needs for various package sizes and configurations. Furthermore, although the embodiments disclosed herein are disclosed in relation to the production of cellulosic yarns, it should be understood that the embodiments disclosed herein can also be applied to the production of non-cellulosic yarns and fibers.

[0014] The fibers, filaments, and / or yarns described herein may be formed from one or more cellulose esters, including but not limited to cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate formate, cellulose acetate propionate, cellulose acetate butyrate, cellulose propionate butyrate, and mixtures thereof. While “cellulose acetate” is used herein by reference, it should be understood that one or more of the above-mentioned cellulose acid esters or mixed esters may be used to form the fibers, nonwovens, and products described herein. Various types of cellulose esters are described, for example, in U.S. Patent Nos. 1,698,049, 1,683,347, 1,880,808, 1,880,560, 1,984,147, 2,129,052, and 3,617,201, each of which is incorporated herein by reference to the extent not inconsistent with this disclosure. In some cases, other types of treated or recycled cellulose (e.g., viscose, rayon, cupro, modal, or lyocell) may or may not be used in forming the fibers described herein. In some cases, other types of recycled component materials may or may not be used in forming the fibers described herein. Examples of recycled component materials include, but are not limited to, textiles, nonwovens, yarns, plastics, and plastic blends.

[0015] When the fibers described herein are formed from cellulose acetate, the fibers described herein can be formed from cellulose diacetate, cellulose triacetate, or mixtures thereof. Cellulose acetate (or other cellulose esters) useful in embodiments of the present invention can have a degree of substitution of 2.2 to 3, 2.25 to 2.8, 2.35 to 2.8, or 2.4 to 2.7. As used herein, the term "degree of substitution" or "DS" refers to the average number of acetyl substituents per anhydroglucose ring of the cellulose polymer, and the maximum degree of substitution is 3.0. In some cases, the cellulose acetate used to form the fibers described herein can have an average degree of substitution of at least about 1.95, 2.0, 2.05, 2.1, 2.15, 2.2, 2.25, or 2.3, and / or about 2.9, 2.85, 2.8, 2.75, 2.7, 2.65, 2.6, 2.55, 2.5, 2.45, 2.4, or 2.35 or less, and the proportion of cellulose acetate with a degree of substitution exceeding 2.15, 2.2, or 2.25 is more than 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99 percent. In some cases, more than 90 percent of the cellulose acetate can have a degree of substitution exceeding 2.2, 2.25, 2.3, or 2.35.

[0016] Cellulose acetate may have a weight average molecular weight (Mw) of 90,000 or less, measured using gel permeation chromatography with N-methyl-2-pyrrolidone (NMP) as the solvent. In some cases, cellulose acetate can have a molecular weight of at least about 10,000, at least about 2,000, 25,000, 30,000, 35,000, 40,000, or 45,000, and / or about 90,000, 85,000, 80,000, 75,000, 70,000, 65,000, 60,000, or 50,000 or less, and / or a molecular weight of 10,000 to 90,000, 20,000 to 80,000, 30,000 to 70,000, or 40,000 to 60,000.

[0017] Referring here to the drawings, Figure 1 is a schematic diagram of an exemplary yarn production system 100. Cellulose acetate or other cellulose esters used in the manufacture of cellulose acetate fibers and / or yarns described herein can be formed by any suitable method known in the art. The process can be carried out in batch or continuously. In some cases, cellulose acetate can be formed by reacting a cellulosic material, such as wood pulp, with anhydride acetic acid and a catalyst in an acidic reaction medium to form cellulose acetate flakes. The cellulosic material and / or anhydride acetic acid may contain recycled components from multiple sources, as disclosed in U.S. Patent Application No. 63 / 374,127, “Cellulose Esters and Cellulose Ester Fibers Having Recycled Content From Multiple Sources,” and are incorporated herein by reference to the extent that they do not contradict any description herein. The flakes can then be dissolved in a solvent such as acetone or methyl ethyl ketone to form a solvent "dope," which can be filtered and fed through at least one spinneret 102, as shown in Figure 1, to form continuous cellulose acetate filaments or fibers 103. In some cases, depending on the desired properties and the final use of the final fiber, titanium dioxide or other matting agents may be added to the dope before filtration, up to about 1 weight percent or more. In other embodiments, titanium dioxide and / or other matting agents less than 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, or 0.01 are added. In other embodiments, the dope is substantially free of titanium dioxide and / or other matting agents.

[0018] In some cases, the solvent dope or flake used to form cellulose acetate fibers may contain little to no additives other than cellulose acetate. Such additives may include, but are not limited to, pigments, colorants, antimicrobial agents, UV stabilizers, flame retardants, antioxidants, heat stabilizers, oxidation promoters, acid scavengers, inorganic substances, photodegraders, biodegraders, degradation promoters, polyesters, enzymes, microorganisms, water-soluble polymers, modified cellulose acetate, water-dispersible additives, nitrogen-containing compounds, hydroxyl-functional compounds, oxygen-containing heterocyclic compounds, sulfur-containing heterocyclic compounds, anhydrides, and monoepoxides, or combinations thereof. In some cases, the cellulose acetate fibers described herein may contain at least about 90, 90.5, 91, 91.5, 92, 92.5, 93, 93.5, 94, 94.5, 95, 95.5, 96, 96.5, 97, 97.5, 98, 98.5, 99, 99.5, 99.9, 99.99, 99.995, or 99.999 percent cellulose acetate, based on the total weight of the fibers. Fibers formed according to the present invention may contain additives other than cellulose acetate, including certain additives listed herein, in amounts of about 10, 9.5, 9, 8.5, 8, 7.5, 7, 6.5, 6, 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.5, 0.1, 0.01, 0.005, or 0.001 percent by weight or less.

[0019] Cellulose acetate fibers can achieve higher levels of biodegradability and / or compostability without the use of additives that have conventionally been used to promote the non-sustainability of similar fibers in the environment. Such additives include, for example, photodegraders, biodegraders, decomposition accelerators, and various other types of additives. Despite being substantially free of these types of additives, cellulose acetate fibers and products derived therefrom have been unexpectedly found to exhibit improved biodegradability and compostability when tested under industrial, household, and / or soil conditions.

[0020] In some embodiments, the cellulose acetate fibers described herein may be substantially free of photodegrading agents. For example, the fibers may contain less than or equal to about 1, 0.75, 0.50, 0.25, 0.10, 0.05, 0.025, 0.01, 0.005, 0.0025, or 0.001 weight percent of a photodegrading agent based on the total weight of the fibers, or the fibers may be free of a photodegrading agent. Examples of such photodegrading agents include, but are not limited to, pigments that act as photo-oxidation catalysts and are selectively enhanced by the presence of one or more metal salts, oxidation accelerators, and combinations thereof. The pigments may include coated or uncoated anatase or rutile titanium dioxide, which may exist alone or in combination with one or more enhancing components such as various types of metals. Other examples of photodegrading agents include benzoin, benzoin alkyl ethers, benzophenone and its derivatives, acetophenone and its derivatives, quinone, thioxanthone, phthalocyanine and other photosensitizers, ethylene-carbon monoxide copolymers, aromatic ketone-metal salt sensitizers, and combinations thereof.

[0021] In some embodiments, the cellulose acetate fibers described herein may be substantially free of biodegradables and / or degrading agents. For example, the fibers may contain biodegradables and / or degrading agents in amounts of about 1, 0.75, 0.50, 0.25, 0.10, 0.05, 0.025, 0.01, 0.005, 0.0025, 0.0020, 0.0015, 0.001, or 0.0005 percent by weight or less, based on the total weight of the fibers, or the fibers may be free of biodegradables and / or degrading agents. Examples of such biodegradables and degrading agents include, but are not limited to, salts of phosphorus oxygen acids, esters or salts of phosphorus oxygen acids, carbonates or salts thereof, phosphorus oxygen acids, sulfur oxygen acids, nitrogen oxygen acids, partial esters or hydrogen salts of these oxygen acids, carbonates and their hydrogen salts, sulfonic acids, and carboxylic acids.

