JP3043414B2 - Polyester thin filament manufacturing method. - Google Patents

Description

Description: The present invention relates to thin filaments of polyester and a method for producing the same.

Historically, synthetic fibers for garments, including polyester fibers, have been supplied to the textile industry for use in textiles and garments, generally to replace and / or improve some of the natural fibers. . For many years, commercially available synthetic textile filaments, such as those produced and used for clothing, have a range similar to that of natural fibers, mostly cotton and wool, which have a high denier per filament (dpf). Was something. But recently, despite the high prices, the natural silk range dpf
With, ie, about 1 dpf, and finer, ie,
Polyester filaments thinner than 1 pf have become commercially available. Recently such a thin dpf, for example about 1dpf
There are various reasons why the interest in thin filaments smaller than this has become industrially interesting.

Many articles have recently been written about increasing interest in fine denier polyester filaments. However, little technical detail is given about the difficulties of the spinning (ie, extrusion and winding) methods that have been used or are considered desirable for producing such fine filaments. However, it is well known to those skilled in the art that conventional manufacturing and curing methods cannot be used for such fine filaments. For example, Textile Month magazine
June 1990, pp. 40-46, discusses three methods of making microfibers. (1) a normal spinning method of fine denier, (2) a method of dividing (high denier) bicomponent fiber, and (3) a method of dissolving one component from high denier bicomponent fiber. . The second and third methods involve first performing a two component spinning process to produce high denier filaments, and then treating such high denier filaments to obtain fine denier filaments. However, such a method is not the subject of the present invention.

The present invention contrasts with a process in which high denier bicomponent filaments are first spun and wound and then further processed to obtain the desired fine denier filaments for use in textiles. The present invention relates to a method for producing thin filaments by a novel direct spinning / winding method. Another possibility for a two-step process for producing fine denier filaments is to spin filaments thicker than 1 denier and then to draw them after the spinning operation, which methods have been previously discussed in the art. It has the serious drawbacks that have come. On the one hand, there is a practical limit to the amount of draw that can be achieved, and the properties of drawn yarns as compared to directly spun oriented yarns have drawbacks as products, and the costs of such processing (ie drawing). Must also be considered. This is especially the case if the spun filaments are first packaged and then a single yarn or warp draw is performed as a separate operation. The method of performing such drawing employs conventional drawing techniques, or includes other techniques, such as including an aerodynamic effect, or re-heating after the filaments have solidified, but still sufficient to perform the drawing. It may include a tensioned advance operation (often performed without a godet with a speed difference, often referred to as spatial stretching). Some previously proposed direct spinning methods use a special polymer composition, for example a composition of a special viscosity, but this has drawbacks, so that a special viscosity or other A method that does not require the use of a special composition is desirable.

In summary, conventional polyester filament manufacturing methods known in the art are intended to produce thin denier polyester filaments by a simple direct spinning / winding operation and are not practically suitable for them, Have the limitations and disadvantages. It would therefore be desirable to provide a direct spinning process for producing thin polyester filaments having the desired dpf and properties without these disadvantages. According to the present invention, this problem is solved. The filaments of the present invention are "spun-oriented" filaments. This meaning will be described below.

Commercially available polyester filaments are made by a "split" method in which the undrawn filament is spun and wound, followed by another drawing step. In the 1950s, Hebeler issued US Pat. Nos. 2,604,667 and 2,60.
No. 4,689 suggests the possibility of spinning a polyester melt at high speed. In the 1970s, Petryl (Petr
High speed spinning of polyesters is suggested, as described in U.S. Pat. No. 3,771,307 to Piazza.
And U.S. Pat. No. 3,772,872 to Reese laid the basis for the production of spun oriented yarns used as draw-textured feed yarns. High speed spinning of polyester melts was first described by Knox in the 1970s in U.S. Pat. No. 4,156,071 and was described by Frankfort and Knox in U.S. Pat. Nos. 4,134,882 and 4,195,051. Is the basis of the method.

As a completely separate step after winding the spun filament obtained by spinning (high-speed) spinning, which shows that the polyester molecules are oriented, and the spun filament,
Alternatively, there is a fundamental difference in microstructure and properties between drawn filaments and oriented filaments as a continuous method before forming and winding solidified filaments before cooling and drawing the melt. .

It is an object of the present invention to provide a thin filament having the characteristics of spin orientation and with the advantageous properties provided by this characteristic.

Some aspects and embodiments of the present invention are as follows.

(1) This is a method for producing a thin filament of polyester oriented by spinning.

(2) Fine filaments of spin-oriented polyester with denier of about 1 or less, improved mechanical quality and uniformity of denier, and particularly adapted for high speed textile processing.

(3) Fine filaments of spun oriented polyester are provided which are particularly suitable for use as draw feed yarns in high speed texturing, crimping and warp processing.

(4) No further stretching or heat treatment is required on flat woven or knitted fabrics dyed by advanced technology,
It is particularly suitable for use as a supply yarn for texturing and indentation crimping without the need for stretching as a directly usable woven yarn, and is uniformly cold-drawn as required and dyed with advanced technology Fine filaments of spun oriented polyester are provided which are capable of producing high shrink warp yarns having dye uniformity suitable for the final purpose.

(5) Fine filaments of spun oriented polyester, particularly suitable for use as woven yarns in flat woven and knitted fabrics dyed with high technology, and a method for producing such finely drawn filaments.

(6) Provided is a bulky polyester thin filament yarn which can be dyed uniformly without using a carrier under atmospheric pressure conditions, and a method for producing the bulky polyester fine filament yarn. .

(7) Mixed filament yarns in which the thin filaments are the filaments of the invention, especially mixed filament yarns in which all filaments are the filaments of the invention, but differ in denier, cross-section and / or latent shrinkage.

 In particular, according to the present invention, the following embodiments are provided.

In a method for producing a thin filament of spun oriented polyester, (i) the polyester polymer has a relative viscosity (LRV) of about 13 to
About 23, a substance having a zero shearing melting point (T _M゜) of about 240 to about 265 ° C. and a glass transition temperature (T _g ) of about 40 to about 80 ° C., and (ii) melting the polyester Heating to a temperature (T _P ) of about 25 to about 55 ° C., preferably about 30 to about 50 ° C. higher than the apparent melting point (T _M ) of the polymer, and (iii) subjecting the resulting melt to polymer (Iv) filtering quickly enough so that the residence time (tr) at the melting point (T _p ) is less than about 4 minutes, and (iv) passing through a capillary of a spinneret a mass flow rate of about 0.07 to about 0.7 g / min. (W), the capillary has a cross section (A _c ) of about 12
5 × 10 ^{-6 to} 1250 × 10 ^-6 cm ² (19.4 to 194 square mil), preferably about 125 × 10 ^{-6 to} 750 × 10 ^-6 cm ² (19.4 to 116.3 square mil), length (L) And a diameter (D _RND ) having a ratio of (L / D _RND ) of at least 1.25 and preferably about 6 or less, especially about 4 or less, and (v) the extruded melt exits the capillary of the spinneret. come time, at least about 2cm to about (12dpf ^1/2) cm shorter distance (L _DQ), preferably a distance of about 1 to about 0.2Dpf, especially about 0.8
Prevents the melt from cooling directly over a distance of about 0.2 dpf, where dpf is the denier per filament of the spun oriented polyester fine filaments, preferably the average denier per strand Dispersion (alon
g-end denier spread (DS) should be less than about 4%, preferably less than about 3%, especially less than about 2%, and (vi) the reduced spinning line preferably has a glass transition temperature (T _g ) Flow rate (V _a ) is about 10 to about
Air is blown radially in the range of 30 m / min to cool below the polymer glass transition temperature (T _g ), and (vii) the apparent spin line distortion (ε _a ) is about 5.7-7.
Strength up to the range of 6 and at an elongation of 7% (T ₇ )
In order to produce filaments particularly suitable as drawn feed yarns having a range of from about 0.5 to about 1 g / d (g / denier), the apparent spin line has an internal stress (σ _a ) of from about 0.045 to about 0.195.
g / d, preferably to a range of about 0.045～ about 0.105 g / d, particularly suitable filaments as drawn feed yarn strength at elongation _7% (T 7) is in the range of from about 1 to about 1.75 g / d In order to create the internal stress of the apparent spinning line (σ _a )
Thinning the filament until it is in the range of about 0.105 to about 0.195 g / d; (viii) about 50 cm to about 140 cm, preferably about 50 cm to about (50
At a distance (L _c ) of +90 dpf ^1/2 ) cm, a low friction surface is used to aggregate the cooled and thinned filaments into a bundle of multifilaments; (ix) A method is provided for winding at a winding speed (V) of about 6 km / min, preferably about 2) to about 5 km / min, especially about 2.5 to 5 km / min.

According to the present invention, there is also provided a fine filament of the following spin-oriented polyester, and a product obtained therefrom.

The denier per filament (dpf) is about 1 or less, preferably about 0.8 to about 0.2 dpf, the polyester polymer has a relative viscosity (LRV) of about 13 to about 23, and a zero shear melting point (T _M゜). About 240-265 ° C, glass transition temperature (T _g )
Is selected to be in the range of about 40 to about 80 ° C., and the fine filament further has (i) a boil-off shrinkage (S) less than the maximum latent shrinkage (S _m ), where Sm = [(550 −E _B ) /6.5]%, and the elongation at break (E _B ) is in the range of about 40 to about 160%. (Ii) The maximum shrinkage tension (ST _max ) is about 0.05 to about 0.2 g / d, and the peak temperature T (ST _max ) is the polymer glass transition temperature (T
_g ) in the range of about 5 to about 30 ° C. higher; (iii) the strength at 7% elongation (T ₇ ) in the range of about 0.5 to about 1.75 g / d, [(T _B ) _n / T ₇ ] is at least about (5 /
T ₇ ), preferably at least about (6 / T ₇ ), where (T _B ) _n is LRV 20.8, matting agent (eg TiO ₂ ) content 0%
(Iv) Desirable average denier variance (DS) for each fiber.
Is characterized by less than about 4%, preferably less than about 3%, especially less than about 2%.

Drawn feed yarn thin filament spun oriented particularly suitable for use as (DFY) is off shrinkage (S) of at least about 12%, elongation at break (E _B) is from about 80% to about 160
%, And wherein the strength at elongation 7% (T ₇₎ is in the range of from about 0.5 to about 1 g / d.

Spin oriented thin filaments particularly suitable for use as a direct use yarn (DUY) have a differential shrinkage (ΔS = DHS
-S) is less than about + 2%, the boil-off shrinkage (S) and the dry heat shrinkage (DHS) are in the range of about 2 to about 12%, and the filament denier dpf (A
BO) is about 1 or less, preferably about 1 to about 0.2 dp
f, more preferably in the range of about 0.8 to about 0.2 dpf, with a strength at 7% elongation (T ₇ ) of about 1 to about 1.75 g / d, and an elongation at break (E _B ) of about 40% to about 90% And the post-yield modulus (M _py ) is in the range of about 2 to about 12 g / d.

Spin-oriented thin filaments that can be uniformly cold-drawn have a shrinkage difference (ΔS = DHS-S) of less than about + 2%, and a boil-off shrinkage (S) and a dry heat shrinkage (DHS) of about 2 to 2%.
The cold crystallization onset temperature T _CC (DSC) is about 12%.
Below 105 ° C., the instantaneous tensile modulus (M _i ) is characterized by at least about 0.

The spin-oriented thin drawn filament having a denier dpf (ABO) after boil-off shrinkage of about 1 or less, preferably about 0.8 to about 0.2 dpf, further comprises (i) boil-off shrinkage (S) and dry heat shrinkage (DH)
S) is in the range of about 2 to about 12%; (ii) the strength at 7% elongation (T ₇ ) is in the range of at least about 1 g / d, and the ratio of [(T _B ) _n / T ₇ ] Is at least about (5 /
T ₇ ), preferably at least about (6 / T ₇ ), where (T _B ) _n is LRV 20.8, matting agent (eg TiO ₂ ) content 0%
Strength at break, the elongation at break (E _B ) being in the range of about 15 to about 55%, and (iii) the modulus after yield (M _py ) is preferably about 5 to about
25 g / d, (iv) preferably the average per-denier variance (DS)
Is characterized by less than about 4%, preferably less than about 3%, especially less than about 2%.

Denier dpf (ABO) after boil-off shrinkage is about 1 to about 0.
Bulk spun oriented fine filaments of 2 dpf, preferably about 0.8 to about 0.2 dpf, further have a boil-off shrinkage (S) and a dry heat shrinkage (DHS) of about 2 dpf.
Elongation at break (EB) of about 15% to about 12%.
The strength at 7% (T ₇ ) is at least about 1 g / d, preferably the modulus after yield (M _py )
Is in the range of about 5 to about 25 g / d, characterized by a relative disperse dye dyeing rate (RDDR) normalized to 1 dpf of at least about 0.1.

Further, according to the present invention, the mixed filament yarn in which the thin filament is the filament of the present invention, in particular, all the filaments are the filaments of the present invention.
Mixed filament yarns having different cross-sections and / or potential shrinkages are provided.

Preferred such spun oriented bulky oriented flat filaments comprise from about 1 to about 3 mole% ethylene-5.
Since it contains -M-sulfoisophthalate units, it can be dyed with a cationic dye. Where M is a cation of an alkali metal such as sodium or lithium.

