CA1138165A - Multi-component composite filament - Google Patents
Multi-component composite filamentInfo
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- CA1138165A CA1138165A CA000338914A CA338914A CA1138165A CA 1138165 A CA1138165 A CA 1138165A CA 000338914 A CA000338914 A CA 000338914A CA 338914 A CA338914 A CA 338914A CA 1138165 A CA1138165 A CA 1138165A
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Abstract
ABSTRACT OF THE DISCLOSURE
A composite filament having an "islands-in-sea" type cross-sectional configuration having, in one embodiment, at least two kinds of islands, wherein the two islands are different in co-efficient of contraction by at least 5%, or wherein one of the filamentary islands comprises a bicomponent filamentary type or eccentric filamentary type. These filamentary islands are relatively well distributed throughout the sea component and the sum of the weight of the filamentary islands is greater than the weight of the sea. Said composite filament may be made into a fabric as a filament of an ordinary denier. It is also possible to obtain a superfine fiber product being bulky or having an improved feel by superfining and heat-treating said composite filament.
A composite filament having an "islands-in-sea" type cross-sectional configuration having, in one embodiment, at least two kinds of islands, wherein the two islands are different in co-efficient of contraction by at least 5%, or wherein one of the filamentary islands comprises a bicomponent filamentary type or eccentric filamentary type. These filamentary islands are relatively well distributed throughout the sea component and the sum of the weight of the filamentary islands is greater than the weight of the sea. Said composite filament may be made into a fabric as a filament of an ordinary denier. It is also possible to obtain a superfine fiber product being bulky or having an improved feel by superfining and heat-treating said composite filament.
Description
1~3~ S
The present invention relates to a multi-component composite filament. Binary composite filaments are well known.
The most representative kind of these filaments is made by removing one component from two components or separating one component from the other to form a bundle of superfine filaments.
However, the so obtained bundle of superfine filaments and fabrics made from such filaments frequently has the following drawbacks:
(1) Because they are superfine filaments, they are extremely low in rigidity and lacking in bulkiness. This result occurs in both of the aforementioned methods of manufacture.
The present invention relates to a multi-component composite filament. Binary composite filaments are well known.
The most representative kind of these filaments is made by removing one component from two components or separating one component from the other to form a bundle of superfine filaments.
However, the so obtained bundle of superfine filaments and fabrics made from such filaments frequently has the following drawbacks:
(1) Because they are superfine filaments, they are extremely low in rigidity and lacking in bulkiness. This result occurs in both of the aforementioned methods of manufacture.
(2) Napped fabrics, for example, velvet-like knitted or woven fabrics, raised fabrics, buffed fabrics of non-woven velveteen, corduroy, seal, fur and electrodeposited fabrics have been commonly lacking in natural tone and high quality feeling. In other words, they have been excessively uniform and monotonous.
(3) It has been difficult to produce fabric having a crisp feel, with crepe, tenseness, and stretch recovery having little tendency for individual threads to be loosened, further having variety in color tone, and resembling silk.
(4) In the case of a bundle of superfine filaments which is 100~ composed of composite filaments, the characteristics of the bundle are frequently less beneficial than might be expected based on the crimp capacity of the fil~aments. On the other hand, in accordance with the present invention, there has now been developed a three or more component composite filament, from which one component may be removed, thus producing a composite filament ~ r 1~381~
consisting of the other two components. Furthermore, a fabric having a peculiar feel may be made from the new filament.
The novel composite filament drastically is improved with respect to the aforementioned drawbacks. In addition, this novel composite filament may have various other novel characteristics which have not been seen in prior composite filaments.
According to the present invention, there is provided a multi-component composite filament having an "islands-in-sea" type cross-sectional configuration and convertible into a bundle of superfine filaments, said composite filament comprising (A) at least two different kinds of filamentary islands having different contracting or crimping properties each dispersed - independently in said sea without maldistribution of such filamen-tary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the respective kinds of filamentary islands having different coefficients of free contraction of at least 5%, or (2) one of said filamentary islands comprising a one component filamentary type and the other of said filamentary islands comprising (a) a bicomponent filamentary type in which a plurality of different polymers are adhered together or (b) an eccentrically shaped filamentary type having at least two components, the sum of the weights of said filamentary islands being greater than the weight of said sea, said filamentary islands being convertible, upon separation from said sea and upon differential contraction, into a bundle of puffy superfine filaments, or (B) filamentary islands and a sea having different .~.................................................. .