[0022] Other examples of such biodegradable and degrading agents include oxoacids having 2 to 6 carbon atoms per molecule, saturated dicarboxylic acids having 2 to 6 carbon atoms per molecule, and organic acids selected from the group consisting of lower alkyl esters of oxoacids or saturated dicarboxylic acids with alcohols having 1 to 4 carbon atoms. Biodegradable agents may also include enzymes such as lipases, cellulases, esterases, and combinations thereof. Other types of biodegradable and degrading agents include cellulose phosphate, starch phosphate, dicalcium phosphate, tricalcium phosphate, calcium hydroxide phosphate, glycolic acid, lactic acid, citric acid, tartaric acid, malic acid, oxalic acid, malonic acid, succinic acid, succinic anhydride, glutaric acid, acetic acid, and combinations thereof.

[0023] The cellulose acetate fibers described herein may also be substantially free of several other types of additives that have been added to other fibers to promote non-sustainability in the environment. Examples of these additives include, but are not limited to, polyesters including aliphatic polyesters and low molecular weight (e.g., less than 5000) polyesters, enzymes, microorganisms, water-soluble polymers, modified cellulose acetates, water-dispersible additives, nitrogen-containing compounds, hydroxyl-functional compounds, oxygen-containing heterocyclic compounds, sulfur-containing heterocyclic compounds, anhydrides, monoepoxides, and combinations thereof. In some cases, the fibers described herein may contain less than about 0.5, 0.4, 0.3, 0.25, 0.1, 0.075, 0.05, 0.025, 0.01, 0.0075, 0.005, 0.0025, or 0.001 weight percent of these types of additives, or the cellulose acetate fibers may contain none of these types of additives.

[0024] Returning to Figure 1, the dope can be extruded through multiple holes in the spinneret 102 into the vertical rotating cabinet 104 to form a continuous cellulose acetate filament. In the spinneret 102, the filament 103 can be stretched into hundreds or thousands of individual filaments. Each spinneret surface has one or more groups of holes for generating groups of filaments, and individually entangled cellulosic yarns are produced from each group of filaments. Each of these groups can contain 2-300, 4-300, 8-150, 12-75, or 15-30 holes, producing a yarn of the corresponding number of fibers. That is, each group of filaments can contain 2-300, 4-300, 8-150, 12-75, or 15-30 individual fibers. The spinneret 102 can operate at any speed suitable for producing filaments of the desired size and shape.

[0025] As used herein, “entanglement” refers to the physical binding of groups of filaments to one another through deformation and entanglement of the filaments. For example, filaments can be entangled by twisting and / or air jetting. Thus, each individual entangled filament is not entangled with one another. Rather, only the groups of filaments in these individually entangled or separately entangled filaments are entangled with one another.

[0026] Individual bundles can be assembled as filament yarn, as will be described in more detail below. As used herein, “filament yarn” or “tow yarn” refers to a yarn formed from multiple continuous, untwisted individual filaments. The filament yarn can be of any preferred size, and in some embodiments, the total denier can be 10–3000, 20–500, 30–300, 40–150, or 50–100.

[0027] The individual filaments, which are generally extruded to align longitudinally and ultimately form a filament yarn, can also be of any preferred size. For example, each filament can have a linear denier (weight per 9000 m fiber length, g) of 0.25–50, 0.5–25, 1–10, 2–6, or 3–5, as measured using the FAVIMAT vibrometer method according to ASTM D1577-01. As used herein, the term “filament” refers to an elongated, continuous single fiber and is distinguished from short fibers cut to a specific length.

[0028] Individual filaments discharged from the spinneret can have any preferred cross-sectional shape. Exemplary cross-sectional shapes include, but are not limited to, circular or any other non-circular (irregular) shape, such as I-shaped (dogbone), ribbon-like or strip-like, closed C-shaped, tri-lobed, multi-lobed, X-shaped, or small crenate. If a filament has a multi-lobed cross-sectional shape, it may have at least four, five, or six or more lobes. In some cases, a filament may be symmetrical along one, two, three, or four or more axes, and in other embodiments, the filament may be asymmetrical. As used herein, the term “cross-section” generally refers to the cross-section of the filament relative to its longitudinal axis. The cross-section of a filament can be determined and measured using quantitative image analysis (QIA).

[0029] In some embodiments, the cross-sectional shape of individual filaments can be characterized according to their deviation from a circular cross-sectional shape. In some cases, this deviation can be characterized by a shape factor of the filament, which is determined by the following formula: shape factor = perimeter / (4π × cross-sectional area) 1 / 2In some embodiments, the shape factor of the individual cellulose acetate (or other cellulose ester) filaments or fibers is at least about 1, 1.01, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.45, 1.5, 1.55, 1.6, 1.65, 1.7, 1.75, 1.8, 1.85, 1.9, 1.95, 2, 2.25, 2.5, 2.75, 3, or 3.25 and / or about 5, 4.8, 4.75, 4.5, 4.25, 4, 3.75, 3.5, 3.25, 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, or 1.25 or less. (Note: These values ​​may also be expressed as a ratio of the enumerated numbers to 1 (e.g., 1.45:1).) The shape factor of a filament or fiber having a circular cross-sectional shape is 1. The shape factor can be calculated from the cross-sectional area of ​​the filament or fiber, and these can be measured using QIA.

[0030] Furthermore, the cross-sectional shape of the filament or fiber can also be compared to a circular cross-section according to its equivalent diameter, where the equivalent diameter is equivalent to the diameter of a circular filament or fiber having the same cross-sectional area as a given filament or fiber. In some embodiments, the cellulose acetate filaments or fibers according to embodiments of the present invention have diameters of at least about 0.0022, 0.0023, 0.0024, 0.0025, 0.0030, 0.0033, 0.0035, 0.0040, 0.0045, 0.0050, 0.0055, 0.0060, 0.0065, 0.0070 It can have an equivalent diameter of 0.0073, 0.0075, 0.0080, 0.0085, 0.0090, 0.0095, 0.0100, 0.0103, 0.0104, 0.0105, 0.0110, 0.0112, 0.0115, 0.0120, 0.0125, 0.0126, 0.013, 0.014, or 0.015 mm. Alternatively, or in addition, cellulose acetate filaments or fibers may have an equivalent diameter of approximately 0.0400, 0.0375, 0.036, 0.0359, 0.0350, 0.0033, 0.0327, 0.0325, 0.0300, 0.0275, 0.0250, 0.0232, 0.0225, 0.0200, 0.0179, 0.0175, 0.016, 0.0150, 0.0127, 0.0125, or 0.0120 mm or less. The equivalent diameter is calculated from the cross-section of the filament or fiber measured using QIA.

[0031] In another embodiment of the present invention, the cross-section of the cellulose acetate fiber is formed with many lobes. Although we do not wish to be bound by theory, after the dope is spun through a spinneret, the spun dope can have a circular cross-section. After the solvent rapidly evaporates from the surface, a skin layer may form on the surface of the fiber. Subsequently, as the solvent evaporates from the inside of the fiber, the skin layer can collapse toward the cross-section of the fiber, resulting in a final multi-lobed cross-section. In yet another embodiment, the cross-section can be small crenose-serrated, defined as having an irregular wavy or sawtoothed contour.