Particularly suitable spun oriented bulky drawn flat filaments which can be uniformly dyed with disperse dyes under atmospheric pressure conditions without a carrier have a dynamic loss modulus peak temperature T (E " _max ). About 115 ° C., preferably about 11 ° C.
Below 0 ° C., the first alternating hydrocarbodienedioxy structural units A, ie [—O—C ₂ H ₄ —O—] and the hydrocarbodienedicarbonyl structural units B, ie [—C
(O) —C ₆ H ₄ —C (O) —], which is a small amount of other hydrocarbylenedioxy structural units A and / or hydrocarbylenedicarbonyl structural units B different from the first structural unit. Denatured, with zero shear melting point (T _M゜)
In the range of 240 ° C. ~ about 265 ° C., the polyester polymer is in the range of the glass transition temperature (T _g) from about 40 to about 80 ° C.), the substantially consists of poly (ethylene terephthalate).

The filaments of the present invention are non-circular in shape to improve tactile and visual aesthetics, and the non-circular filaments have a form factor (SF) of at least about 1.25.
It is. The form factor (SF) is defined as the ratio of the measured filament parameter (P _M ) to the calculated parameter (P _RND ) for a circular filament of equivalent cross-sectional area. The hollow filaments are then spun from the capillary orifice of the spinneret with partitions and subsequently crushed, resulting in a lightweight fiber with increased bulk and filament bending modulus to improve the drapability of the textile. You can make cloth.

 Embodiments of the present invention will be further described with reference to the accompanying drawings.

FIG. 1 is a graph in which the speed (V) of the spinning line is plotted against the distance (x). The spinning speed increases from the speed at extrusion (V _o ) to the final (drawing speed) after the filament has been completely thinned (typically measured at the point of consolidation Vc). The internal stress (σ _a ) of the apparent spinning line is expressed as being proportional to the spinning line viscosity at the neck point (η) _N [ie, approximately LRV / T _p ⁶ (where T _p is in ° C.). And the velocity gradient (dV / dx) at the neck point (where the spinning speed is about 2-4 km
/ In the case of the order of minutes is approximately proportional to V ² / dpf, when the spinning speed is higher than that, seen to be substantially proportional to V ^3/2 / dpf in the case for example of about 4 to about 6km / min Out) is proportional to the product of The temperature of the spinning line is also scaled with respect to the distance (x) of the spinning line, which decreases uniformly with distance, while the speed of the spinning line rises sharply at the neck point. Is observed.

FIG. 2 is a graph plotting the birefringence (Δ _n ) of the spin-oriented filament against the apparent internal stress (σ _a ) of the spinning line. Here, the slope is "force-optical coefficient" SOC
And the SOC values of lines A, B and C are each 0.7
5, 0.71 and 0.645 (g / d) ^-1 with an average SOC of about 0.
7 Lines A and C are typical relationships found in the literature for 2GT polyester. The value of the internal stress (σ _a ) of the apparent spinning line is consistent with the literature value.

FIG. 3 is a graph plotting the strength (T7) at the elongation of the spun-oriented filament at 7% at the apparent internal force (σ _a ) of the spinning line. As shown in FIGS. 2 and 3, the relationship between the birefringence (Δ _n ) and the T ₇ with respect to the internal force of the apparent spinning line is almost linear, which means that the T ₇ is an average of the filament. It shows that it can be used as a useful parameter representing the orientation. Birefringence (Δ
_n ) is an extremely difficult to measure structural parameter that is typical for thin filaments with denier less than 1.

FIG. 4 is a graph in which the apparent internal force (σ _a ) of the spinning line and the strength (T ₇ ) at an elongation of 7% (T ₇ ) are plotted on a natural logarithmic scale with respect to the spinning line elongation ratio E _R (= V / V _o ). (Where the E _R values 200 and 2000 are represented on the x-axis, for example, as 0.2 and 2, ie, as E _R / 1000). Here, the natural logarithmic scale 1n (E _R ) indicates the apparent spinning line distortion (ε
called _a), V is the speed of the final (retrieval) spinline, V _o is the extrusion rate of the capillary. The process according to the invention is described in the closed section ADLI, where section ADHE (II) is preferred for making filaments for direct use and section EHLI (I) is preferred for making drawn feed yarns. Particularly preferred methods are represented by the areas BCGF and FGKI.

FIG. 6 is a graph in which the secant M _py (tan β in FIG. 5) is graduated with respect to the birefringence (Δ _n ) of the spun oriented filament. tan
For yarns where α is substantially equal to tanβ, the post-yield modulus (M _py ) is a useful measure of molecular orientation.

FIG. 7 shows the relative disperse dye dyeing speed (RDD normalized to 1 dpf).
R) is a graph graduated with respect to the average filament birefringence (Δ _n ).

FIG. 8 shows the free volume (V _f , _am , defined below) of the amorphous portion of the fiber as the peak temperature T of the mechanical loss modulus of the fiber.
5 is a graph graduated against (E ″ _max ), where the mechanical loss modulus peak temperature is taken as a measure of the glass transition temperature, which is typically less than the T _g of the polymer. 20 ° C. to about 50 ° C. Higher values of T (E ″ _max ) correspond to higher free volumes (V _f , _am ) of the amorphous part, and thus improve dyeability. Yes, it is. Here is the relative disperse dye dyeing speed (RDDR)
Value (normalized to 1dpf) is at least about 0.
Is one.

FIG. 9 is a graph in which the density (ρ) of the filament is graduated with respect to the birefringence (Δ _n ). Here, the diagonal line shows the combination of the density (ρ) and (Δ _n ) when the orientation ratio (f _a ) of the amorphous portion calculated and used for the free volume V _f , _am shown in FIG. 8 is increased. I have.

FIG. 10 shows a differential thermal analysis (DSC) spectrum showing the thermal transition corresponding to the glass transition temperature (T _g ) of the fiber, the “cold” onset of crystallization T _CC (DSC) and the zero shear melting point T _MT .
The zero shear melting point TMo of the fiber is higher than the zero shear melting point T _M゜ of the polymer due to the orientation and crystallinity of the melting point of the fiber. To determine the zero shear melting point T _M゜ of the polymer, the molten DS
The C sample is heated again in the DSC method to extract the SDC spectrum of the polymer but not of the fiber.

FIG. 11 is a shrinkage tension (ST) -temperature spectrum of the spun oriented thin polymer filaments of the present invention, where the highest shrinkage tension ST ( _max ), peak temperature T ( _STmax ), and heat fixation have a significant adverse effect on dyeability. 2 shows a preferred "heat _set " temperature _Tset , which is the highest temperature that does not give

FIG. 12 shows a typical drawn feed yarn of the invention (curve C), a typical direct use yarn of the invention (curve B), and a preferred direct use yarn of the invention similar after relaxation heat treatment, ie after dyeing. It is an elongation / strength (T = load (g) / original denier) curve with respect to (curve A).

FIG. 13 shows the preferred values of the strength at break (T _B ) _n standardized for the content of LRV and matting agent (for example, TiO 2) (T _B ).
as the ratio of _n / T _7, against the reciprocal of T _7, i.e. a graph graduated against 1 / T _7. Here, in curve A, [(T _B ) _n /
T ₇ ] = (5 / T ₇ ), and the curve B has [(T _B ) _n / T ₇ = (6 / T ₇ )
It is a T _7).

FIG. 14 is a graph plotting the ratio T ₇ / (V ² / dpf) against the product of the number of filaments (# _c ) per bundle extruded yarn and the ratio (D _ref / D _sprt ) ^2. . Where D _ref and D _sprt
Is the reference spinneret diameter (eg, about 75 cm) and the diameter of the spinneret being tested. The slope "n" obtained from the log-log scale is negative and about 0.7 (-0.7). That is, the strength (T ₇ ) at an elongation of 7% is (V ² / dpf) and [(# _c ) (D _ref / D
_sprt ) ² ] changes in proportion to ^-0.7 . In other words, the strength at 7% elongation (T7) is equal to the extruded density of the filament.
It increases linearly almost in proportion to the 0.7th power (+ 0.7th power). The extrusion density of the filament can be used as a processing parameter for spinning fine denier filaments at high spinning speeds (V). At high spinning speeds, for example in the range of about 4 to 6 km / min, the apparent spinning line force increases more slowly with spinning speed (V), ie (V ^3/2 / dpf) Was found to increase in proportion to

The polyester polymer used to make the spun oriented filaments of the present invention has a relative viscosity (LRV) of about 13 to about 2
3. Those having a zero shearing melting point (T _M゜) of about 240 to 265 ° C. and a glass transition temperature (T _g ) of about 40 to about 80 ° C. (where T _M゜ and T _g are nitrogen Second DS under atmosphere
C measured at a heating rate of 20 ° C. per minute from the heating cycle). This polyester polymer is a linear condensation polymer composed of structural units A and B which are present alternately,
Wherein A is a hydrocarbylenedioxy unit in the form of [—O—R′—O—], and B is [—C (O) —R ″ —C
(O)-]. Wherein R 'is primarily as in ethylenedioxy (glycol) unit _{[-O-C 2 H 4 -O-} ] [-C 2 H 4 -] a, R "is 1,4-benzene dicarbonyl unit _{[-C (O) -C 6 H} 4 -C (O) -] primarily as in [-C ₆ H ₄ -] a, such as at least 85
% Of the repeating units are ethylene terephthalate units [—O—C _{2
H 4 -O-C (O)} -C 6 H 4 -C (O) - present as.

Although abbreviated herein as PET or 2GT, suitable poly (ethylene terephthalate) based polymers are available from John Wiley and Sons Limited, 1971, H. Ludwig, “Polyester Fibers, Chemistry and Technology (Polyester Fibers, Chemistry a)
nd Technology) ”DMT method and edging (E
dging) U.S. Pat. No. 4,110,316. Also, for example, up to about 15% of the hydrocarbylenedioxy and / or hydrocarbylenedicarbonyl units are replaced by different hydrocarbylenedioxy and hydrocarbylenedicarbonyl units to improve disperse dye dyeing, feel, and aesthetic properties at low temperatures. Also included is a copolymerized polyester. Suitable replacement units are Most US Pat. No. 4,444,710 (Example 6) and Pacofsky US Pat.
No. 8,844 (column 4) and U.S. Pat. No. 4,639,347 to Hancock et al. (Column 3).

The polyester polymer can be modified with an ionic dyeing site, for example, an ethylene-5-M-sulfoisophthalate residue. Where M is a cation of an alkali metal,
For example, sodium or lithium. For example, ethylene-5-sodium-sulfoisophthalate residue may be added in the range of 1 to about 3 mol% to impart a dyeability to the polyester filament with a cationic dye. In this regard, Griffing and Remington U.S. Pat. No. 3,018,272.
No. 4,929,69 to Hagewood et al.
No. 8, Duncan and Scrivener
See U.S. Pat. No. 4,041,689 to Ener (Example 6) and U.S. Pat. No. 3,772,872 to Piazza and Leeds (Example 7). Adding some diethylene glycol (DEG) as described in Bosley and Duncan U.S. Pat. No. 4,025,592 to adjust the dyeability or other properties of spun oriented filaments and filaments drawn therefrom. Which can be added in combination with a chain branching agent as described in Goodley and Taylor U.S. Pat. No. 4,945,151.

According to the present invention, the following steps provide a fineness of about 1 to about 0.2 denier per filament (dpf), preferably about
A method is provided for making a spun oriented polyester filament ranging from 0.8 to about 0.2 dpf.

(A) fusing the polyester polymer as described above and heating to a temperature (T _p ) of about 25 to about 55 ° C., preferably about 30 to about 50 ° C. above the apparent melting point (T _M ) _a . Where (T _M )
_a is greater than zero shear temperature (T _M °) as a result of the shearing action exerted during extrusion polymer, wherein _{(T M) a = [T} M ° ^{+ 2 × 10 -4 (L /} D RND) G a] , Defined by Where L is the length of the extrusion capillary, D _RND is the diameter of the capillary in the case of a circular capillary, and D _RND (cm) is the same section A _c (cm ² ) in the case of a non-circular capillary. The equivalent diameter calculated from the diameter of the rounded capillary, G _a (sec ^-1 ) is the apparent capillary shear rate defined below.

(B) using the obtained polymer, for example, Phillips
ps) pack cavities as described in U.S. Pat. No. 3,965,010 [Jamies
on) U.S. Patent No. 3,249,669, similar to that illustrated in Figures 2-31] through an inert medium, wherein the rate is sufficiently high so that the residence time ( _tr ) is about 4
Within minutes. Where _tr is the free volume (V _F , cm ³ ) of the filter cavity (filled with inert filtration medium) and the volumetric flow rate of the polymer melt through the filter cavity (Q, cm ³ / min) And the ratio (V _F / Q). The volume flow rate (Q) of the polymer melt through the filter cavity is the mass flow rate in the capillary (w, g / min)
And the number of capillaries per cavity (# _c ) divided by the density of the melt (here, about 1.2195 g / cm ³ ). That is, Q = # _c w / 1.2195. The free volume (V _F , cm ³ ) of the filter cavity (filled with inert filtration medium) is determined experimentally by standard liquid displacement methods using a low surface tension liquid such as ethanol. . In the above equation for the residence time of the melt, the mass flow rate (w) in the capillary is expressed as w = [(dpf ·
V) / g] (where V is the spinning take-off speed expressed in km / min) gives the filament denier, take-off speed (V), and the number of filaments per filter cavity (# _c ) Increases,
Residence time t _r is reduced, and also the residence time t _r and the free volume of the filter cavity (V _F) is decreased to decrease. The free volume (V _F ) of the cavity changes the pack cavity and
It can also be reduced by using an inert filtration medium that can provide sufficient filtration with a small free volume. The number of filaments per filter cavity (ie, the number of capillaries) ( _#c ) extrudes a bundle of two or more multifilaments from a single filter cavity for a given yarn count. That is, it can be increased by spinning a large number of filaments and then splitting the bundle of filaments into bundles of small filaments having the desired yarn denier (hereinafter multi-end). In this case, it is preferable to use a finishing agent metering cylinder positioned at a position of about 50 to about (50 + 90 dpf ^1/2 ) cm.