;-contracting or crimping properties, the filamentary islands dispersed independently in the sea without maldistribution of such filamentary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the filamentary islands and the sea having different coefficients of free contraction of at least 5%, or (2) the filamentary islands being a member selected from the group consisting of a bicomponent filamentary type in which a plurality of different polymers are adhered together and an eccentrically shaped filamentary type having at least two components, and the sea being a member selected from the group consisting of a one component filamentary type and a multicomponent filamentary type having one major component, with the proviso that said filamentary islands are of a different filamentary type from said sea, said filamentary islands and said sea being convertible, upon separation from each other and upon differential contraction, into a bundle of puffy superfine filaments.
In another aspect of the present invention, there is provided a method of forming a fabric from the multi-component 61!~'nc~ 0.~9~C
composite filament o'f claim 1, said fabric being composed of an aggregation of a plurality of bundles of superfine filaments, said method comprising taking a plurality of said composite filaments and forming a sheet-like fabric, separating said filamentary islands from said sea and then differentially contracting the filamentary islands or the filamentary islands and the sea to form said bundles of superfine filaments in which each type of superfine filament is dispersed wichout maldistribution in a said bundle.
In yet a further aspect, the invention provides a fabric ~ ., ' ~ .' :
1~3~
composed of an aggregation of a plurality of bundles of superfine filaments, each such bundle being obtained by separating said superfine filaments from a multi-component composite filament, each such bundle comprising at least two different types of superfine filaments which have different coefficients of free contraction, each type of superfine filament being dispersed without maldistri-bution in said bundle, and wherein either (a) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type and a multi-component filamentary type having one major component and the other superfine filament comprises (1) a bicomponent filamentary type in which a plurality of different polymers are adhered together or (2) an eccentrically shaped fila-mentary type having at least two components, or (b) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type, a bicomponent filamentary type in which a plurality of different polymers are adhered together, and an eccentrically shaped filamentary type having at least two components and the other of said superfine filaments is a member selected from the group consisting of a one component filamentary type and a multi-component filamentary type having one major component, with the proviso that said superfine filaments and said other superfine filaments are of different filamentary types.
Thus two particular types of multi-component composite filament of the present invention may be stated as follows:
(1) A multi-component composite filament having an "islands-in-sea" type cross-sectional configuration in which at least two different kinds of filamentary islands are dispersed ~:' independently without maldistribution to one side in a sea component (i.e., the different filamentary islands are not unevenly distri-buted such that the weight of any one component predominates on any one side of the composite filament), wherein the respective filamentary islands have different coefficients of free contraction of at least 5%, and wherein the sum of the weights of these filamentary islands exceeds the weight of the sea.
(2) A multi-component composite filament having an "islands-in-sea" type cross-sectional configuration in which at least two different kinds of filamentary islands are dispersed independently without maldistribution of any one component to one side in a sea component, wherein one individual kind of filamentary island consists of an island of the usual type and the other individual kind of filamentary island comprises a binary bi-component-type or eccentric-type composite superfine filament, and wherein the sum of the weights of these filamentary islands exceeds the weight of the sea.
Particular embodiments will now be described in detail with reference to the acoompanying drawings, in which:
Figure 1 is a schematic view showing a bundle of super-fine filaments obtained from a conventional composite filament.
Figures 2a and b are explanatory views showing the principle by which superfine filaments become bulky.
Figures 3 - 36 are cross-sectional views of various embodiments of composite filaments according to the present invention.
Figure 37 is a schematic view showing overlap of crimps .: ~
.
1~31~1~i5 (at the time of free crimping) of a bundle of conventional super-fine filaments.
Figure 38 is a schematic view showing bulkiness and peculiarity of a bundle of superfine filaments (at the time of free crimping) according to the present invention.