[0032] According to some embodiments, filaments or fibers 103 discharged from cabinet 104 can be at least partially coated with at least one fiber finishing agent by at least one finishing agent applicator 106 to produce coated fibers 107. As used herein, the terms “fiber finishing agent” and “finishing agent” refer to any suitable type of coating that, when applied to a fiber, modulates the friction applied by and to the fiber, thereby altering the relative mobility of the fibers with respect to each other and / or the surface of the fiber. A finishing agent is different from an adhesive, binder, or other similar chemical additive that, when applied to a fiber, prevents movement between fibers by causing them to stick together. A finishing agent, once applied, still allows movement of fibers with respect to each other and / or other surfaces, but can modulate the ease of this movement by increasing or decreasing the frictional force. In some cases, the finishing agent does not modulate the frictional force between fibers, but instead can impart one or more other desirable properties to the finally coated fiber.

[0033] In some embodiments, a filament or yarn may have at least two finishing agents applied to all or part of its surface at one or more points in the fiber manufacturing process. In other cases, the fiber may contain only one finishing agent, or the fiber may contain no finishing agent at all. When two or more finishing agents are applied to the fiber, these finishing agents may be applied as a blend of two or more different finishing agents, or they may be applied separately at different times in the process. For example, in some cases, the fiber may be at least partially coated with a spinning or spinning finishing agent applied to the filament yarn at one or more points in the process of forming the fiber. For example, in some embodiments, the spinning finishing agent may be added to the fiber immediately after spinning. Alternatively, or in addition, the spinning finishing agent may be added to the filament yarn immediately before any subsequent fiber processing, such as texturing or crimping, if applicable. In some cases, no spinning finishing agent may be applied.

[0034] For the application of the spinning finish agent, any suitable method may be used, such as spraying, brushing, dipping, or using a squeeze roller, lick roller, or kiss roller. When used, the spinning finish agent can be any suitable type and may provide at least about 0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.70, 0.80, 0.90, or 1 percent of finish-on-yarn (FOY) on the filament or fiber. Alternatively, or in addition, the finishing agent may be applied in amounts of approximately 10.0, 9.0, 8.0, 7.0, 6.0, 5.0, 4.0, 3.0, 2.0, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.90, 0.80, 0.75, 0.70, 0.65, 0.60, or 0.50 percent or less of finishing agent (FOY) based on the total weight of the dry fiber. As used herein, “FOY” or “finish-on-yarn” means the amount of finishing agent on the fiber or filament, excluding added moisture. One or more types of finishing agents may be used. In some cases, the finishing agent may be hydrophobic.

[0035] Furthermore, in some embodiments, the topcoat (and / or spinning) finishing agent may include other additives, such as antistatic agents. Additionally, the finishing agent may also include one or more other additives, such as wetting agents, antioxidants, biocides, rust inhibitors, pH adjusters, emulsifiers, and combinations thereof. It is also possible to add one or more additives that do not add friction-modifying properties to the fibers as a coating.

[0036] If an antistatic agent is present, any suitable antistatic agent may be used, and in some cases the antistatic agent may include polar compounds and / or hydrophilic compounds. If additives are used, any appropriate amount, for example, based on the total weight of the fibers, of at least about 0.10, 0.15, 0.20, 0.25, 0.30, or 0.35 weight percent and / or about 3, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.90, 0.80, 0.70, 0.60, or 0.50 weight percent or less of the additive may be used.

[0037] When fibers are coated with an antistatic finish, the coated fibers may exhibit an electrostatic half-life of approximately 100, 90, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 22, 20, 17, 15, 12, 10, 8, 5, 3, 2, 1.5, or 1 second or less, as measured according to AATCC 84-2011. In some embodiments, the fibers may have an electrostatic half-life of approximately 30, 25, 20, 18, 15, 12, 10, or 8 minutes or less. In other embodiments, the half-life of the electrostatic charge of the coated fiber may be at least about 30 seconds, at least about 1 minute, at least about 5, 8, 10, 15, 20, 30, 40, 50, 60, 75, 9 or 100 minutes, and / or within about 120, 110, 100, 90, 75, 60, 45, 40, 35, 30, 20, 15 or 12 minutes, as measured according to AATCC 84-2011.

[0038] In some embodiments, this half-life may be 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5 percent or less of the half-life of the static electricity of the same but uncoated fiber. In some embodiments, the half-life of the static electricity of the coated fiber may be at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent less than the half-life of the static electricity of the same but uncoated fiber.

[0039] Alternatively, or in addition, the coated fibers described herein may have a surface resistivity (Log R) of at least about 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, or 9 and / or about 11, 10.5, 10, 9.75, 9.5, 9.25, 9, 8.75, 8.5, 8.25, 8, 7.75, 7.5 or less, measured in accordance with AATCC TM76-2011. Surface resistivity was measured using a Monroe Electronics resistivity meter (model 272A) connected to a Keithley Instruments insulating box (model 6104), using an insulating cup for measuring the resistivity of the fiber. Surface resistivity (Log R) was calculated by multiplying the surface resistance by the ratio of the length of the test area to the width, and expressing the result as a base-10 logarithm of the calculated value.

[0040] In some embodiments, the fiber or filament yarn can be at least partially coated with at least one spinning finish agent and at least one topcoat finish agent. The total amount of all finishing agents applied to the fibers or filament yarn according to embodiments of the present invention may be at least about 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.0, or 1.05 percent FOY, and / or about 10, 9, 8, 7, 6, 5, 4, 3, 2, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, 0.90, 0.80, 0.75, 0.70, 0.65, 0.60, 0.55, 0.50, or 0.45 percent FOY, based on the total weight of the dry fibers. The amount of finishing agent on the fibers, expressed as a weight percentage, can be measured by solvent extraction according to ASTM D2257.

[0041] In some cases, when the filament yarn is coated with a spinning finish agent and / or a topcoat finish agent, the filament yarn may exhibit a fiber-to-fiber (F / F) coefficient of friction (COF) of at least about 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, or 0.40 and / or about 0.55, 0.50, 0.45, 0.42, 0.40, 0.35, 0.33, 0.30, 0.25, 0.20, 0.15, 0.14, 0.13, 0.12, 0.11, 0.10, 0.09, 0.08, 0.07, or 0.06 or less. The F / F coefficient of friction (COF) of a continuous filament can be measured according to ASTM D3412, with specific yarn parameters, a speed of 100 m / min, an input tension of 10 grams, and with a single twist applied to the filament.

[0042] In another embodiment, the yarn described herein may have an F / F friction coefficient value measured using a continuous tension tester electronic device (CTT-E) with specific yarn parameters, a speed of 20 m / min, an input tension of 10 grams, and a single twist applied to the filament, in accordance with ASTM D3412, which may fall within one or more of the above ranges.

[0043] Furthermore, filament yarns coated with spinning finishing agents and / or topcoat finishing agents according to embodiments of the present invention may exhibit fiber-to-metal (F / M) friction coefficients of at least about 0.01, 0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.57, 0.60, or 0.65 and / or about 0.80, 0.75, 0.70, 0.65, 0.60, 0.55, 0.50, 0.45, or 0.40 or less. The F / M friction coefficient (COF) value of a continuous filament can be measured according to ASTM D3108 with specific yarn parameters, a speed of 100 m / min, and an input tension of 48 grams.

[0044] In another embodiment, the yarn described herein may have an F / M friction coefficient value measured using a continuous tension tester electronic device (CTT-E) with specific yarn parameters, a speed of 100 m / min, and an input tension of 10 grams, according to ASTM D3108, which may fall within one or more of the above ranges.

[0045] The coated fibers described herein may also exhibit strengths exceeding expectations. For example, in some embodiments, the coated fibers, as measured according to ASTM D3822, have at least about 0.5, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.0, 1.05, 1.1, 1.15, 1.20, 1.25, 1.30, or 1.35 gram force / denier (g / denier) and / or 2.50, 2.45, 2.40, 2.35, 2.30, 2.25 It can be formed from filaments exhibiting tensile strengths of 2.20, 2.15, 2.10, 2.05, 2.00, 1.95, 1.90, 1.85, 1.80, 1.75, 1.70, 1.65, 1.60, 1.55, 1.50, 1.47, 1.45, or 1.40 g / denier and / or 0.5–3.0, 1–2, or 1.25–1.5 g / denier. Furthermore, in some embodiments, the elongation at break of the coated fiber can be at least about 5, 6, 10, 15, 20, or 25 percent and / or about 50, 45, 40, 35, or 30 percent or less and / or 5–50, 10–40, or 20–30, as measured according to ASTM D3822.