(C) Pass the filtered melt through the capillary of the spinneret,
Extrude at a mass flow rate (w) in the range of 0.07 to about 0.7 g, where the capillary has a cross section A _c = (π / 4) D _RND ² of about 125 × 10 ⁻⁶ to about 1250 ×
10 ^-6 cm ² (19.4-194 square mils), preferably about 125 × 10
^-6 to about 750 × 10 ^-6 cm ² (19.4 to 116 square mils), and the length (L) and diameter (D _RND ) are such that the ratio of L / D _RND is about 1.25 to about 6, preferably about 1.25.約 4, where Ga (sec ⁻¹ ) = [(32 / 60π) (W / ρ) / D _RND ³ ], and w is the mass flow rate in the capillary (g / min). , Ρ is the melt viscosity of the polyester (assuming 1.2195 g / cm ³ ) and D _RND is the diameter of the capillary in cm (defined above).

(D) preventing the polymer from being directly cooled over a distance L _DQ of at least about 2 cm and less than about (12 dpf ^1/2 ) cm as the newly extruded polymer melt exits the spinneret. . Where dpf is the denier per filament of the spun oriented polyester polymer.

(E) Carefully cool the extruded melt until it is below the glass transition temperature (T _g ) of the polymer. This cooling is accomplished using a layered transverse quench flow fitted with a delay tube [Dauchert, U.S. Pat. No. 3,067,458.
issue]. The temperature of the quench air (T _a ) is lower than T _g , and the speed of the quench air (V _a ) ranges from about 10 to about 30 m / min.

(F) Distortion of apparent spinning line (ε
_a ) until about 5.7 to about 7.6, preferably about 6 to about 7.3. The apparent strain ε _a of the spinning line is defined as the natural logarithm (ln) of the spinning line elongation ratio (E _R ), where E _R is the take-off speed (V) and the capillary extrusion speed (V _o ).
And the ratio. That epsilon _a relative D _RND in cm is given by _{ln (E R) = ln (} V / V o) = ln [(2.25 × 10 5 πρ) (D RND 2 / dpf)].

(G) Spun oriented filaments, particularly drawn feed yarns (DF) having a strength (T ₇ ) value at an elongation of 7% in the range of about 0.5 to about 1 g / d.
In order to produce spun oriented filaments particularly suitable for making Y), the apparent spin line internal stress (σ _a ) during the thinning process is from about 0.045 to about 0.195 g / d, preferably from about 0.045 to about 0.145 g / d. 0.105 g / d, and a directly used yarn (DU) having a strength (T ₇ ) value at an elongation of 7% in a range of about 1 to about 1.75 g / d.
To produce spun oriented filaments particularly suitable for making Y), the apparent spin line preferably has an internal force (σ _a ) of about 0.105 to about 0.195 g / d. Here, the apparent internal force (σ _a ) of the spinning line is determined by the viscosity (η _m ) of the melt to be thinned and the speed gradient of the spinning line at a point where the thinning step is substantially completed (hereinafter referred to as a neck point). dV / dx). The apparent spin line internal stress (σ _a ) increases with increasing LRV of the polymer, and also increases dpf, given spinneret surface area (A _o cm ² ), and polymer temperature (T _P ) Then it was found to decrease. This is represented by an empirical relation of the form (σa) = k (LRV / LRV _20.8 ) (T _R / T _P ) ⁶ (V ₂ / dpf) × (A _o / # _c ) ^0.7 . Where k is 10
^-2 (ρ _m / SOC), where ρ _m is the density of the spun oriented filaments (eg, about 1.345 to 1.385 g / cm ³ , about 1.36 g / c
m ³ ), and SOC is the “force-optical coefficient” for the polyester polymer (eg, about 0.7 as a reciprocal unit of g / d for a 2GT homogeneous polymer). T _R is a reference temperature of the polymer defined in (T _M ° + 40 ℃), T _M ° is the zero shear (DSC) polymer melting point, T _P is the polymer melt spinning temperature (° C.), V is km / withdrawal rate, expressed in minutes, # _c is represented by # _c / cm ² by the number of filaments for the extrusion surface a _o given (i.e., the number of capillaries), LRV is measured polymer (in the laboratory Of) viscosity, L
RV _20.8 is the corresponding reference LRV value for a 2GT homopolymer having an LRV value of 20.8 and a polyester polymer having the same zero-shear "Newton" melt viscosity (η _o ) at 295 ° C (LRV is defined below) . (For example, cationic dyeable polyesters with an LRV of 15 are in the range of about 20 LRV 2GT homopolymer as indicated by the pressure drop across the capillary, so the preferred reference LRV for such modified polymers is (H) It is determined experimentally by the standard capillary pressure drop method.) (H) Cool and sufficiently thin the filament using a low friction surface, such as a finishing roll (ie, wear the filament). Into a bundle of multifilaments, preferably without any stoppage, preferably from the surface of the spinneret.
At a distance (L _c ) of 50 to about 140 cm, preferably about 50 to (50 + 90 dpf ^1/2 ) cm, a finish metering cylinder (eg as described in Agers US Pat. No. 4,926,661) is used. The finish is usually an aqueous emulsion containing from about 5 to about 20% by weight solids, such that the finish on the yarn is from about 0.4 to about 2% by weight depending on the final processing requirements.

(I) Interlacing the bundles of filaments in a manner using an air jet substantially as described in Bunting and Nelson U.S. Pat. No. 2,985,995 and Grey U.S. Pat. No. 3,563,021. In this case, the degree of entanglement between the filaments (in this case, see the quick pin modulus RPC measured by the method described in US Pat. No. 3,290,932 to Hitt) is selected according to the requirements of the yarn packaging and end use.

(J) winding the multifilament bundle at the unloading speed (V); The take-off speed is defined as the surface speed of the first drive roll and is about 2 to about 6 km / min, preferably about 2 to about 5 k
m / min, especially in the range of about 2.5 to about 4.5 km / min. In order to prevent the finish from depositing on the surface of the interlaced jet described in Harris U.S. Pat. Except for the use of an interlaced jet fluid) by dragging air by relaxing the spinning line between the first drive roll and the take-up roll with an overfeed of about 0.5 to about 5%. Decrease contractile force.

The polyester thin filaments of the present invention have a simplified direct spinning orientation (SDSO) without drawing and heat treatment
Produced by the method, a good balance between shrinkage and dyeing behavior makes the polyester thin filaments of the invention particularly suitable as a substitute for natural continuous fibers such as silk. . By carefully choosing the parameters of the SDSO process, fine filaments with excellent mechanical quality and uniformity can be made. For example, thin filaments having a shrinkage of less than about 12% can be used as multifilament direct use yarns (DUY) and can be processed in high speed woven and knitted processing without producing cut filaments. Also, filaments having a shrinkage factor preferably greater than about 12% can be used in high speed fabric drawing operations, such as friction twist texturing, air jet texturing, indented crimping, and warp drawing operations without producing cut filaments. It can be used as a multifilament drawn yarn (DFY).

The fine filaments of the present invention have excellent mechanical qualities, and yarns made from these filaments can be drawn-pseudo-twisted and air jet textured, warp drawn,
It has the feature that it can be used without cutting filaments in high-speed textile processing, such as drawing gear and push-in knitting, and textile and warp knitting with air and water. The filaments of the present invention also have excellent denier uniformity (as defined herein as the denier dispersion DS of each strand) and can be used in textile fabrics dyed with advanced techniques. The filaments of the present invention can be used as filaments in drawn feed yarns (and tows), and preferably filaments having a boiler shrinkage (S) and dry heat shrinkage (DHS) about 12% greater are particularly suitable for drawn feed yarns. . Shrinkage
The filaments of the present invention of less than 12% are particularly suitable for flat, non-textured multifilament yarns and also as texturing yarns such as air jet texturing, geared crimping, and push-in crimping. In this case, it is not necessary to perform stretching. The flat textured filaments of the present invention can be cut into staple fibers and flocs. However, filaments that shrink less than 12% can be uniformly cold drawn as described in US Pat. No. 5,066,447 to Knox and Noe.

In contrast to the polyester thin filaments produced according to the invention, for example, an aerodynamic or mechanical drawing and / or heat treatment step is performed to reduce the filament denier and / or molecular orientation and / or crystallinity. Thin filaments made using spinning techniques that include a step to increase the shrinkage tension (ST)
_max ) is about 0.2 or higher, (2) the maximum of the contraction tension appears at a temperature T (ST _max ) higher than about 100 ° C., that is, a temperature higher than the dyeing temperature under atmospheric pressure), and (3) drying heat shrinkage. (DHS) increases with temperature in the normal fabric dyeing and finishing temperature range from about 100 to about 180 ° C (ie, T =
(100-180 ° C.), d (DHS) / dT> 0), and the difference in shrinkage (ΔS = DHS−S) (where S is boil-off shrinkage, DHS is dry heat shrinkage) is about + 2% or more, Before or after dyeing, the polyester fine filaments or the textile products made therefrom must be subjected to a high temperature treatment to impart sufficient thermal dimensional stability to the textile fiber fabrics made from these fine filaments. (4) These conventional filaments have poor dyeability, and in order to obtain a uniformly dyed fiber cloth having a deep color tone, pressure is applied at a high temperature using a chemical dyeing aid called a carrier. Need to be stained.

In particular, according to the present invention, the following filaments are provided.

1. Fine filaments of a spun oriented polyester having a relative viscosity (LRV) of about 13 to about 1 dpf or less, preferably about 0.8 dpf or less, especially about 0.6 dpf or less and about 0.2 dpf or more. A zero-shear polymer melting point (T _M゜) in the range of about 240 to about 265 ° C. and a glass transition temperature (T _g ) of the polymer in the range of about 40 to about 80 ° C .; The filament further has (a) a difference in shrinkage (ΔS = DHS-S) of about + 2% or less, preferably about + 1% or less, particularly about 0% or less, where S is boil-off shrinkage and DHS is dry heat shrinkage. (B) The maximum contraction tension (ST _max ) is about 0.05 to about 0.2 g / d, and the peak temperature T (ST _max ) of the maximum contraction tension is about (T _g
+ 5 ° C.) to about (T _g + 30 ° C.), ie, about 75 to about 10 for poly (ethylene terephthalate) having a polymer T _g of about 70 ° C.
0 ° C., (c) Strength (T ₇ ) at an elongation of 7% is about 0.5 to about 1.75 g
/ d, and the ratio of [(T _B ) _n / T ₇ ] is at least (5 / T ₇ ),
Preferably at least (6 / T ₇ ), where (T _B ) _n
Is the elongation at break standardized on the basis of LRV 20.8 and a matting agent (for example, TiO ₂ ) content of 0%, where (T _B ) _n = (T _B )
[20.8 / LRV) ^0.75 ] (1-x) ^-4 , strength at break (T _B ) = T (1 + E _B / 100), and E _B , that is, elongation at break is about 40% to about 160 %, X is the weight-based content of the matting agent, T is the strength defined by dividing the load at break (g) by the original unstretched denier, and (e) average Denier variance (DS) per bottle is about 4%
Less than about 3%, especially less than about 2%.

2. Draw Yarn (DFY), a spun oriented thin filament that is particularly suitable as a draw yarn for high speed pseudo-twisting and air jet texturing, drawing warp processing, draw crimping and indentation crimp texturing. (A) boil-off shrinkage (S) and dry heat shrinkage (DH
S) is less than larger and best potential shrinkage than about 12%, respectively _{(S M = [(550-} E B) /6.5])%), elongation at break (E _B) is about 80% to 160% (B) strength (T ₇ ) at an elongation of 7% is about 0.5 to about 1 g / d
A filament characterized by the following.

3. Spun oriented fine filaments particularly suitable as direct use yarns (DUY); (a) Boil-off shrinkage (S) and dry heat shrinkage (DH
S) ranges from about 2% to 12%, preferably from about 6 to about 12% for woven fabrics and from about 2 to about 6% for knitted fabrics, and the boil-off filament denier dpf (ABO) = Dpf
(BBO) × [(100 / 100-S)] is in the range of about 1 to 0.2 dpf, preferably about 0.8 to about 0.2 dpf, especially about 0.6 to about 0.2 dpf, and (b) strength at an elongation of 7% ( T ₇₎ is from about 1 to about 1.75 g /
d, the elongation at break (E _B ) is in the range of about 40 to about 90%, and (c) is defined by the secant tan β in FIG. 5 (ie, M _py = (1.2T ₂₀ −1.07T ₇ ) /0.13 A) a filament having a post-yield modulus (M _py ) of about 2 to about 12 g / d;

4. Fine filaments having a spun orientation that can be cold-drawn without heat setting to produce filaments for textiles. (I) Boil-off shrinkage (S) and dry heat shrinkage (DH)
(Ii) the cold crystallization onset temperature T _CC (DSC) is less than about 105 ° C. as measured by differential thermal analysis at a heating rate of 20 ° C./min. iii) Momentary tensile modulus M _i (= [d (force) /
d (elongation)] × 100) is greater than about 0. Here, [d (force) / d (elongation)] is a gradient when the force (g / stretched denier) is graduated with respect to the elongation (%), and the stretching force is the stretching force (g) in the stretched denier. a value obtained by dividing the stretching denier is defined as the ratio between the residual stretching denier unstretched _{(RDR = 1 + E B (} %) / 100).