[0046] In one embodiment of the present invention, the fibers and filament yarns described herein contain little to no plasticizers and unexpectedly exhibit high biodegradability under industrial, household, and soil conditions, even when compared to cellulose acetate fibers with higher plasticizer content.

[0047] In some embodiments, the fibers described herein may contain or be free of plasticizers in amounts less than approximately 50, 30, 27, 25, 22, 20, 17, 15, 12, 10, 9.5, 9, 8.5, 8, 7.5, 7, 6.5, 6, 5.5, 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.5, 0.25, or 0.10 percent, based on the total weight of the fiber and / or yarn. Where plasticizers are present, they may be incorporated into the fiber itself by solvent doping or blending with cellulose acetate flakes, or they may be applied to the surface of the fiber or filament by spraying, centrifugal force from a rotating drum device, or immersion bath.

[0048] Examples of plasticizers that may or may not be present in or on the fibers include, but are not limited to, aromatic polycarboxylic acid esters, aliphatic polycarboxylic acid esters, lower fatty acid esters of polyhydric alcohols, and phosphate esters. Further examples include, but are not limited to, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, dihexyl phthalate, dioctyl phthalate, dimethoxyethyl phthalate, ethyl phthalyl ethyl glycolate, butyl phthalyl butyl glycolate, tetraoctyl pyromelitate, trioctyl trimelitate, dibutyl adipate, dioctyl adipate, dibutyl sebacate, dioctyl sebacate, diethyl azelaate, dibutyl azelaate, dioctyl azelaate, glycerol, trimethylolpropane, pentaerythritol, sorbitol, glycerin triacetate (triacetin), diglycerin tetraacetate, triethyl phosphate, tributyl phosphate, tributoxyethyl phosphate, triphenyl phosphate, and tricresyl phosphate, as well as combinations thereof. In some embodiments, the fibers of the present invention may not contain any type of plasticizer or other additives, and may consist of, or essentially consist of, cellulose acetate and a spinning finish agent with a FOY of 1 percent or less.

[0049] Furthermore, the cellulose acetate fibers described herein may not have undergone additional processing steps designed to enhance the biodegradability of the fibers. For example, the fibers may not be hydrolyzed or treated with enzymes or microorganisms. The fibers may contain adhesives or binders in amounts of about 1, 0.75, 0.5, 0.25, 0.1, 0.05, or 0.01 weight percent or less, and may contain 1, 0.75, 0.5, 0.25, 0.1, 0.05, or less than 0.01 weight percent of modified or substituted cellulose acetate. In some embodiments, the fibers may not contain any adhesives or binders and may not be formed from any substituted or modified cellulose acetate. The substituted or modified cellulose acetate may include cellulose acetate modified with polar substituents, such as substituents selected from the group consisting of sulfates, phosphates, borates, carbonates, and combinations thereof.

[0050] In one embodiment, after a finishing agent has been applied, the cellulose acetate fibers are passed through at least one discharged entanglement (TF) jet released from at least one entanglement nozzle 108. The TF jet exposes the cellulose acetate fibers to turbulent air, thereby forming one or more nodes along the length of the yarn. The formation of these nodes facilitates the spinning, weaving, knitting, and processability of the yarn. In one embodiment, or in combination with any of the other embodiments mentioned, the TF jet may be sprayed at a pressure of 10 to 30 pounds per square inch (psi). In one embodiment, or in combination with any of the other embodiments mentioned, the yarn has an entanglement node density of 1 to 50, 2 to 30, 4 to 20, or 6 to 15 per foot.

[0051] In some embodiments, the individual entangled yarns formed from the resulting cellulose acetate fibers have a water content of 3.5–30 percent, 3.5–25 percent, 3.5–20 percent, 3.5–15 percent, 4–10 percent, 4–8 percent, or 5–7 percent based on the total weight of the yarn. Furthermore, in some embodiments, the individual entangled yarns formed from the resulting cellulose acetate fibers have a residual solvent content of 0–30 percent, 2–20 percent, or 4–15 percent based on the total weight of the yarn.

[0052] In some embodiments, after entanglement, the resulting individual entangled yarns 109 are sent to at least one winder 112 via at least one yarn guide 110. As will be described in more detail below, the newly formed yarns can be accumulated on a core or tube, the core or tube can be removed from the winder 112, and the resulting individual entangled yarns are wound around the core or tube as individual yarn packages of cellulose material.

[0053] Referring here to Figures 2-10, the yarn guide 110 receives multiple individually entangled yarns 109 entangled by the entanglement nozzle 108 (shown in Figure 1), and then feeds the yarns 109 toward the winder 112 to produce one or more yarn packages. Specifically, each yarn guide 110 includes a guide arm 116 capable of individually guiding one or more yarns 109 toward the winder 112. Each winder 112 includes a rotatable winding frame 118, and at least one core 120 is detachably coupled to the rotatable winding frame 118 and rotatable with the rotatable winding frame 118, thereby allowing the yarns 109 to be wound onto or co-wound with the core. As will be described in more detail below, each winding frame 118 can accommodate multiple cores 120 on it. In this way, multiple individually entangled yarns 109 can be wound around each common core 120. In one embodiment, or in combination with any of the other embodiments mentioned, the number of threads wound onto or co-wound with the core 120 is 20 or less, 15 or less, 10 or less, 5 or less, or 4 or less.

[0054] As used herein, "co-winding" refers to winding two or more threads 109 around a common core simultaneously.

[0055] As described above, the spinneret 102 (shown in Figure 1) is modified to output one or more separate filament groups, each generating individual entangled yarns 109. Thus, in one embodiment, or in combination with any of the other embodiments mentioned, the yarns 109 originate from the same spinneret.

[0056] In one embodiment, or in combination with any of the other embodiments mentioned, the core 120 has a substantially cylindrical shape. In other words, the core 120 does not include a flange or other structure defined at the end of the core 120 for supporting the yarn wound onto the core 120 from the side.

[0057] In one embodiment, or in combination with any of the other embodiments mentioned, the core 120 has a length of 2 to 24 inches, 4 to 12 inches, or 5 to 8 inches.

[0058] In one embodiment, or in combination with any of the other embodiments mentioned, the core 120 is made of a non-metallic material. Examples of non-metallic materials include corrugated cardboard and / or plastic materials.

[0059] In one embodiment, at least two individual entangled yarns 109 are wound around a common core 120 to define one or more yarn sections on the core. Each yarn section can co-wind one or more individual entangled yarns together around the core 120. These yarns 109 are not twisted together on the core 120. That is, even when one or more yarns 109 are fed from a single guide arm 116 toward the winder 112, these yarns 109 are not permanently twisted or entangled before reaching the winder 112, but are combined and co-wound on the core 120. Thus, each yarn 109 can be wound individually from the core 120.

[0060] As used herein, “individually wound,” “individually windable,” and their variations mean that threads can be wound simultaneously and / or sequentially from each core and are separable from one another. As used herein, “simultaneously wound,” “simultaneously windable,” and their variations mean that threads can be wound simultaneously from each core and are separable from one another. As used herein, “sequentially wound” and “sequentially windable” mean that one thread can be wound from a core without winding another thread from the same core.

[0061] For example, referring specifically to Figures 2 to 4, the first guide arm 122 feeds the first yarn 124 toward the first core 126 on the first reel 127, the second guide arm 128 feeds the second yarn 130 toward the second core 129 on the first reel 127, the third guide arm 132 feeds the third yarn 134 toward the third core 131 on the second reel 133, and the fourth guide arm 138 feeds the fourth yarn 140 toward the fourth core 135 on the second reel 133. In this way, the yarns 124, 130, 134, and 140 are wound around their respective cores 126, 129, 131, and 135 to simultaneously produce four yarn packages 142.

[0062] Referring to Figures 3 and 4, a first reel 127 and two yarn packages 142 formed thereon are shown. For example, one yarn package 142 includes a first core 126 and a first yarn section 144 formed from a first yarn 124, while the other yarn package 142 includes a second core 129 and a second yarn section 146 formed from a second yarn 130. Thus, each yarn package 142 is individually detachable from the first reel 127. For example, the yarn package 142 associated with the first core 126 can be removed, and then the yarn package 142 associated with the second core 129 can be removed. Thus, the size and weight of the package sections are reduced, which improves the processability of the yarn 109 wound on the package sections.

[0063] In one embodiment, the threads 124 and 130 can be wound around a common core to form thread sections 144 and 146 on the common core, similar to those shown in Figures 3 and 4. For example, as also shown in Figure 3A, such a multi-section thread package may include thread sections 144 and 146 spaced apart from each other on the common core. Alternatively, as also shown in Figure 4A, such a multi-section thread package may include thread sections 144 and 146 adjacent to each other and substantially in contact with each other on the common core to enhance the stability of the thread package. Therefore, the yarn 109 can be wound around separate sections of the common core, which increases the winding capacity of the cabinet 104 (shown in Figure 1) while also allowing the yarn 109 to be wound individually from the common core.

[0064] As used herein, “separate sections” of the core are defined as the space between two parallel planes that extend perpendicular to the longitudinal axis of the core.

[0065] Referring now to Figures 5 and 6, in one embodiment, a first guide arm 122 feeds a first yarn 124 toward a first core 126, a second guide arm 128 feeds a second yarn 130 toward the first core 126, a third guide arm 132 feeds a third yarn 134 toward the second core 129, and a fourth guide arm 138 feeds a fourth yarn 140 toward the second core 129. The yarns 124 and 130 are wound around separate sections of the first core 126, and the yarns 134 and 140 are wound around separate sections of the second core 129 to produce two multi-section yarn packages 150. For example, referring to Figure 6, one yarn package 150 includes a first core 126, a first yarn section 152 formed from the first yarn 124, and a second yarn section 154 formed from the second yarn 130. The other yarn package 150 includes a second core 129, a third yarn section 156 formed from a third yarn 134, and a fourth yarn section 158 formed from a fourth yarn 140. The yarn sections 152, 154, 156, and 158 may be spaced apart from each other, or they may be adjacent to each other on their respective cores 126 and 129 and substantially in contact with each other.

[0066] Therefore, the yarn 109 can be wound around separate sections of the first core 126 and the second core 129, thereby increasing the winding capacity of the cabinet 104 (shown in Figure 1) while allowing the yarn 109 to be wound individually from each core.

[0067] In an alternative embodiment, the threads 124, 130, 134, and 140 can be wound around a common core 120 to form a single package 155 having thread sections 152, 154, 156, and 158 on the common core, similar to the package shown in Figure 6A.

[0068] Referring here to Figures 7 and 8, in one embodiment, the first guide arm 122 feeds the first yarn 124 and the second yarn 130 toward the fifth core 157, and the second guide arm 128 feeds the third yarn 134 and the fourth yarn 140 toward the sixth core 159. Specifically, the yarn pairs are combined in the respective guide arms 122 and 128, but are not twisted or permanently entangled before being wound onto the respective cores 157 and 159. Thus, the yarn pairs define a combined yarn 160 that is wound around the respective cores 157 and 159, thereby enabling the simultaneous production of two yarn packages 162. For example, referring to Figure 8, the yarn package 162 includes a combined yarn 160 wound around at least one common section of the first core 157. In one embodiment, the combined yarn 160 is co-wound around the core 157 along the length direction of the core. Therefore, the yarn package 162 has a section formed by winding one or more threads onto the yarn package.

[0069] As used herein, “combined” means two or more threads that occupy at least one common section of a core. Combined threads can be wound individually from the core (i.e., wound simultaneously with separate threads, not sequentially).

[0070] Referring here to Figures 9 and 10, in one embodiment, the first guide arm 122 feeds the first yarn 124 and the second yarn 130 toward the first core 129, and the second guide arm 128 feeds the third yarn 134 and the fourth yarn 140 toward the second core 126. Specifically, the yarn pairs are combined in the respective guide arms 122 and 128, but they are not twisted or permanently entangled before being wound onto the first core 129 and the second core 126. The yarn pairs define combined yarns 164 and 166 that are wound around the respective cores 126 and 129, and multiple yarn packages 168 are produced simultaneously. For example, referring to Figure 10, one yarn package 168 includes a first core 129 and a first yarn section 172 formed from a combined yarn 166, while the other yarn package 168 includes a second core 126 and a second yarn section 170 formed from a combined yarn 164. Thus, each yarn package 168 has a section formed by winding one or more yarns (i.e., combined yarns) onto its yarn package. Therefore, similar to the section packages described above, the combined yarn sections increase the winding capacity of the cabinet 104.

[0071] In one embodiment, threads 164 and 166 can be wound around a common core to form thread sections 170 and 172 on the common core, similar to the section shown in Figure 10A. Similar to the embodiments shown in Figures 3A and 4A, the thread sections 170 and 172 may be spaced apart from each other on the common core, or they may be adjacent to each other and substantially in contact with each other on the common core.

[0072] The embodiments described above are for illustrative purposes only. Using the systems and methods described herein, yarn packages having any number of yarns, combined yarns, and / or yarn sections can be manufactured.

[0073] In one embodiment, or in combination with any of the other embodiments mentioned, the yarn 109 is wound around each core 120 in a spiral pattern. For example, each core may have a longitudinal axis 174, and the yarn 109 can be wound around the core at an angle of 0.1 to 89 degrees, 0.1 to 60 degrees, 1 to 30 degrees, 2 to 20 degrees, or 5 to 12 degrees with respect to the longitudinal axis 174. Thus, the yarn can be accumulated along the longitudinal direction of the core.

[0074] In one embodiment, or in combination with any of the other embodiments mentioned, the yarn package manufactured as described above may have a combined weight including at least the core and the yarn wound on the core of 1 to 40 pounds, 2 to 3 pounds, 4 to 20 pounds, or 5 to 15 pounds.

[0075] In one embodiment, or in combination with any of the other embodiments mentioned, each winding section may have a width defined with respect to the longitudinal axis 174 of 1 to 8 inches, 1.5 to 6 inches, or 2 to 3 inches on the core.

[0076] The cellulose acetate fibers, filaments, and / or yarns described herein can be used to form nonwoven webs usable in several types of textile products. For example, in some cases, the coated fibers described herein may be suitable for use in forming nonwoven fibers that exhibit unexpectedly improved properties such as strength, durability, flexibility, softness, and absorbency. Furthermore, the fibers described herein exhibit unique properties such as low friction, high strength, and high durability, which facilitate the faster, more efficiently, and more uniformly processing of the fibers into nonwoven webs.

[0077] Fibers, filaments, and / or yarns, and nonwoven fabrics formed therefrom, can be biodegradable, meaning that such fibers are expected to decompose under certain environmental conditions. The degree of decomposition can be revealed by the weight loss of a sample exposed to specific environmental conditions for a predetermined period. In some cases, fibers, or materials used to form nonwoven webs or products manufactured from fibers, may show a weight loss of at least about 5, 10, 15, or 20 percent after being buried in soil for 60 days, and / or after being exposed to a typical municipal composting unit for 15 days, they may show a weight loss of at least about 15, 20, 25, 30, or 35 percent. However, the rate of decomposition may vary depending on the specific end use of the fiber, as well as the composition of the remaining product, and the specific test. Exemplary test conditions are shown in U.S. Patents 5,970,988 and 6,571,802.