As long as the post-heating _set temperature (T _set ) is lower than the temperature at which the shrinkage tension does not decrease significantly further as the temperature increases, the shrinkage (S) of the drawn filament can be reduced as necessary without significant loss of dyeability. Can be reduced. That is, it is preferable to maintain _Tset at a temperature substantially lower than the temperature at which rapid (re) crystallization starts. Where T
_The highest value for _set is defined as the temperature at which the slope of the contractile tension versus temperature spectrum [d (ST) / dT] rapidly decreases (decreases negatively). See FIG.

5. Suitable drawn yarns made by drawing the spun oriented filaments of the present invention include: (a) a denier dpf (ABO) per filament after boil-off shrinkage of about 1 to about 0.2 dpf, preferably about 0.8 to about 0.2 dpf;
(B) boil-off shrinkage (S) and dry heat shrinkage (DH
S) is about 2 to about 12%, preferably about 2 to about 12% for knitted fabrics.
About 6%, for textiles about 6 to about 10%, (c) strength at 7% elongation (T ₇ ) of at least about 1 g
/ d, the ratio of [(T _B ) _n / T ₇ ] is at least about (5 / T ₇ ), preferably at least about (6 / T ₇ ), where (T _B ) ⁿ
Is LRV20.8, a breaking strength normalized matting agent (e.g., TiO ₂₎ content of 0% as a reference, E _B is about 15% to about 55
(E) the modulus after yield (M _py ) ranges from about 5 to about 25 g / d; (f) the relative disperse dye dyeing rate (RDD) normalized to 1 dpf.
R) is at least about 0.1, preferably at least about 0.15; (g) the peak temperature of the mechanical loss modulus, T (E ″);
_max ) is about 115 ° C. or less, preferably about 110 ° C. or less, and (h) the average per-denier dispersion (DS) is about 4%.
Or less, preferably about 3% or less, particularly about 2% or less.

6. The bulky thin filament yarn (or tow) is obtained by subjecting the thin filament yarn of the invention to a bulking process, such as air jet texturing, pseudo-twist texturing, indentation and gear crimp operations. The bulk filaments have an individual filament denier (after shrinkage) of about 1 or less, preferably about 0.8 or less, boiler shrinkage (S) and dry heat shrinkage (DHS) of about 12% or less; (E ″ _max ) is about 115 ° C. or less, preferably about
110 ° C. or less, characterized by an RDDR of at least about 0.1, preferably at least about 0.15.

Particularly suitable filaments for use in directly-used yarns (or tows) are: (a) average crystal size (CS) with wide angle X-ray scattering (WA
XS) is about 50 to about 90 angstroms as measured from the 010 surface, and the density value (ρ _m ) is about 1.355 to about 1.395 g / cm ³
Volume crystallization ratio _{X v = (ρ m -1.335)} /0.12 is about 0.2 to about 0.5 corrected for matting agent content for, (b) the average orientation factor f = Δ _n / Δ _n ° (here Where Δ _n゜ is the average intrinsic birefringence, assuming 0.22 here) is about 0.25
About 0.5, and the orientation ratio f _a of the amorphous portion = (f−X _v f _c )
/ (1-X _v) of about 0.4 or less, preferably about 0.3 or less, where (delta _n) is the average birefringence, = f _c is the crystal portion of the orientation ratio f _c (180-COA) / 180, COA is the crystal orientation angle measured by WAXS, and (c) the free volume of the amorphous portion (V _f , _am ) is at least 0.5
× 10 ⁶ cubic angstroms, V _f , _am (CS) ³
_{[(1-X v) /} X v)] is defined by _{[(1-f a) /} f a], about 115 ° C. or less, preferably 110 ° C. or less of dynamic loss modulus peak temperature T (E _"max (D) characterized by a relative disperse dye dyeing rate at atmospheric pressure normalized to 1 dpf of at least about 0.1, preferably at least about 0.15.

Yarn properties are described in U.S. Pat.Nos. 4,134,882 and 4,156,071.
No., and measured by the method described in 5,066,447,
Relative Disperse Dye Dye Speed (RDDR) was normalized to 1 dpf, Dry Heat Shrink (DHS) was measured at 180 ° C., and Laboratory Relative Viscosity (LRV) was defined by Broaddus US Pat. No. 4,712,998. About (HRV-1.
2). HRV is disclosed in U.S. Pat.Nos. 4,134,882 and 4,1
56,071. The value of LRV _20.8 is zero shear "Newton" melt viscosity η _o (measured by the same capillary pressure drop method at the same mass flow rate and temperature, for example).
The reference LRV for a polyester polymer equal to 0.8 LRV of a 2GT homogeneous polymer. In Tables 1 to 8 below, numerals representing powers attached to the shoulders of alphanumeric characters are indicated using the symbol "^" (for example, 10 ² = 10 ^).
2) a very small or very large number (eg 0.0
0254 cm and 254000 cm / min) are 0.254 and 254 for convenience, and the units are “cm × 10 ^ 2” and “cm /
Seconds × 10 ^ 3-3 ". The broken line (----) in the number column indicates that the value was not measured, and" NA "in the number column indicates that the measured value cannot be applied. The dashed arrow (---->) indicates that the parameter for the item is the same as the previous item, and the spinning speed (V) is measured in units of yards / minute and km / minute. And rounded at the second decimal place (for example, 4500 yards / minute =
4,115km / min => 4.12).

 The following examples illustrate the invention.

The polymer has an LRV of about 13 to about 23 ([η] of about 0.5 to about 23).
0.7), preferably in the range of about 13 to about 18 for ionically modified polymers and about 18 to about 23 for non-ionically modified polymers, with a zero shear melting point ( T _M゜)
Poly (ethylene terephthalate) having a glass transition temperature in the range of about 40 ° C. to about 80 ° C. and containing small amounts of matting agents and surface friction modifiers (eg, SiO ₂ and TiO ₂ ). Melts at the polymer temperature (T _P ) (in ° C),
Filter through an inert medium for the dwell time (t _r , min) and then through the capillary of the spinneret of diameter (D _RND ) and length (L) and the mass flow rate w [= (dpf・ V) /
g] (g / min) and the apparent capillary shear rate (G _a (sec- ¹ ) =
Extrude at {(32 / π) (w / ρ) / D _RND ³ )]. Here, the dimensions of the capillaries are given in units of cm, and the removal speed (V) is given in units of km / min.

Most of the example filaments were spun using a spinneret having a filament density per extruded surface area of typically about 2.5 to about 13, but the capillary spin hole pattern (filament placement pattern) was quenched. Up to about 25 extruded filaments as long as they are optimized for mold (ie, radial or lateral) and initial quench delay ocean "shroud" and air velocity length / contour patterns (see Example 1) A bundle of dense filaments could be spun and quenched. The density of the extruded filament is the number of filaments extruded into the shroud ( _#c )
Divided by the extruded surface area (A _c ) (ie, # _c / A _c , c
m ^-1 ). The shroud has a newly extruded filament of at least 2 cm and about (12 dpf ^1/2 ) cm
To prevent direct exposure to quenching air for a distance not exceeding. Next, the extruded filaments are preferably treated with the polymer T _g, where Ta is about 70 for _a 2GT homopolymer.
° C.) lower than the temperature T _a (T _a linear velocity V _a at about 22 ° C.) is here
(M / min) with air directed radially from about 10 to about 30 m / min, and cooled with caution to a temperature below the T _g of approximately polymer. A suitable spinning device that can be used is U.S. Pat.
Nos. 2, 4,156,071 and 4,529,368.

Delayed quenching distance (L _QD ), quenching air temperature (T _a ). By adjusting the flow rate of the quenched air (V _a ) and the distance of the consolidation point (L _c ), the dispersion of denier (DS) and the variation of the stretching tension (DTV) were kept to a minimum. Polymer spinning temperature (T
_{Increasing P} ) (but keeping it below approximately [(T _M ) _a + 55 ° C]), the continuity and mechanical quality of the spinning (ie
(T _B , g / d) usually increases, but the uniformity per line usually decreases and shrinkage increases. High shear rate (G _a ) capillaries (ie small diameter capillaries) are used to spin at high temperature (T _P ) due to mechanical quality requirements while keeping the loss of uniformity per piece to a minimum. In addition, heat can be applied to the extruded filament. However, the ratio of L / D _RND is large, for example, 9
The use of high shear rate capillaries, such as x50 mil capillaries, makes the spinning operability worse than expected (see Example 3). Under such high shear conditions with low mass velocities in the capillaries, the polymer melt will have a premature ordering of the molecules induced by shearing (eg, reduced chain entropy and possible early "crystal nucleation"). Generation)) occurs. This is especially the case when the residence time (t _r ) of the filtered polymer melt before extrusion is about 4 minutes or more. In this case, it is believed that molecular ordering (possible initial crystal nucleation) raises the apparent polymer melting point from zero shear value (T _M゜) to apparent value (T _M ) _a . Therefore, the difference in spinning temperature T _P −
(T _M ) _a decreases. In order to keep the spinning temperature difference large enough, for _a selected value of L, D _RND and _Ga , the overall polymer temperature T _P is _calculated by the formula 2 × 10 ⁻⁴ (L / D _RND ) G _a (In ° C)
Need to be further increased by the amount defined by

In order to maintain a balance between spin continuity, mechanical quality and line-to-line uniformity, the internal stress (σ _a ) of the apparent spin line at the “neck point” is adjusted to about 0.
045 to about 0.195 g / d, and at the same time, the extrusion strain ε _a of the melt.
To about 5.7 to about 7.6. The thinned and cooled filaments are aggregated into a multifilament bundle, and the spinning speed (V, km / km) defined by the surface speed of the first drive roll.
Minutes). Externally applied spinning line tension caused by friction surfaces (and dragged air) is the first
About 0.5-5% between the drive roll and the take-up roll
Is removed prior to packaging by making a slight oversupply. The finish is applied at the point of consolidation and interlaced, preferably after the first drive roll.
The value of the amount of finish on the yarn (% by weight) and the degree of entanglement (RPC) are chosen according to the final processing requirements.

The thin filaments of the polyesters of the present invention have good mechanical quality and uniformity, and have a lower linear density than natural silk but higher than spider silk. That is, from about 1 to about 0.2 per filament. In addition, uniform dyeing can be performed without using a high temperature and a chemical dyeing aid. That is, it is more similar to natural silk.

Advantageously, if desired, the fine denier filament yarns of the present invention can be treated with caustic soda in a spin-finish operation [Grindstaff and Leeds, U.S. Pat. , The hydrophilicity can be increased, and the transportability and comfort of moisture can be improved. Filaments with different deniers and / or different cross-sections can be incorporated to reduce the degree of filling between filaments and improve tactile sensation, visual aesthetics and comfort. A unique dyeing effect can be obtained by mixing filaments with different degrees of polymer modification, for example a homogeneous polymer dyeable with a disperse dye and an ionic copolymer dyeable with a cationic dye.

Knox US Patent No. 4,156,071, McLean (M
acLean) and U.S. Patents 4,092,229 and Leeds, U.S. Patents 4,883,032, 4,996,740, and 5,
Thin filaments with low shrinkage are obtained by incorporating about 0.1 mol% of a chain branching agent or increasing the viscosity of the polymer by about +0.5 to about +1.0 LRV units, as described in U.S. Pat. be able to.

The thin filament yarn of the present invention may be, for example, warp drawing, air jet texturing, false twist texturing,
Suitable for gear crimping and push-in crimping. Also, less shrinkable filaments can be used as flat textile yarns for direct use and as feed yarns for air jet texturing and push crimping without the need for stretching. Filaments (and tows made therefrom) can also be crimped (if necessary) and cut into supple fibers and flocs. Textile fabrics made from these improved yarns can be surface treated using conventional grinding and brushing operations to achieve a suede-like feel. The tribological properties of the filament surface can be varied by choosing the cross-section, matting agent, and by treatments such as alkaline etching. In order to improve the combined strength and uniformity of the filaments, these filaments are used for final processing, which requires the use of thin filament yarns without cutting the filaments, and for uniform dyeing using dyes which require high technology. It is particularly suitable for

The polyester yarns of fine denier filaments of the present invention are particularly suitable for making textile fabrics having a high number of moisture barriers, such as rain gear and medical clothing. The surface of woven and knitted fiber fabrics can be fluffed (brushed or polished). To further reduce the denier, the filaments can be treated (preferably in the form of a textile) by a conventional alkali treatment. Fine filament yarns, in particular filament dyeable with cationic dyes, can also be used as covering yarns for elastomeric treated yarns (and staples), preferably by air entanglement as described in Stranchan US Pat. No. 3,940,917. The method can also be used. The fine filaments of the present invention can be mixed with high-denier polyester (or nylon) filaments as an online operation in the spinning process or in an offline operation, resulting in a bulk that can be bulked by post-processing with a mixed dyeing effect and / or mixed shrinkage. Ability can be given. In this case, the bulkiness can be developed as an off-line process, for example by oversupply with heating and at the same time beaming / slashing, or in the form of a textile cloth, for example in a dyeing bath. The degree of interlacing applied during spinning and the type / amount of finish are selected according to the needs of the textile treatment and based on the ultimately desired aesthetic requirements of the yarn / fiber fabric.

The process according to the invention and the products obtained thereby are further illustrated below.