[0078] In some embodiments, the cellulose acetate fibers may be biodegradable fibers, and such fibers may be used to form textile products such as fabrics, nonwovens, filters, and yarns. Unexpectedly, the cellulose acetate fibers described herein have been found to exhibit a high level of environmental non-sustainability, characterized by better-than-expected decomposition under various environmental conditions. The fibers and textile products described herein may meet or exceed the acceptance criteria set by international testing methods and authorities for industrial compostability, household compostability, and / or soil biodegradability.

[0079] To be considered "compostable," a material must meet the following four criteria: (1) it must be biodegradable; (2) it must be disintegrable; (3) it must not contain heavy metals in excess of a maximum amount; and (4) it must not be ecotoxic. As used herein, the term "biodegradable" generally refers to the tendency of a material to chemically decompose under specific environmental conditions. Biodegradability is an inherent property of the material itself, and a material may exhibit different degrees of biodegradability depending on the specific conditions to which it is exposed. The term "disintegrable" refers to the tendency of a material to physically decompose into smaller fragments when exposed to specific conditions. Disintegration depends on both the material itself and the physical size and composition of the article being tested. Ecotoxicity measures the effect of a material on plants, and the heavy metal content of a material is determined according to the procedures presented in standard test methods.

[0080] Cellulose acetate fibers can exhibit at least 70 percent biodegradation in a period of 50 days or less when tested under aerobic composting conditions at ambient temperature (28°C ± 2°C) according to ISO 14855-1 (2012). In some cases, when tested under these conditions, also known as so-called "household composting conditions," cellulose acetate fibers can exhibit at least 70 percent biodegradation in a period of 49, 48, 47, 46, 45, 44, 43, 42, 41, 40, 39, 38, or 37 days or less. These conditions may not be aqueous or anaerobic. In some cases, when tested for 50 days under household composting conditions according to ISO 14855-1 (2012), cellulose acetate fibers may exhibit total biodegradation of at least approximately 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, or 88 percent. This may represent relative biodegradation of at least approximately 95, 97, 99, 100, 101, 102, or 103 percent compared to cellulose subjected to the same test conditions.

[0081] For a material to be considered "biodegradable," it must exhibit at least 90 percent biodegradation in total under household composting conditions, according to the French standard NFT51-800 and the Australian standard AS5810 (e.g., compared to the initial sample), or at least 90 percent biodegradation of the maximum degradation of a suitable reference material after reaching a plateau for both the reference and test items. The maximum test period for biodegradation under household composting conditions is one year. The cellulose acetate fibers described herein can exhibit at least 90 percent biodegradation within one year, as measured under household composting conditions according to 14855-1 (2012). In some cases, cellulose acetate fibers may exhibit at least approximately 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 percent biodegradation within one year, as measured under household composting conditions according to 14855-1 (2012), or the fibers may exhibit 100 percent biodegradation within one year.

[0082] Furthermore, or alternatively, the fibers described herein may exhibit at least 90 percent biodegradability within approximately 350, 325, 300, 275, 250, 225, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, or 50 days, as measured under household composting conditions in accordance with ISO 14855-1 (2012). In some cases, the fibers may be at least approximately 97, 98, 99, or 99.5 percent biodegradable within approximately 70, 65, 60, or 50 days, as tested under household composting conditions in accordance with ISO 14855-1 (2012). As a result, cellulose acetate fibers can be considered biodegradable when tested under household composting conditions, for example, according to French standard NFT51-800 and Australian standard AS5810.

[0083] Cellulose acetate fibers, when tested under aerobic composting conditions at 58°C (±2°C) according to ISO 14855-1 (2012), can exhibit at least 60 percent biodegradation in a period of 45 days or less. In some cases, when tested under these conditions, also known as so-called "industrial composting conditions," the fibers can exhibit at least 60 percent biodegradation in a period of 44, 43, 42, 41, 40, 39, 38, 37, 36, 35, 34, 33, 32, 31, 30, 29, 28, or 27 days or less. These conditions may not be aqueous or anaerobic. In some cases, when tested for 45 days under industrial composting conditions according to ISO 14855-1 (2012), the fibers may exhibit total biodegradation of at least approximately 65, 70, 75, 80, 85, 87, 88, 89, 90, 91, 92, 93, 94, or 95 percent. This may represent relative biodegradation of at least approximately 95, 97, 99, 100, 102, 105, 107, 110, 112, 115, 117, or 119 percent compared to cellulose fibers subjected to the same test conditions.

[0084] To be considered "biodegradable" under industrial composting conditions, at least 90 percent of the organic carbon in the entire product (or in each component present in more than 1 percent by dry mass) must be converted to carbon dioxide by the end of the test period, in accordance with ASTM D6400 and ISO 17088 standards, compared to the control or absolute value. According to European standard ED13432 (2000), the material must exhibit at least 90 percent biodegradation in total, or at least 90 percent of the maximum biodegradation of a suitable reference material after reaching a certain state for both the reference and test items. The maximum test period for biodegradability under industrial composition conditions is 180 days. The cellulose acetate fibers described herein can exhibit at least 90 percent biodegradation within 180 days, as measured under industrial composting conditions according to 14855-1 (2012). In some cases, cellulose acetate fibers may exhibit at least about 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 percent biodegradation within 180 days, as measured under industrial composting conditions according to 14855-1 (2012), or the fibers may exhibit 100 percent biodegradation within 180 days.

[0085] Furthermore, or alternatively, the cellulose acetate fibers described herein may exhibit at least 90 percent biodegradability within approximately 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, or 45 days, as measured under industrial composting conditions according to ISO 14855-1 (2012). In some cases, cellulose acetate fibers may be at least approximately 97, 98, 99, or 99.5 percent biodegradable within approximately 65, 60, 55, 50, or 45 days, as tested under industrial composting conditions according to ISO 14855-1 (2012). As a result, the cellulose acetate fibers described herein can be considered biodegradable when tested under industrial composting conditions in accordance with ASTM D6400 and ISO 17088.

[0086] Fibers or textile products can exhibit at least 60 percent biodegradation in soil within 130 days, measured under aerobic conditions according to ISO 17556 (2012) at ambient temperature. In some cases, when tested under these conditions, also known as so-called "soil composting conditions," fibers can exhibit at least 60 percent biodegradation within 130, 120, 110, 100, 90, 80, or 75 days or less. These may not be under aqueous or anaerobic conditions. In some cases, when tested for 195 days under soil composting conditions according to ISO 17556 (2012), fibers can exhibit at least approximately 65, 70, 72, 75, 77, 80, 82, or 85 percent total biodegradation. This can represent at least approximately 70, 75, 80, 85, 90, or 95 percent relative biodegradation compared to cellulose fibers subjected to the same test conditions.

[0087] Under soil composting conditions, as defined by Vincotte's "OK biodegradable SOIL" conformity mark and DIN CERTCO's "DIN Gepruft Biodegradable in Soil" certification scheme, a material must meet one of the following requirements to be considered "biodegradable": either exhibit a biodegradation rate of 90 percent or more overall (e.g., compared to an initial sample), or, after both the reference material and the test product have reached a stable state, exhibit a biodegradation rate of at least 90 percent of the maximum degradation rate of a suitable reference material. The maximum test period for biodegradation under soil composting conditions is two years. The cellulose acetate fibers described herein may exhibit at least 90 percent biodegradation within two years, 1.75 years, 1 year, 9 months, or 6 months, as measured under soil composting conditions according to ISO 17556 (2012). In some cases, cellulose acetate fibers may exhibit at least approximately 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 percent biodegradation within two years, as measured under soil composting conditions according to ISO 17556 (2012), or the fibers may exhibit 100 percent biodegradation within two years.