Example 1 0.3 having 19 LRV (corresponding to about 0.6 [η])
Poly containing wt% of TiO ₂ (ethylene terephthalate) was spun yarns 100 and 300 filaments of nominal dpf. A 300 filament yarn was spun using a spinneret of varying configuration: for example, the following were made: (i) Capillary / capillary larger than about 40 mils (1 mm) without fusion of the filaments to each other. By controlling the distance, two or more capillaries from a single counterbore; (ii) 300 "equally spaced" single capillaries; and (iii) an effective extruded filament density of about 12.5 to about 25 ( Effective extrusion surface area (A) to increase FED
₀ ) 300 capillaries arranged in concentric rings that occupy about 50% of the "outer" half of the "outer"half; however, immediately after extrusion, the polymer melt flow in the spinneret (iii) converges Forming a conical bundle similar to the bundle of spinnerets (i) and (ii); and thereby an effective extruded filament density (EFD) of that degree for spinneret configurations (i) and (ii). That is, the effective extruded filament density (EFD) for such an unevenly distributed filament configuration less than 25 and greater than 12.5 is determined experimentally according to the procedure of the graph in FIG. . Experimentally, it has been discovered that filaments equally spaced over the entire extrusion zone and filaments spaced around the periphery in concentric rings have approximately the same effective filament extrusion density. This is because the bundle of filaments has a similar configuration immediately after extrusion. The data in Table I for a 300 filament yarn was first spun with capillaries arranged in concentric rings occupying about 50% of the effective extrusion surface area. The newly extruded filament is cooled to room temperature by using a radial quenching device, which is essentially as described in U.S. Pat. No. 4,156,071, except at 3500 ypm (3.2 km Per minute) and about 1 inch (2.54 cm) for yarn spun at 4500 yp.
m had "shroud" length of protection of about 2.25 inches for yarns spun at (4.12Km / min) (5.72 cm) a (L _DQ). Filament yarns spun at 3500 ypm (3.2 km / min) have a high boiling shrinkage (S),
It is particularly suitable as a supply yarn (DFY) in stretch warping, stretch air jet crimping, stretch false twist crimping, and stretch crimping. It is located at a spinning interval
Boiling shrinkage (S) when it increases to 4500ypm (4.115Km / min)
Decreases to a value smaller than 12%, and the differential shrinkage (ΔS = DHS−
S) is a peak temperature T of less than + 2% and less than 100 ° C.
(ST _max) maximum shrinkage tension (ST _max) in is less than 0.175 g / d, and the yield strength (strength at 7% elongation herein, T _7, approximated by) is greater than 1 g / d, an additional stretching or These filaments are perfectly suitable for direct use applications that do not require heat treatment, for example as filaments in flat, air-jet crimped and crimped filaments of stuffer boxes.

Filaments spun from a spinneret capillary having a cross-sectional area (A _c ) of 176.8 mil ² (0.1140 mm ² , 1.14 × 10 ⁻³ cm ² ) are 28.3 mil ² (0.0182 mm ² , 1.82 × 10 ⁻⁴ cm ²⁾ it was observed to have a strong lower break than spun filaments from the spinneret capillary (T _B) with a _c) of. Also, the lower tenacity of the yarn of this Example I is due in part to the polymer
LRV is lower (19 / 20.8). Normalized value (in this case (represented by T _{B) n)} for the T _B and the break was measured strength (T _B), for the yarns about 1.057
(20.8 / LRV) is defined by the product of ^0.75 (1-x) ^-4 ; thereby the normalized breaking strength (T _B )
_n is 20.8 and 0% of the reference LRV and TiO ₂ , respectively.
About 6% higher when compared to.

The fine filament yarn of this example uses the same method as the ordinary fully drawn yarn, without the use of a dye carrier.
For a PDDR value of 055, a relative disperse dye rate (R
It was possible to dye deep shades at ambient conditions (100 ° C.) as given by the DDR) value (normalized for 1 dpf).

Fewer filaments (and lower denier)
For example, a bundle of 300 filament yarns, preferably at the exit of the radial quenching chamber, by using a guide of the separation of the weighed finished chips, respectively, by a bundle of 150, 100 and 75 filament yarns, respectively. 2, 3, or 4 individual bundles.
Multi-ending allows for a higher mass flow rate (W) through the filter pack cavity, thereby reducing the residence time ( _tr ) in the pack cavity / yarn line.

Nominal 20.8LRV containing Example II 0.1 wt% TiO ₂ (about 0.65
[Η]) from poly (ethylene terephthalate)
At a take-off speed (V) of ypm (3.66 km / min), a radial quenching device, essentially as described in Example I, but with a delay "shroud" length of about 2.2 inches (5.72 cm) Fine filaments were spun using an apparatus having a _length ( _LDQ ). Examples II-5 and II-6 had poor workability and no yarn was collected. Using a 15 x 60 mil (0.38 x 1.52 mm, 0.038 x 0.152 cm) capillary
The low apparent shear rate (G _a ) for the 0.5 DPF filament spun at 4000 ypm (3.66 km / min) is believed to be due to poor workability and broken filaments. Even increasing the temperature T _p to about 299 ° C. did not provide acceptable processing. Processing and product details are summarized in Table I.

Example III In Example III, convergence was achieved in Examples III-1 to II.
U.S. Pat.No. 4,92 for I-9 and III-11 to III-25
68 and 136 (untwisted and twisted) filament yarns were spun essentially according to Example II except by a weighing tip as described in 6,661. Example II
I-10 used a metering finish roll surface to converge the filaments as described in Examples I and II. Other processing details are summarized in Tables I and II.
Example III-1 to III-5 and III-12~III-15 filaments having a larger T ₇ value of about 1 g / d, as filaments in the filament yarns of the textile material used directly,
It is particularly suitable as a feed yarn in air-jet crimping without drawing; and, where appropriate, Knox and Noe US Pat. No. 5,066,4.
As described in No. 47, in warp drawing (and air jet crimping), uniform drawing can be performed without heating (at ordinary temperature). Has a T ₇ value less than about 1 g / d
The filaments of III-6, 7 and III-16 to III-25 may be drawn feed yarns (DFY), such as filaments in drawn false twist crimping (FTT) and drawn air jet crimping (AJT), or It is particularly suitable as a drawn supply yarn in warp drawing.

In Examples III-1 to III-5, a 50 denier 68 filament yarn was spun from a single pack cavity and twisted in a shrink guide to obtain a 100 denier 136 filament yarn of excellent mechanical quality. . For example, Example III-4 is equal to about 9.5 break / ¹⁰⁹ meters 0.39
It had a spinning continuity of break / 1000bl (0.86 / 1000kg). The yarn of Example III-4 was undrawn and stretched using a Barmag F
Wound with an interlace of about 10 cm (measured by the rapid pin count procedure described in U.S. Pat. No. 3,290,932) for air blast crimping using K6T-80 and flat on woven and warp knitted fabrics Wound at about 5-7 RPC for direct use as a textile fiber. Examples III-6 and 7 were drawn at 1.44x and 1.7x, respectively, without breaking the filaments to give drawn 35 denier 68 filament yarns. Example II
III-6 is preferred over III-7 because the spinning productivity of I-6 (spin denier × spinning speed) is about 25% greater than in Example III-7. The yarn of Example III-6 was successfully drawn at room temperature at a draw ratio of 1.44 ×.

No. 4,134,882, Frankfort (F
L / D of 9 mil (0.229 mm, 0.0229 cm) capillary spinnerets as taught by rankfort) and Knox
Increasing the _RND ratio from 2.22 to 5.56 was expected to significantly improve mechanical quality by processing the shear heating of the extruded polymer melt; where the degree of capillary shear heating was (Frankfort) and Knox (Knox): 660 (WL / D
⁴ ) ^0.685 ° C, where D is given in mils and W is given in lb / h; however, broken filaments were observed for Examples III-8 and III-11. Acceptable quality was obtained for Example III-12, where the residence time ( _tr ) during filtration in the pack cavity was 6 by spinning 136 filaments.
Reduced for 8 filaments. 136 single thread bundles
It could be pulled out as a bundle of filaments or split and wound up a bundle of two 68 filament yarns.
High L / D _RND capillary spinneret for about 4 minutes less than the residual time (t _r), without using a high "Input" polymer temperature (T _p), it has been discovered that it is necessary to spin . See Example IX for a more detailed description of spinning using a high shear capillary spinneret. In Examples III-12 to III-15, 136 to 9 x 36 mils (0.2
29 × 0.916 mm, 0.0229 × 0.0916 cm) to spin a 136 filament yarn, which reduces the filtration retention time (t _r ).
Yarns of excellent mechanical quality were obtained, reduced by 50%. High filament count yarns are particularly suitable for stretch air jet crimping (AJT) and false twist crimping (FTT), where the configuration of a straight stretch crimping machine is preferred. Examples III-19, 22, 24 and 25
From the nominal 0.5 dpf as described in Example XII.
Warp yarn drawing was used to prepare flat yarn.

The structural properties of the filament of Example III-10 are 6%
5 represents a spun drawn filament of the present invention having less shrinkage. Example III-10 was 1.3667 g / cm ³ (0.03% Ti
Has a density ([ρ-measured = ρ-fiber-0.0087 (TiO ₂ %)]) corrected for O ₂ and has a calculated volume crystallinity fraction of 0.264 [X _v = (ρ _m −1.335) ) /0.12] and
Crystallinity wt% of _{0.281 [X w = (1.455 /} ρ c) X v]; 70 average crystal size of angstroms (Å) (CS); 0.93 crystal orientation function of _{[f c = (180-COA} ) / 180], an average crystal orientation angle (COA) of 12 degrees; an average orientation function of 0.34 [f =
△ amorphous orientation function of _n /0.22] and _{0.13 [f a = (f-} X V
f _c ) / (1−X _v )] and the average birefringence (△ _n ) and the amorphous-free volume of about 6 × 10 ⁶ cubic angstroms (（ ³ ) [(V _f , _am ) = [( 1−X _v ) / X _v ] [(1-f _a )
−f _a ] CS ³ ]. The filament of this example is
Also, the differential birefringence (△ _95-5 ) of 0.0113, N _{iso of} 1.5882, 8
An acoustic velocity (SV) of 2.72 km / s giving an acoustic modulus (M _son ) of 3.6 g / d, a contraction modulus of 3.1 g / d [M _S =
(ST _max / S) 100] to give a peak temperature T (S
Maximum shrinkage tension of 0.143 g / d in _{T max) (ST max),} 4.6
% Boiling shrinkage (S), differential shrinkage less than + 1% (ΔS =
DHS-S) to give a dry heat shrinkage (DHS) of 5.0%, an initial modulus of 71.6 g / d with a post-yield modulus (M _py ) of 5.35 g / d, and an undispersed dye rate (DDR) of 0.144 and about 0.10
It had a relative disperse dye rate RDDR of 4, normalized to 1 dpf.

Example IV 0.035,0.3 and 1 wt% of TiO ₂ nominal 21.2LRV (about
0.66 [η]) poly (ethylene terephthalate) with a delay “shroud” length ( _LDQ ) of about 2-5 / 8 inches (6.
7 cm), and spun using a radial quench spinning apparatus essentially as described in Example I, and bundles of filaments were weighed at 43 inches (109 cm) from the face of the spinneret with a finishing tip. Converge. Other processing details are summarized in Tables III and IV. TiO ₂ weight%
It is observed that the strength at break (T _B ) of these fine filaments decreases with increasing. The amount of TiO ₂ is usually about 0.035% with the the requirements of the smallest yarns / metal and yarn / yarn friction varies between about 1% for desired mechanical quality and Miteki aesthetic.

Example V Nominal 21.1 LRV containing 0.3% by weight TiO ₂ (about 0.655
[Η]) poly (ethylene terephthalate)
Spinning was performed using equipment similar to IV. Example V-1
V-4, IV-9 and IV-10 are 12 × 50 mil (0.305 × 1.2
A spinneret capillary of 70 mm (0.0305 x 0.127 cm) is used.
Examples V-5, 7, 8 and 11 were 9x36 mil (0.229x
A 0.914 mm (0.0229 x 0.0914 cm) spinneret capillary is used, and Example V-6 is 6 x 18 mil (0.152 x 0.0457 c).
m) 85 of 100 filaments for warp drawing and drawn air jet crimping (AJT) using a spinneret capillary
Spin the denier feed yarn. Delay quenching length ( _LDQ )
Is 2-5 / 8 (6.7c) in Examples V-8 and V-10.
m) to 4-5 / 8 (11.7 cm). Increasing the delay length ( _LDQ ) increased the non-uniformity along the ends and the inter-filament denier non-uniformity by 2x, as measured optically from the cross-section of the yarn bundle. Delay length (L
Excellent uniformity can be obtained when _DQ ) is less than about (12 dpf ^1/2 ) cm.

Example V-7 was compared with Examples V-11 to V-13 by 2400,
Repeated at 3000 and 350 ypm (2.2, 3.05 and 3.35 km / min); where the drawn feed yarn was spun with varying capillary mass flow rates (W) to draw the spun dpg to a final denier of about 0.5 dpf. [Where dpf is stretched
= Spun dpf / drawing ratio = spun dpf x (RDR of drawn yarn / R of spun yarn
DR), where the residual draw _{ratio, RDR = (1 + E B} ,% / 10
0)]. Examples V-11 to V-13 are 7% less than about 1 g / d
It has a tenacity (T ₇ ) value in elongation and shrinkage of undrawn yarn is 12
%, It was particularly suitable as a drawn feed yarn. The results of the warp yarn drawing are summarized in Example VII.

Example VI In the exceptional example VI, Example V-13 was changed to 3300 ypm (3.02 km /
Minute), spinning denier, delayed quenching length (L
_DQ ) was repeated for spinning temperature (T _p ) and convergence guide length (L _c ). Example VI has a 3.8% denier spread (DS) and has been successfully stretched at 1.35 × to 2.3%
Spread of denier, tenacity 4.4 g / d, of 32.5% E _B and
A drawn 0.3 DPF 100 filament yarn having a boiling shrinkage (S) of 6.3% was obtained. In this example, as the denier of the total yarn bundle and the denier of the individual filaments were reduced, the uniformity along the ends was observed to deteriorate unless the process was rebalanced.
It is necessary to increase the temperature of the polymer to ensure good spin continuity at these low mass flow rates. By reducing reduced delay lengths (L _DQ) to about 2.9cm and convergence lengths (L _c) to 109Cm～81cm, denier spread along the end (DS) is 12.1% (Example VI-
It was improved from 1) to less than 4%. For yarns with a DPF less than 0.5, the same D as for 0.5 to about 1 dpf
It is difficult to achieve an S value. Processing and product details are summarized in Tables III and III.