[0088] Furthermore, or alternatively, the cellulose acetate fibers described herein may exhibit at least 90 percent biodegradability within approximately 700, 650, 600, 550, 500, 450, 400, 350, 300, 275, 250, 240, 230, 220, 210, 200, or 195 days, as measured under soil composting conditions according to ISO 17556 (2012). In some cases, cellulose acetate fibers may be biodegradable to at least approximately 97, 98, 99, or 99.5 percent within approximately 225, 220, 215, 210, 205, 200, or 195 days, as tested under soil composting conditions according to ISO 17556 (2012). As a result, the cellulose acetate fibers described herein can meet the requirements for obtaining Vincotte's "OK biodegradable SOIL" conformity mark and the standards of DIN CERTCO's "DIN Gepruft Biodegradable in Soil" certification scheme.

[0089] In some embodiments, the cellulose acetate fibers (or textile products) of the present invention may contain less than 1, 0.75, 0.50, or 0.25 weight percent of components whose biodegradability is unknown. In some cases, the fibers or textile products described herein may not contain components whose biodegradability is unknown.

[0090] In addition to being biodegradable under industrial and / or household composting conditions, the cellulose acetate fibers or cellulose acetate fiber products described herein may also be compostable under household and / or industrial conditions. As stated above, a material is considered compostable if it meets or exceeds the requirements set out in EN13432 for biodegradability, disintegration capacity, heavy metal content, and ecotoxicity. The cellulose acetate fibers or fiber products described herein may demonstrate sufficient compostability under household and / or industrial composting conditions to meet the requirements for obtaining Vincotte's "OK compost" and "OK compost HOME" conformity marks.

[0091] In some cases, the cellulose acetate fibers and textile products described herein may have volatile solids concentrations, heavy metal and fluorine content that meet all the requirements presented by EN13432(2000). Furthermore, cellulose acetate fibers may not adversely affect the quality of compost (including chemical parameters and ecotoxicity tests).

[0092] In some cases, cellulose acetate fibers or textile products may exhibit at least 90 percent disintegration within 26 weeks, measured under industrial composting conditions according to ISO 16929 (2013). In some cases, fibers or textile products may exhibit at least approximately 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 percent disintegration within 26 weeks under industrial composting conditions, or fibers or products may exhibit 100 percent disintegration within 26 weeks under industrial composting conditions. Or, or in addition, fibers or products may exhibit at least 90 percent disintegration within approximately 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, or 10 weeks, measured under industrial composting conditions according to ISO 16929 (2013). In some cases, the cellulose acetate fibers or textile products described herein may exhibit at least 97, 98, 99, or 99.5 percent disintegration within 12, 11, 10, 9, or 8 weeks, as measured under industrial composting conditions in accordance with ISO 16929 (2013).

[0093] In some cases, cellulose acetate fibers or textile products may exhibit at least 90 percent disintegration within 26 weeks, measured under household composting conditions according to ISO 16929 (2013). In some cases, fibers or textile products may exhibit at least approximately 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 percent disintegration within 26 weeks under household composting conditions, or fibers or products may exhibit 100 percent disintegration within 26 weeks under household composting conditions. Or, or in addition, fibers or products may exhibit at least 90 percent disintegration within approximately 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, or 15 weeks, measured under household composting conditions according to ISO 16929 (2013). In some cases, the cellulose acetate fibers or textile products described herein may exhibit at least 97, 98, 99, or 99.5 percent disintegration within 20, 19, 18, 17, 16, 15, 14, 13, or 12 weeks, as measured under household composting conditions in accordance with ISO 16929 (2013).

[0094] Cellulose acetate fibers can be used, for example, to form textile fabrics for agricultural, medical, food, and other applications. In some embodiments, textile fabrics can be prepared from yarns containing cellulose acetate as described herein. As used herein, textile fabric is a material made from yarn that is either woven, knitted, crocheted, knotted, embroidered, braided or woven, lace, or carpet pile. Textile fabrics can include geotextile fabrics, carpet piles, and cloths (including cloths). Geotextile fabrics as used herein in connection with textile fabrics are woven or knitted. Suitable types of textile fabrics that can be formed from cellulose acetate fibers include, but are not limited to, clothing (underwear, socks, hats, shirts, trousers, dresses, scarves, gloves, etc.), bags, baskets, upholstered furniture, window shades, towels, tablecloths, bedspreads, flat covers, artwork, filters, flags, backpacks, tents, handkerchiefs, rags, balloons, kites, sails, parachutes, automotive interiors, heat-resistant protective clothing for firefighters and welders, bulletproof and puncture-resistant protective clothing, medical textile fabrics such as implants, and agricultural textile fabrics for crop protection.

[0095] The additional advantages of various embodiments will become apparent to those skilled in the art by considering the disclosures herein. It will be understood that the various embodiments described herein are not necessarily mutually exclusive unless otherwise indicated herein. For example, features described or illustrated in one embodiment may, but do not necessarily, be included in other embodiments. Thus, this disclosure encompasses various combinations and / or integrations of the specific embodiments described herein.

[0096] definition As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transitional clauses used to move the subject listed before the term to one or more elements listed after the term, and the elements listed after the transitional clause are not necessarily the only elements that constitute the subject.

[0097] As used herein, the terms “including,” “includes,” and “include” have an open-ended meaning, similar to “comprising,” “comprises,” and “comprise.”

[0098] As used herein, the terms “having,” “has,” and “have” have an open-ended meaning, similar to “comprising,” “comprises,” and “comprise.”

[0099] As used herein, the terms “containing,” “contains,” and “contain” have an open-ended meaning, similar to “comprising,” “comprises,” and “comprise.”

[0100] As used herein, the terms "a," "an," "the," and "said" mean one or more.

[0101] As used herein, the term "and / or" means that when used to enumerate two or more things, any one of the enumerated things may be taken alone, or any combination of two or more of the enumerated things may be taken. For example, if a composition is described as containing components A, B, and / or C, the composition may include A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0102] The preferred embodiments of the invention described above are for illustrative purposes only and should not be used to limit the meaning of the interpretation of the scope of the invention. Obvious modifications to the exemplary embodiments described above can be readily made by those skilled in the art without departing from the spirit of the invention.

[0103] The inventors hereby express their intention to determine and evaluate the reasonably fair scope of the invention on the basis of the doctrine of equivalents whenever the invention relates to any device that does not substantially deviate from, but falls outside, the literal scope of the invention as set forth in the following claims. Numerical range

[0104] This specification uses numerical ranges to quantify certain parameters relating to the present invention. Naturally, where numerical ranges are given, such ranges should be interpreted as literal support for claims that specify only the lower limit of the range and claims that specify only the upper limit of the range. For example, if the disclosed numerical range is 10 to 100, it serves as literal support for claims that specify "greater than 10" (no upper limit) and claims that specify "less than 100" (no lower limit).

[0105] Furthermore, lists of numbers following descriptive terms such as "at least" and "not greater than or equal to" should be interpreted as providing literal support for ranges based on all the numbers following the descriptive term. For example, a statement specifying "at least 2, 5, or 10, and / or 100, 50, or 25 or less" provides literal support for the ranges "at least 25," "50 or less," and "at least 10 and 25 or less." [Examples]

[0106] In the conventional process of extruding filaments and producing yarn packages, each group of yarn is extruded from a single spinneret, passes through a cabinet, then through a set of auxiliary devices, and then wound onto separate cores to form a package on a winder. To increase yarn production capacity, multiple opening groups can be incorporated into a single spinneret, making it possible to extrude multiple groups of filaments or yarn from a single spinneret. Multiple yarn groups can be wound onto a single core using different methods without increasing the number of existing winders. Examples 1-4 describe production processes for conventional packages, conventional packages with increased capacity, combined packages with increased capacity, and section packages with increased capacity, respectively, using two spinnerets in a single cabinet as the basic unit.