Poly nominal 21LRV Ru containing Example VII 0.035 wt% of TiO ₂ (ethylene terephthalate), 9 × 36 mil (0.229 × 0.914m
m, 0.0229 x 0.0914 cm) and 12 x 50 mil (0.305 x 1.27)
0 mm, weighing capillary and about 197 mils ² of 0.0305 × 0.0127 cm)
(1.27mm ^2, 0.0127cm ²⁾ area of the Y-shaped exit orifice, which is about 15.9 mils with about 1.5 L / D _RND (0.40mm,
A thin trilobal filament was spun using a D _RND of 0.04 cm) (essentially as described in US Pat. No. 4,195,051). 9 x 36 mil measuring capillary is 12 x 50
It provided better mechanical quality and denier uniformity along the ends than the mill metering capillaries. A 100 filament yarn could be drawn to a nominal 50 denier or about 0.5 dpf without forming broken filaments.

Example VIII About 2 mol% of ethylene 5- having a nominal LRV of about 15.3
A poly (ethylene terephthalate) polymer modified with sodium-sulfoisophthalate was converted to 2.2 inches (5.6 cm) essentially as described in U.S. Pat. No. 4,529,638.
A laminar cross-flow quench apparatus with a delay of about 1 mm and was spun by converging a bundle of filaments at about 43 inches (109 cm) with a metering tip guide. Lower LRV is usually preferred for ionically modified polyesters. This is because ionic sites are used as crosslinkers and provide higher melt viscosities. The 15 LRV used here had a melt viscosity close to that of the 20 LRV homopolymer. However, low
When spinning homopolymers of LRV, it is typically advantageous to add a viscosity generator, such as tetra-ethyl silicate [Mead and Reese, US Pat. No. 3,335,211. As described in]. Generally, an ionically modified polyester having an LRV in the range of about 13 to about 18 and an LRV in the range of about 18 to about 23
It is preferred to use non-ionically modified polyesters with LRV. Pick up speed 2400ypm (2.2Km
/ Min) to 3000ypm (2.74Km / min). As expected, cationic copolymer yarns are lower than their
It had lower T _B value based on LRV. Lower LRV is preferred in fluffed and brushed fabrics and for tows to be cut into flocks. The as-spun yarn could be drawn into a 100 filament yarn of about 50 denier without breaking the filament. The cationically modified polyester had an RDDR value of 0.225, whereas the 2GT homopolymer spun under similar conditions had 0.125.

Nominal 21.9LRV containing Example IX 0.3 wt% of TiO ₂ (about 0.67
[Η]) poly (ethylene terephthalate)
Spinning using an analogous to IV at an air flow rate of about 30 m / min. Examples IX-1 to IX-3 are 12 × 50 mil (0.305 × 1.270)
Examples IX-4 to IX-8 use 9 x 36 mils (0.229 x 0.914 mm, 0.02 mm).
29 × 0.0914 cm) spinneret capillary used; and
IX-9 to IX-11 are 6 × 18 mil (0.152 × 0.457 mm, 0.0152
× 0.0457cm) as a direct use textile fiber for warp knitted fabrics and fabrics using a spinneret capillary and as a feed yarn for air jet and crimping of stuffer boxes that do not require stretching. Spin a suitable, nominally 50 denier, 100 filament, low shrink yarn.

No. 4,134,882, Frankfort (F
rankfort) and Knox (Knox) teach,
Increasing the capillary shear rate (G _a ) was expected to improve mechanical quality. This improvement was observed for a 12x50 mil capillary for a 9x36 mil capillary;
However, unexpectedly, higher polymer temperatures were required to spin using a 6 × 18 mil capillary. Higher shear rate (G _a ) of 6 × 18 mil capillaries
From the calculation of the increase in polymer temperature for the 6 × 18 mil capillary, as with the teachings of Frankfort and Knox, than for the 9 × 36 and 12 × 50 mil capillaries, Lower polymer temperature (T _p )
Was expected to actually need. However,
To provide acceptable spin continuity for a high shear 6 × 18 mil capillary spinneret, it was necessary to increase the polymer temperature by about 5-6 ° C. At these low mass flow rates (W), a 6 × 18 mil capillary induces molecular ordering of the polymer melt and further induces nucleation, producing the effect of increasing the apparent polymer melting point. Which is expressed by the following experimental expression as a function of capillary shear (G _a ): (T _M )
^{_{a = T M 0 + 2 ×}} 10 -4 [L / D RND) (G a), ℃. The difference polymer spin temperature is defined here by: [T _p- (T _M ) _a ] = [(T _p -T _M ⁰ )-[2 × 10 ^-4 (L / D _RND ) G _a ] Effectively reduces as the product of the shear rates (G _a ) of the _fibers , and the product-ratio of L / D _RND increases; and thus, for spin continuity, the minimum differential spinning temperature is at least about 25 ° C., preferably It is necessary to increase the polymer temperature T _p to maintain at least about 30 ° C. This is contrary to what would be expected from the teachings of Frankfort and Knox.
Processing and product results are summarized in Tables IV and V.

Nominal 21.9LRV containing Example X 0.3 wt% of TiO ₂ (about 0.62
[Η]) poly (ethylene terephthalate)
Using an apparatus similar to VI, spinning was performed with air flow rates varying from about 11 to about 30 m / min. Examples X-1 to X-9 are 12 × 50
Mill (0.305 x 1.270 mm, 0.0305 x 0.0127 cm) spinneret capillaries are used and Examples X-10 to X-16 use 9 x 36 mil (0.229 x 0.914 mm, 0.0229 x 0.0914 cm) spinneret capillaries. Nominal 70 denier 100 filaments suitable for use as direct use textile fibers for warp knitted fabrics and fabrics, and as feed yarns for air jet and stuffer box crimping that do not require stretching Spinning yarn with low shrinkage. It was observed that the mechanical article improved at higher polymer temperatures and lower air flow rates. Variations in the distance L _c of the convergence guide had little effect on the mechanical properties as observed for the higher dpf filaments [Bayer, DE 2,814,104]. In the meantime, changes in processing to improve mechanical quality caused degradation in denier uniformity along the edges.Both excellent mechanical quality and denier uniformity Requires a balance between "hot" polymer for polymer quality and "rapid" cooling of the polymer for homogeneity.The combination of "hot" polymer and slow instantiation through the use of a low quench rate will reduce the shroud. Using a delayed and / or heated delayed quench,
In contrast to the teachings of Frankfort and Knox, which produced superior quality filaments of denier greater than one. The balance between a higher "input" polymer temperature (T _p ) using shear heating through a smaller diameter capillary spinneret and a rapid quench through a short (L _DQ ) generally provides a better balance of yarn properties. Is possible. Reducing the convergence length (L _c ) has improved uniformity and reduced winding tension as a result of lower air resistance. Frankfor
At higher spin deniers at t) and Knox, no significant improvement in shortening the convergence length is found. Processing and product results are summarized in Tables V and VI.

Example XI The thin filament feed yarns of Examples V-11, 12 and 13 were obtained at room temperature and 155 degrees Celsius, at 1.45K and 1.45K, respectively.
It was drawn uniformly at a draw ratio of 5 × and 1.55 × to give a drawn yarn of nominally 50 denier and 100 filaments which could be used as a flat textile fiber. The drawn fine filament yarn has excellent mechanical quality and denier uniformity along the ends, with a boiling shrinkage (S) of less than about 6%. Cold drawn yarns have slightly lower shrinkage than hot drawn yarns, and
Slightly more uniform. With low levels of interlacing and different finishes, these yarns can be cold drawn and air jet crimped, resulting in Knox
And Noe US Pat. No. 5,066,447. The spun yarn of these fine filaments
Further, it can be used as a supply yarn for air injection / stuffer box / friction twist crimping. Table VII summarizes the warp drawing process and product details.

Example XII Examples III-20 to 25 were repeated by varying the spinning speed and spin denier to produce a drawn feed yarn that could be drawn to produce a 35 denier 68 filament yarn. A nominal 50-60 denier as-spun yarn with excellent mechanical quality and denier uniformity is cold drawn and heat set at 160-180 ° C. to provide mechanical quality and denier along the edges A low shrinkage filament of nominally 0.5 dpf without loss of uniformity was obtained. Table IV details of spinning process and products
And V, and the details of the corresponding stretching process and product are summarized in Table VII.

In Example XIII Example XIII, it was investigated ability to obtain a yarn of fine Fimento high T _7. A spinning apparatus similar to that in Example X was used. Nominal 20.8 LRV (0.65 [η]) poly (ethylene terephthalate) containing 0.3% by weight TiO ₂ was prepared using a 9 × 36 mil (0.229 × 0.914 mm, 0.0229 × 0.25 mm).
Extruded through a continuity of spinning of about 0914 cm) and about 2.25
Example I except having a delay length L _DQ of inches (5.7 cm)
Cooling was performed using a radial quench device as described in The cooled filament is then removed about 32 inches (81.3 inches) from the face of the spinneret using the guide of the weighing finish tip.
at a convergence length (L _c ) of the yarn bundle. Pick up speed (V) from 4500ypm (4.12km / min) to 5300ypm
Varied by (4.85Km / min), to give a direct use of textile fibers of 68 and 100 filaments with a T ₇ value of about 1-1.5 g / d. Processing and product details are summarized in Table VI. Example XI
The tensile properties of II are lower than the polymer melt temperature (T _p ) and higher quench air flow rate (V _a ) in Example X.
Inferior for use.

Example XIV A 91 denier 100 filament yarn made according to Example IV was air jet crimped at 300 Km / min using a Barmag FK6T-80; the freshly spun yarn was 1.0 × Draw at room temperature at draw ratios of 1.1 ×, 1.2 × and 1.32 ×, and in turn air-crimp using 125 lb / in ² (8.8 kg / cm ² ) using ordinary air blast. , About 0.7-0.9 (before boiling shrink) and about 0.77-0.
A loft having a filament denier of 94 dpf (after boiling shrinkage) was obtained. The denier of the crimped filament yarn that was not drawn shows an increase in yarn denier of about 11% due to bulk (eg, filament loops) where the ratio (denier) _AJT / (denier) _FLAT is preferably greater than about 1.1; however, the denier of the filaments did not show an increase in denier. The strength of the crimped yarn was, as expected, lower than that of the flat yarn stretched for the filament loops; however, it is suitable for the bulk fabric end use. Even at 1.32 × draw, a crimped yarn having a residual elongation of 27.2% (corresponding to a residual draw ratio RDR of 1.27) is obtained, with boiling shrinkage (S) and dry heat shrinkage (DHS)
Was only about 12.7% and 11%, respectively, with shrinkage (ΔS = DHS-S) less than about (1.7%). Heat consolidation can reduce these shrinkages to about 2% if desired. Examples XVI-1 and 2 were uniformly partially cold drawn by providing an RDR of about 1.4x in the drawn yarn as defined herein.
The ability of these fine filaments to be uniformly and partially stretched contributes to the crystal structure of the as-spun filaments and, as in US Pat. No. 5,066,447 to Konx and Noe, %, Preferably less than about 10%, especially less than about 8%. In Examples XIV-5-5, 68 filament yarns were sequentially cold drawn and air jet crimped. Shrinkage increases with draw ratio, higher shrinkage AJ
Route to T thread manufactured. Processing and product data for Example XIV are summarized in Table VIII.

At least one AJT yarn has been heat set to a shrinkage of less than about 3%, and a second AJT yarn has not been heat set and has two or more cold delayed AJT yarns having significantly higher shrinkage. Co-mixing (twisting) provides a simplified route to mixed shrink yarns. Similar mixed AJT yarns can have a lower shrinkage component provided by another technique, for example, with or without heat consolidation, rather than hot drawing. Alternatively, a mixed AJT yarn can be obtained by co-mixing a bundle of two or more filaments, wherein both bundles are stretched by cold drawing without post-heating, but the bundles have different elongations. The film is drawn at room temperature, preferably about 10% or more. The resulting mixed shrink-drawn yarn can be AJT to obtain a mixed shrink-crimped (bulky) yarn. Also, the incorporation of filaments of different denier and / or cross-section can be used to reduce filament / filament packing, thereby improving the aesthetics and comfort of the implant. A unique dyeing effect can be obtained by modifying different polymers, for example, by co-mixing drawn filaments of a homopolymer dyeable with a disperse dye and an ionic copolymer dyeable with a cationic dye. AJT processing and product details are summarized in Table VIII.