[0107] Example 1 A first yarn was produced from a first spinneret in one cabinet, and a second yarn was produced from a second spinneret in the same cabinet. The two yarns were kept separate within the cabinet through two yarn guides at the exit. After exiting the cabinet, the two yarns were individually lubricated and then wound onto a shared godette roll. Next, each yarn was entangled and then wound onto separate cores on winding frames of a common winder. The processing capacity of this conventional procedure is defined as the standard capacity.

[0108] Example 2 First and second yarns were produced from a first spinneret in one cabinet, and third and fourth yarns were produced from a second spinneret in the same cabinet. The four yarns were kept separately within the cabinet through four yarn guides at the exit. After exiting the cabinet, these yarns were individually lubricated and then wound onto a common godette roll. Next, each yarn was entangled and then wound onto a core. The first and second yarns were wound separately onto two cores on a common winding frame of the first winder. Similarly, the third and fourth yarns were wound using the second winder. Compared to the conventional process, this embodiment doubled the processing capacity of one cabinet while maintaining the same output per winder.

[0109] Example 3 First and second yarns were produced from a first spinneret in one cabinet, and third and fourth yarns were produced from a second spinneret in the same cabinet. The four groups of yarns were kept separate within the cabinet through four yarn guides at the exit. After exiting the cabinet, these yarns were individually lubricated and then wound onto a common godette roll. Next, each yarn was entangled and then wound. Then, the first and second yarns were combined, passed through the first yarn guide, and co-wound onto the same section of the first core on the winding frame of the winder. Similarly, the third and fourth yarns were co-wound onto the same section of the second core on the winding frame of the same winder using the second yarn guide. Compared to the conventional process, this embodiment doubled the processing capacity of both the cabinet and the winder.

[0110] Example 4 First and second yarns were produced from a first spinneret in one cabinet, and third and fourth yarns were produced from a second spinneret in the same cabinet. The four groups of yarns were kept separate within the cabinet through four yarn guides at the exit. After exiting the cabinet, these yarns were individually lubricated and then wound onto a common godette roll. Next, each yarn was entangled and then wound. The first yarn was wound onto the first section of the first core on the winding frame of the winder, and the second yarn was co-wound onto the second section of the same core. The third and fourth yarns were similarly co-wound onto the two sections of the second core on the winding frame of the same winder. Compared to the conventional process, this embodiment doubled the processing capacity of both the cabinet and the winder.

[0111] Table 1 summarizes the production procedures, processing capacity, and yarn package parameters for Examples 1–4. All examples were based on the same manufacturing conditions, including doped solids, doping temperature, draw ratio, and rotation speed within the range described herein. The yarn specifications were 75 denier with 19 filaments, FOY of 2.0 percent, tensile strength of 1.3 gpd, elongation of 21 percent, and 11 entangled nodes per foot. Package dimensions were measured using a ruler, and package weight was obtained by weighing on a calibrated scale and then subtracting the weight of the core. The twist angle was calculated from known winding speeds in the transverse and winding direction. In Examples 2–4, the processing capacity was doubled compared to Example 1 due to an increase in the number of groups resulting from changing from a conventional spinneret to a spinneret with multiple hole groups. In Examples 3 and 4, the number of yarns per winder was doubled compared to Examples 1 and 2 by winding multiple yarns per core. In Example 4, the package's section structure results in small gaps between sections, defined as the inter-section distance. As a result, the package in Example 4 has a lower weight, and the torsion angle is set higher to ensure package stability. [Table 1]

Claims

1. The core and A cellulosic yarn package comprising: two to four individually entangled cellulosic yarns wound around the core, wherein each of the cellulosic yarns is not permanently entangled with one another on the core.

2. The core and The system comprises a plurality of individually entangled cellulosic threads wound around the core, The threads are not permanently entangled with each other on the core. Each of the aforementioned yarns is a cellulose yarn package with a density of less than approximately 300 denier.

3. The cellulose yarn package according to claim 1, wherein the yarns can be individually wound from the core.

4. The cellulose yarn package according to claim 1, wherein the yarn can be wound simultaneously from the core.

5. The cellulose yarn package according to claim 1, wherein each of the aforementioned yarns can be sequentially wound from the core.

6. The cellulose yarn package according to claim 1, wherein the yarn is co-wound with the core.

7. The cellulosic yarn package according to claim 1, wherein the yarn comprises at least one of spun yarn and / or filament yarn.

8. The cellulose yarn package according to claim 1, wherein each of the yarns is in the range of approximately 10 to approximately 300 denier.

9. The cellulose yarn package according to claim 1, wherein each yarn comprises 2 to 300 individual filaments.

10. The cellulose yarn package according to claim 1, wherein each of the yarns has a denier (dpf) per filament in the range of about 0.25 to about 50.

11. The cellulosic yarn package according to claim 1, wherein each yarn has a density of approximately 1 to approximately 50 entangled nodes per foot.

12. The cellulosic yarn package according to claim 1, wherein the yarn comprises at least one material selected from the group consisting of cellulose acetate material, modified cellulose material, recycled material, biodegradable material, and combinations thereof.

13. The cellulose acetate material has an acetyl substitution degree of about 2.2 to about 3, as described in claim 12, for the cellulose yarn package.

14. The cellulose yarn package according to claim 1, wherein the yarn is coated with at least one finishing agent.

15. The finishing agent comprises one or more components selected from the group consisting of water, mineral oil, antistatic additives, surfactants, phosphate-containing salts, and combinations thereof. The cellulose yarn package according to claim 14, wherein the total amount of the finishing agent is in the range of about 0.1 to about 10 weight percent of each of the yarns.

16. The cellulose yarn package according to claim 1, wherein each yarn has a water content of approximately 3.5 to approximately 30 percent based on the total weight of the yarn.

17. The cellulose yarn package according to claim 1, wherein the yarn has a residual solvent amount in the range of about 0 to about 30 percent based on the total weight of the yarn.

18. The cellulosic yarn package according to claim 1, wherein the yarn contains one or more additives selected from the group consisting of pigments, colorants, antibacterial agents, ultraviolet stabilizers, flame retardants, antioxidants, heat stabilizers, oxidation promoters, acid scavengers, inorganic substances, photodegrading agents, biodegrading agents, decomposition accelerators, polyesters, enzymes, microorganisms, water-soluble polymers, modified cellulose acetates, water-dispersible additives, nitrogen-containing compounds, hydroxyl-functional compounds, oxygen-containing heterocyclic compounds, sulfur-containing heterocyclic compounds, anhydrides, and monoepoxides.

19. The cellulose yarn package according to claim 1, wherein at least one of the yarns is formed from a filament having a shape selected from the group consisting of a circular cross-sectional shape, an irregular cross-sectional shape, and a small cone-shaped irregular cross-sectional shape.

20. The cellulose yarn package according to claim 1, wherein the yarn is formed by wet spinning, dry spinning, or melt spinning.

21. The cellulose yarn package according to claim 1, wherein the yarn is made from a material having a weight-average molecular weight of 10,000 to 90,000, as measured using gel permeation chromatography with N-methyl-2-pyrrolidone (NMP) as the solvent.

22. The thread filament is, at least, Tensile strength of 0.5–3.0 g / denier, measured according to ASTM D3822, The cellulose yarn package according to claim 1, having at least one property selected from the group consisting of 5 to 50 percent elongation at break, as measured according to ASTM D3822.

23. The cellulosic yarn package according to claim 1, wherein the yarn package weighs approximately 1 to approximately 40 pounds.

24. The cellulose yarn package according to claim 1, wherein the number of threads wound around the core is 20 or less.

25. The cellulosic yarn package according to claim 1, wherein the core has a cylindrical shape without flanges.

26. The cellulose yarn package according to claim 1, wherein the core has a length of about 2 to about 24 inches.

27. The cellulose yarn package according to claim 1, wherein the core is made of a material selected from the group consisting of non-metallic materials, plastic materials, and / or cardboard materials.

Images