Example XV In Example XV, a yarn was spun for use as a draw feed yarn (DFY) in false twist crimping (FTT). Example XV-1, 68 filament yarn of nominal 58 denier at 500 m / min using an L900PU machine with a 1.707 D / Y ratio
After crimping at a draw ratio of 1.628 ×, a tenacity (T) of 4.1 g / d, an elongation at break (E _B ) of 26.8%, a tenacity at 7% elongation of 2.19 g / d (T ₇ ) and 44.6 g A nominally 37 denier (0.54 dpf) 68 filament crimped yarn having an initial modulus (M) of / d was produced. In Example XV-2,
Nominal 118 denier 200 filament shrink feed yarn, 1.
Except at a stretch ratio of 1.461 × with a D / Y ratio of 59, Example XV−
As in 1, prepared for false twist crimping,
Strength (T) of about 3.25 g / d and elongation at break of about 23.9% (E
A crimped yarn of 200 filaments of 83.5 nominal denier with _B ) was produced. Also, a 200 filament yarn is disclosed in Knox and Noe in US Pat. No. 5,066,447.
As No. teachings and successfully "partially" warp drawn at a draw ratio of 1.49 ×, 200 filaments of nominal 79.6 denier with a tenacity and 45.1% elongation at break of 4.81g / d (E _B) Was manufactured. In Example XV-3, a nominal 38 denier 100 filament yarn was prepared for use as a draw feed yarn in false twist crimping and warp drawing. Processing workability for Example XV-3 was even better using a 6 × 18 mil (0.152 × 0.457 mm) capillary than using a 9 × 36 mil (0.229 × 0.914 mm) capillary. . The yarn of Example XV-3 is an example.
Warp stretching over a range of conditions in XVIII, from 0.22 to 0.22 for woven and knitted fabrics
A 0.27 dpf 100 filament yarn was produced.

Example XVI In Example XVI, 1 containing 0.035% by weight of TiO ₂
2.2 LRV polyester polymer, 318 mil ² (0.2
9 x 36 mils (0.229 x 0.914 m) with existing orifices in the cross section of a 05 mm ² ) 4-diamond corrugated ribbon
m) at 285 ° C. through a metering capillary. A bundle of 80 denier 100 filaments was quenched using a radial quench apparatus similar to that used in Example III with a 2.9 cm delay length, and 10
At 9 cm, it was converged by a weighing tip applicator and withdrawn at 2350 ypm (2.15 km / min). Four
A yarn quenched with 7.5 mpm room temperature air yields a denier spread (DS) along the end of about 1.6-1.8%, a BOS of about 2.8%,
With an average elongation at break (E _B ) of 2.9% and an average strength at break (T _B ) of 4.56 g / d, a (T _B ) _n / T ₇ ratio of about 4.3 was obtained.
When the quench air velocity to reduce the 21.7 m / min, T _B of about 4.46 g / d
And the (T _B ) _n / T ₇ ratio was about 4.5. Lower T _B
The value (ie, less than about 5) is the result of the shape of the cross-section of the corrugated filament, and such filaments are processed in, for example, false twist crimping (FTT) and air-jet crimping (AJT). Can be used,
Here, for a more spin-like aesthetic, destruction of the filament is desirable in order to obtain even thinner filaments (ie, even less than about 0.2 dpf).

Example XVII In Example XVII, a 50 filament of nominal 43 denier with about 16-17% concentric voids was run at 3500 ypm (3.5 km / min).
And at 4500 ypm (4.12 km / min). Nominal 2
1. Essentially Champaneria et al., U.S. Patent No. 3,745,061, Farley and Barker, UK Patent No. 1,106,263, Hodge
ge), U.S. Pat. No. 3,924,988 (FIG. 1), Most
t), US Pat. No. 4,444,710 (FIG. 3), British Patent No. 83
No. 8,141, and British Patent No. 1,106,263, using a segmented capillary orifice with a 15 × 72 mil (0.381 × 1.829 mm) metering capillary, using a 2LRV
Was post-coagulated at 290 ° C. to form hollow filaments. The geometry of the entrance capillary (counterbore) to the segmented orifice was adjusted to optimize extrudate swelling and minimize premature collapse of the hollow melt spinline. The ratio of the inner and outer diameters of the circular cross-section formed by the segmented orifices was adjusted to obtain a void content of greater than about 10%, preferably greater than about 15%. Void content extrusion void area (πID ^2/4), mass flow rate, the viscosity of the melt polymer (i.e., compared to LRV / T _p) that is discovered to increase with increasing together and withdrawal rate (V), And choose the above processing parameters, at least about 10
%, Preferably at least about 15% void content (VC). For example, the thin hollow filaments were quenched using a radial quench device equipped with a short delay length shroud, as described in Example Example XVI, except that the air flow was reduced to about 16 m / min. At a distance of less than 140 cm, it converged through the applicator of the weighing tip. 3.
The yarn spun at 2 km / min is about 9 gpd / 90% / 45 gp, respectively.
It had a tenacity / elongation / modulus of d and a tenacity at 7% elongation (T ₇ ) of about 0.88 g / d. The yarns spun at 4.115 km / min each had a tenacity / elongation / modulus of about 2.65 gpd / 46% / 64 gpd and a tenacity at 7% elongation (T ₇ ) of about 1.5 g / d. The yarn spun at 3.2 and 4.12 Km / min had a boiling shrinkage (S) of about 3-5%.

Example XIII In Example XIII, the spun yarn of Example XV was 1.4 ×
Stretching over a range of stretching ratio of ~ 1.7K, respectively,
Was produced yarn drawn filaments of denier from 26.6 to 22.2; the strong increases the 5.61 g / d from 4.38 g / d, and increases the draw ratio, the elongation at break (E _B) is from 36.6% 15.8
%. All drawn yarns had a boiling shrinkage (S) of about 4%. Table VIII for processing and product details
checking ...

Example XIX In Examples XIX-1 and XIX-2, a nominal 0.5 DPF
200 filament and 168 filament yarns (feed yarns from Examples XV-3 and 4, respectively) were spun at 44000 ypm (4.02 km / min) for use as flat yarns for woven and knitted fabrics direct use. These yarns can also be air jet crimped (AJT) without stretching to produce low shrink AJT yarns with a nominal 3% shrinkage.

Example XX In Example XX, a filament of the invention of less than 1 denier is replaced with a higher denier filament, for example,
Low shrink filaments and / or Piazza and Reese US Pat. Nos. 3,7, as described in Knox US Pat. No. 4,156,071.
Mixed filament yarns are prepared by co-mixing high shrink filaments, such as those described in US Pat. No. 72,872, for example, to reduce the low shrink filaments of the invention to Piazza and Reese. Offers the potential for mixed shrinkage (eg, post-bulking in fabrics), such as when combined with high shrink filaments. Mixed dpf low shrink filaments, such as those made by co-spinning the filaments of the present invention with the filaments described in Knox, U.S. Pat. No. 4,156,071;
On-line heat treatment using a heated tube or steam jet, where essentially no denier reduction of the yarn filaments of the yarn occurs (ie, there is no spaced drawing)
The present invention provides a unique blended post-shrink bulkable filament yarn wherein the shrinkage of filaments of less than 1 denier of the present invention is essentially unchanged, but the higher denier filaments (eg, 2-4 dpf) ) Shrinkage greater than 10% from initial boiling shrinkage less than about 6-10%,
Typically it increases to about 15-13%. The mixed shrink yarn produced by the described intermediate heat treatment is different from that obtained by combining the low shrink filaments of the present invention with the higher shrink filaments of Piazza and Reese. The resulting high shrinkage filaments have significantly improved shrink strength (eg, at least about 0.15 g / d), thereby generating bulk from mixed shrinkage even in very tightly structured woven fabrics be able to.

The combination of high shrinkage and high shrinkage tension (herein referred to as shrinkage force) has conventionally been, for example, ordinary LOY / MOY /
It was obtained by fully stretching the POY and then performing no or low temperature annealing. The less than one denier filament of the present invention migrates to the surface on the mixed shrink, providing a soft, luxurious aesthetic, even in the tightest structured fabric. The heat treatment typically increases the tension during the heat treatment after the filaments are completely thinned and quenched to a temperature below their glass transition temperature, the magnitude of the observed increase in shrinkage tension due to said heat treatment. In a manner that is of a size equal to Near room temperature crystallization temperature T _CC (DSC), (typically about 55 to about 115 ° C)
Choosing a heat treatment condition that is higher and less than about the maximum crystallization temperature T _C (typically about 150 to about 180 ° C. for most polyesters) results in high shrink tension with very good dyeability (eg, high RDDR). It gives the filaments, but the process of a temperature higher than T _C gives the filaments of higher shrinkage tension dyeability is reduced. The filament is heated at a high pressure with superheated steam (eg,
140140 psi) or by passing through a heated tube. The high and low DPF filaments can be spun from separate pack cavities and then combined to form a single mixed dpf filament bundle or spun from a single pack cavity, where Capillary dimensions (L
And D) and providing a different mass flow rates and select the number # _c of the capillary; for example, the denier ratio of the spun _{filaments, [(dpf) b / (} dpf) a] approximately [(L _a D _b) / L _b D _a )
ⁿ × (V _a / V _b ) × (D _b / D _a ) ³ ]
Where a and b mean filaments of different deniers; n = 1 for a Newton polymer melt
(And here empirically determined from a conventional capillary pressure drop test) and the measured average dpf =
_{[(# A dpf a + #} b dpf b) / (# a + # b]. In addition, by using the heat treatment process above, as defined by the requirements of the particular end use, 1 denier invention Increasing the lower shrinkage of lower fimentation, eg, about 3 at high shrink tension (and shrink force) for tightly structured fabrics
% To about 6-8% is possible.

Example XXI In Example XXI, uniform cold drawing into 50 denier 68 filament undrawn flat textile fiber and heat treatment at 160, 170 and 180 ° C to about 4-5
% Boiling shrinkage (S) and about 3.5 g / d T ₇ , about 4.5 g / d strength and about 27% elongation at break (E _B ) of a nominal 36 denier.
A 50 filament drawn yarn was produced. The drawn yarn has a Uster% of about 2.1-2.4% and can be used for critically dyed fabrics.

Example XXII The fine denier weft yarn of the present invention can be used to cover elastomeric yarn (and tape) by the entanglement of high velocity air jets taught in Strachan US Pat. No. 3,940,917. it can. Thin filaments of the polyester prepared from cationic dyeability modified polymers for the elastomeric yarn, for example, for Lycra (Lycra ^R), the dye from the elastomeric yarn "bleed", for example, nonionic dispersing that observed for Lycra which was covered with a polyester homopolymer dyed with a dye (Lycra ^R), it is particularly suitable to prevent. The direct use filaments of the present invention are preferred for air entanglement coating processes (and
Particularly preferred are those having increased shrinkage, shrinkage tension, and shrinkage force as described in XX), and the coated elastomeric yarn can be prepared under atmospheric conditions without using a carrier, for example,
It can be dyed, similar to the dye bath used to dye elastomeric yarns coated with nylon filaments (excluding anionic acid dyes).

Some examples of fabrics made from the yarns of the present invention are as follows: 1) Low-shrink 70 denier 100 filament direct use flat yarn weft and 70 denier 34 filament ordinary warp yarn. Made using drawn POY warp yarns, and 420 on a high speed water jet loom
164 warps / inch warp woven at a weft / min and 92
Formed a plain weave fabric with filling of weft / inch,
2) Use 70 denier 100 filament direct use thread warp over and 60
3) lounge satin weave, in combination with denier 100 filament false twist crimped weft, to form a satin weave with 172 warps and 100 wefts / inch weft; Crepe decine, comprising a warp yarn of 70 denier 100 filaments direct use yarn and a weft yarn of a 60 denier 100 filament false twist crimped yarn of 2 twists.

For convenience, the symbols, transformations and analytical expressions used previously are described below: PET Poly (ethylene terephthalate) 2GT PET TiO ₂ Titanium dioxide SiO ₂ Silicon dioxide () _f “Fiber” () _p “Polymer "() _m" measured "dpf denier / filament (1g / 9000m) dpf (ABO ) DPF dpf after boiling shrinkage (BBO) spread% denier along the DPF DS ends before boiling shrinkage (± sigma) DTV stretching Fluctuation of tension (%) [η] Intrinsic viscosity (IV) LRV Relative viscosity (Lab) IV Intrinsic viscosity LRV _{20.8 At} 295 ° C (C), the same melting as a 20.8LRV homopolymer (unmodified 2GT). LRV of polyester polymer having viscosity C η _a Apparent melt viscosity (Poise) η ₀ Melt viscosity as shear rate-> 0 X Weight fraction of matting agent T _M ⁰ Zero-Shear polymer melting point (° C.) (T _m) of _a polymer Multiplying the melting point (° C.) T glass transition temperature of _g polymer (° C.) T _p the polymer melt spin temperature (° C.) T _a quench air temperature (° C.) T _s spin line surface temperature t _r filtration residence time (min) w Capillary Mass flow rate (gpm) q Capillary volume flow rate (cm ³ / min) Q Spin pack flow rate (gpm) #c Number of filaments / spin pack V _F Spin pack (filled) free-volume (cm ³ ) L Capillary length L / D _RND capillary length - ratio D _RND x equal cross-sectional area rounded capillary (a _c) equal to the capillary diameter D _ref reference cross-sectional area of diameter a _c a copolymer of diameter D _SPRT test spinneret spinneret diameter ( cm ² ) G _a Apparent capillary shear rate (sec ^-1 ) ε _a Apparent spinline distortion E _R Apparent spinline elongation ratio EFD Elongated filament density dV / dx Velocity gradient δ _a Apparent internal spinline distortion ( g / d) V _a Quenched air layer velocity (m / min) L _DQ quenching delay length (cm) L _c Convergence length (cm) V Spinning speed at _c convergence (Km / min) V Spinning (removal) speed Km / min) V ₀ Capillary extrusion speed (m / min) A ₀ Spin pack extrusion area (cm ² ) dV / dx Spinline velocity gradient η Melt viscosity (Poise) DQ delayed quenching () _N ypm, y / min yard / min mpm, m / min meter / min gpm, g / min gram / min measured at “neck” point σ _m Fiber density measured (g / cm ³ ) σ _c Fiber density corrected for matting agent σ _a Amorphous density (1.335 g / cm ³ ) X _v Crystallinity of volume fraction X _w Weight % Crystallinity S boiling shrinkage% DHS dry heat shrinkage% △ S shrinkage difference (DHS-S) S _m maximum shrinkage potential (%) ST shrinkage tension (g / d) ST _max maximum shrinkage tension (g / d) T (ST _max ) Peak temperature of contraction tension (° C) P _S Contraction force (g / d) (%) T _SET maximum adjustment temperature Mi Instantaneous tensile modulus (g / d) M Initial (Young) tensile modulus (g) / d) M _py after ya 'S modulus (g / d) T ₇ potent in 7% elongation (g / d) T ₂₀ strong at 20% elongation (g / d) T potent (g / d) T _B break strength (g / dd) (T _B ) _n normalized T _B (g / d) gpdd, g / dd gram / stretched denier gpd, g / d gram / (original unstretched) denier SF form factor (= P _M / P _RND ) P _M Measured perimeter (P) P _RND P RDDR of a round fiber of equal area RDR Relative disperse dye speed (min ^1/2 ) DDR Disperse dye speed (min ^1/2 ) RDR Residual stretch ratio 1.ab × For example, the value “ draw ratio E _B elongation at break 1.ab "(%) tan [alpha secant after yield modulus (g / d) tanβ tangent after yield modulus (g / d) △ _n birefringence △ _a birefringence of amorphous regions △ _c Birefringence in crystalline region △ ⁰ Intrinsic birefringence SOC Stress-optical coefficient (gpd) ^-1 f _a Amorphous orientation function f _c Crystal orientation function COA Crystal orientation angle (WAXS) LPS Long-term interval (SAXS, I) CS average (WAXS, 010) crystal size Tcc (TSC) DSC Cold crystallization temperature (℃) T (E "max ) E" peak temperature E "dynamic loss modulus (g / d) M _son acoustic modulus M _S shrinkage modulus (g / d) SV acoustic velocity (Km / min ) V _f , _am Amorphous free volume (Å ³ ) Å Angstroms mil 0.001 inch = 0.025 mm = 25.4 microns μ microns (10 ^-6 m = 10 ^-4 cm = 10 ^-3 mm) Km / min km / min = ¹⁰³ meters / min A hydro carbonate over dioxy units [-O-
R'-O-] B hydrocarborene carbonyl unit [-C
(O) -R "-C (O)-] R ', R" hydrocarborene group C, H, O carbon, hydrogen, and carbon -O- "oxy" (ether) bond-(O) -carbonyl group PRC Rapid pin count FOY Weight finish% on yarn AJT Air jet crimping LOY Low drawn yarn MOY Medium drawn yarn HOY Highly drawn yarn POY Partially drawn yarn SOY Spun drawn yarn DUY Direct use yarn FDY Fully drawn yarn Yarn that can be bulked after PBY WDFY warp stretched supply yarn DFY stretched supply yarn DTFY stretched crimped supply yarn FTT false twist crimping SBC crimping of stuffer box SBT crimping of stuffer box SDSO Simplified direct spinning and stretching WAXS Wide Angle X-ray scattering SAXS Small angle X-ray scattering DSC Differential scanning calorimeter RAD Radial quenching XF Cross-flow quenching DT Stretching tension (gpd) DTV Stretching tension variation (%) IFDU Uniformity of denier between filaments RND Round TR I Trefoil RIB Ribbon HOL Hollow ABO After boiling shrinkage BBO Before boiling shrinkage RV Relative viscosity FVC Void content fraction EVA Extrusion void area ID Inside diameter OD Outside diameter d Filament diameter (cm) N _iso isotropic refractive index

Continued on the front page (72) Inventor Frank Huat, Hans Rudolf Edward Edward 27858 Greenville Court Naasque Air Apartments 28B, North Carolina, United States 28 Be (72) Inventor Jyonson, Stephen Batzkner 28403 North Carolina, USA Wilmington Williams Road 218 (72) Inventor Knox, Benjamin Hewies, 19808 Wilmington Oregon Road 40, Delaware, USA (72) Inventor Most, Elmer Edwin, Junior 28501, North Carolina, United States Kinston Stockton Road 1220 (56) Reference Reference JP-A-62-97907 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) D01F 6/62

Claims (19)

(57) [Claims] 1. A process for producing fine filaments of a spun oriented polyester having a denier in the range of about 1 to about 0.2, wherein: (i) the polyester polymer has a relative viscosity (LRV) of about 13;
~ 23, with a zero shear melting point (T _M゜) of about 240 ~
It is in the range of about 265 ° C and has a glass transition temperature (T _g ) of about 40-8.
(Ii) melting the polyester and heating to a temperature (T _P ) in the range of about 25 to about 55 ° C. higher than the apparent polymer melting point (T _M ) _a ; (Iii) filtering the obtained melt at a sufficiently high speed with a residence time (t _r ) of about 4 minutes or less; (iv) filtering the filtered melt at a mass flow rate (w of about 0.07 to about 0.7 g / min); ) Is extruded through the capillary of the spinneret, the capillary having a cross-sectional area (A _c ) of about 125 × 10 ⁻⁶ cm ² to about 1250 × 10 ⁻⁶ c
m ² , length (L) and diameter D _RND are selected such that the ratio of (L / D _RND ) is at least about 1.25 and not more than about 6; (v) the extruded melt is When leaving the capillary,
Prevents and at least 2cm about (12dpf ^1/2) over a cm or less distance (L _DQ)該熔Torubutsu is cooled directly, the denier per filament of where the polyester filament dpf is spun orientation have Said sub (Vi) cooling the extruded melt to a temperature below the glass transition temperature (T _g ) of the polymer and making it thinner so that the apparent spin line distortion (ε _a ) is about 5.7 to about 7.6. The apparent spinning line internal force (σ _a ) is in the range of about 0.045 to about .195 g / d; (vii) then cooling the cooled filaments from the spinning surface by about 5
Consolidating into a multifilament bundle using a low friction surface at a distance (L _c ) of 0 to about 140 cm; (viii) removing the multifilament bundle at a removal speed (V) of about 2 to about 6 km / min; Winding at a speed in the range. 2. The polyester of claim 1 wherein said polyester comprises from about 1 to about 3 mole% of ethylene-5-M-sulfoisophthalate structural units, wherein M is an alkali metal cation. Method. Wherein the polyester is substantially polyethylene (ethylene terephthalate), first hydrocarboxy dioxy structural units _{A [-O-C 2 H 4} -O-] and hydrocarbonoxy dicarbonyl present alternately Structural unit B [-
(O) C—C ₆ H ₄ —C (O) —], which differs from the alternating first hydrocarbylenedioxy structural unit A and hydrocarbylenedicarbonyl structural unit B by a small amount. Hydrocarbylenedioxy structural unit A and / or hydrocarbylenedicarbonyl structural unit B
A polyester polymer having a zero shear melting point (T _M゜) in the range of about 240-265 ° C and a glass transition temperature (T _g ) in the range of about 40-80 ° C. The method of range 1. 4. An apparent spin line distortion (ε _a ) of about 6
~ 7.3, strength at 7% elongation (T ₇ ) is about
Apparent spin line internal stress ([sigma] _a ) to obtain an average degree of orientation represented by 0.5 to about 1.75 g / d.
2. The method according to claim 1, wherein 5. The polymer temperature (T _P) was increased from about 30 to about 50 ° C. than the melting point (T _{M) a} a commensurate only of polymer, about 125 capillary cross-sectional area of the spinneret (A _c) The density of the extruded filament (# _c / _Ao ) should be about 2.5 × 10 ⁻⁶ cm ² to about 750 × 10 ⁻⁶ cm ^2.
To about 25 present / cm ^2, to cool the melt which is extruded,
The temperature (T _a ) is lower than the polymer glass transition temperature (T _g ),
It is performed using radially directed air with _a velocity (V _a ) in the range of about 10 to about 30 m / min.
The method is performed using a finish metering guide tube at a distance (Lc) in the range of about (50 + 90 dpf ^1/2 ) cm, and the take-out speed (V) is about 2 to about 5 km / min. The method described in. 6. The filament has a denier of about 0.6 to about 0.2.
The method according to any of claims 1 to 4, wherein the dispersion (DS) of denier is about 2% or less. 7. A filament having a denier of about 1 to about 0.1 per filament.
In the filaments of spun oriented polyester in the range of 2, the polyester has a relative viscosity (LRV) of about 13 to
The polymer has a zero shear melting point (T _Mゼ ロ) of about 23
The glass transition temperature (T _g ) of the polymer is in the range of about 40-80 ° C .; (i) the boil-off shrinkage (S) is less than the maximum latent shrinkage (S _m ) , Where Sm = [(550−E _B ) /6.5]%,
Elongation at break (E _B ) is in the range of about 40 to about 160%; (ii) maximum contraction tension (ST _max ) is about 0.05 to about 0.2 g / d, and peak temperature T (ST _max ) is located about 5 to about 30 ° C. range higher than the glass transition temperature of the polymer (T _g), (iii) strength at elongation _7% (T 7) is about 0.5 to about 1.75 g /
d, and the ratio of [(T _B ) _n / T ₇ ] is at least about (5
/ T ₇ ), where (T _B ) _n is the normalized strength at break, the elongation at break (E _B ) is in the range of about 40 to about 160%, and (iv) 1 A filament having a denier dispersion (DS) of less than about 4% per strand. 8. The material has a boil-off shrinkage (S) and a dry heat shrinkage (DHS) of at least about 12% and a strength at break (E _B ).
Is about 80 to about 160%, strength at elongation _7% (T 7)
8. The filament of claim 7, which is particularly suitable for use as a drawn feed yarn having a weight of about 0.5 to about 1 g / d. 9. The shrinkage difference (ΔS) is less than about + 2%, and the boil-off shrinkage (S) and the dry heat shrinkage (DHS) are about 2%.
In the range of about 12 percent, denier filaments after shrinkage is about 1 or less, T ₇ is in the range of from about 1 to about 1.75g / d, (E _B) is from about 40 to about 90% _8. The filament of claim 7 which is in the range and has a post-yield modulus (M _py ) in the range of about 2 to about 12 g / d, particularly suitable as a direct use textile yarn. 10. The method of claim 1, wherein the difference in shrinkage (ΔS) is less than about + 2%.
Boil-off shrinkage (S) and dry heat shrinkage (DHS) range from about 2 to about 12%, and the onset temperature of cold crystallization, T _CC (D
8. The filament according to claim 7, wherein the filament has a SC) of about 105 [deg.] C. or less and an instantaneous tensile modulus of at least 0 and can be uniformly cold drawn. 11. Denier dpf (ABO) after boil-off shrinkage
Is about 1 to about 0.2 dpf, the polyester has a relative viscosity (LRV) in the range of about 13 to about 23 and a zero shear melting point (T _M゜) of the polymer. A glass transition temperature (T _g ) of the polymer in the range of about 40-80 ° C .; (i) boil-off shrinkage (S) and dry heat shrinkage (DH)
S) is in the range of about 2 to about 12%; (ii) the strength at 7% elongation (T ₇ ) is at least about 1 g / d
Where the ratio of [(T _B ) _n / T ₇ ] is at least about (5 / T ₇ ), where (T _B ) _n is the normalized strength at break and the elongation at break (E _B ) is in the range of about 15 to about 55%; (iii) the post-yield modulus (M _py ) is in the range of about 5 to about 25 g / d; (iv) the average per-denier variance ( DS) is about 4% or less filament. 12. A drawn filament of a bulk spun oriented polyester having a fineness of about 1 to about 0.2 dpf (after boil-off shrinkage), said polyester having a relative viscosity (LRV) of about 13 to about 23. The polymer has a zero shear melting point (T _M゜) in the range of about 240 to about 265 ° C., the glass transition temperature (T _g ) of the polymer in the range of about 40 to 80 ° C., i) Boil-off shrinkage (S) and dry heat shrinkage (DH
S) is in the range of about 2 to about 12%; (ii) the strength at 7% elongation (T ₇ ) is at least about 1 g / d
A filament having an elongation at break (E _B ) in the range of about 15 to about 55% and a modulus after yield (M _py ) of about 5 to about 25 g / d. 13. The filament according to claim 11, wherein the peak temperature T (E ″ _max ) of the mechanical loss modulus is about 115 ° C. or less. 14. The method of claim 11 wherein the relative disperse dye dyeing speed (RDDR) is at least about 0.1.
Or the filament according to 12. 15. The filament according to any of claims 7-14, wherein the filament has a form factor (SF) of at least about 1.25. 16. A filament according to any of claims 7 to 15, wherein the filament has a denier of about 0.6 to about 0.2 dpf. 17. A filament according to any one of claims 7 to 16 wherein the denier variance (DS) of each filament is about 2% or less. 18. The polyester fiber comprises about 1 to about 3 mol%.
The filament according to any one of claims 7 to 17, comprising a structural unit of 5-ethylene-M-sulfoisophthalate, wherein M is a cation of an alkali metal. 19. The polyester is a substantially a poly (ethylene terephthalate), first hydrocarboxy dioxy structural units A present alternating _{[-O-C 2 H 4 -O-} ]
And the hydrocarbylene dicarbonyl structural unit B [-
(O) C—C ₆ H ₄ —C (O) —], which differs from the alternating first hydrocarbylenedioxy structural unit A and hydrocarbylenedicarbonyl structural unit B by a small amount. Hydrocarbylenedioxy structural unit A and / or hydrocarbylenedicarbonyl structural unit B
The polyester polymer having a zero shear melting point (T _M゜) in the range of about 240-265 ° C. and a glass transition temperature (T _g ) in the range of about 40-80 ° C. Range 7 ~
19. The filament according to any one of 18.