Figure 1 is a schematic view of a bundle of superfine filaments, illustrative of the present invention, as well as a conventional bundle of superfine filaments. Selected filaments of such a bundle, enlarged, are also shown in Figure 2(a). However, when this bundle is subjected to contraction, in accordance with the present invention, it appears as shown in Figure 2(b), wherein a superfine filament is contracted and is crimped, while other superfine filaments which are less contracted are properly inter-posed among the contracted superfine filaments and the resulting superfine filament bundle becomes puffy. Accordingly, when filamentary islands of components A or B are maldistributed in sea C and A and B are not mixed at least somewhat symmetrically, there is little uniformity of puffiness. This is not preferred. It is preferable that these filamentary islands of components A or B
should be well mixed and mutually interposed. In this sense, it is important that the multi-component composite filament of the present invention be convertible to a bundle of puffy superfine filaments.
The composite filament according to the present invention is convertible to a superfine multifilament bundle, wherein crimped or slack superfine filaments and straight superfine filaments co-exist without maldistribution, by dividing and contracting !
.
~ ' ~319~i5 treatments to be described in detail hereinafter. The superfine filament bundles of the present invention may be roughly divided into three types.
A first type has at least two different kinds of filamentary islands of components A or B, both A and B being independently dispersed in a sea C of another component.
Filamentary islands of components A or B may have various types of cross-sectional areas, examples of which are shown in Figures 3 - 10.
Filamentary islands of components A or B in Figure 3 are shown to be dispersed in a regularly interposed pattern in sea C.
When the deniers of these islands are within the range of 2 - 0.6 d, this composite filament is very useful as a material for producing silk-like and wool-like fabrics in a manner to be described in detail hereinafter. This composite filament is also effective as a starting material for making plush, velveteen and corduroy.
Figure 4 is an example wherein two filamentary islands of components A or B are in a regularly dispersed but random mixed arrangement. The islands of components A and B are mutually, but randomly interposed.
In Fi-gure 5, filamentary islands of components A or B are disposed in a manner similar to the filamentary islands in Figure 3.
However, a composite filament of this type may be called a peeling type o~ an exposed surface type because the other surfaces of the islands are exposed. When the islands are separated and become independent, the sea C remains as a fiber, requiring separate consideration.
Figure 6 shows an example wherein one of the filamentary t ,i ~3~65 islands of components A or B, the inner grouping of islands of component A in the example illustrated, is surrounded by the outer grouping of the other island of component B. In this case, too, one island is interposed with respect to the other.
Figure 7 shows another example in which the grouping of filamentary islands of component A extends through the grouping of islands of component B.
Figure 8 is a peeling type composite filament, with both types of filamentary islands having exposed surfaces. In this case, after mechanically peeling the islands of components A or B
from the sea C, it is possible to further halve the islands.
Figure 9 is a hollow type composite filament wherein four islands of component A and four islands of component s are provided and wherein it is possible to peel away the interposing sea C, or otherwise to remove the sea C.
Figure 10 is an example of another form of composite filament wherein filamentary islands of components A or B are regularly but differently disposed. In this example, a denier mix is accompanied by a mixing of heterogeneous cross sections. When a wool-like composite filament is to be made, a filament of the type shown in Figure 10 is especially preferable as a starting material. In this case, a multi-lobal cross section (at least trilobal) is especially preferable.
In the cases illustrated in Figures 3 - 10, it is necessary that there be a difference in coefficient of contraction between the two filamentary islands of components A and B
respectively. That difference should be at least 3~, but 1~381~S
preferably is at least 5%. This is especially true in the case of filaments in which the sea C is peeled away but is allowed to remain in the admixture with the filamentary islands. The difference in coefficient of contraction as referred to herein, means a difference in the coefficient of free contraction without hinderance. Ordinarily, the coefficient of contraction of a filament in a knitted or woven fabric is often lower than its unhindered coefficient of free contraction due to restrictions in the fabric. Even though the difference of the respective coefficients is small, it still greatly affects fabric bulkiness.
Accordingly, the respective coefficients of contraction are measured after separating or peeling the filamentary islands of components A and B from the sea C by use of a solvent or decompo-sition agent which has the least effect upon the filamentary islands of components A and B. Contraction may be measured by any one of a variety of procedures including boiling water contraction, solvent contraction and high-temperature heating contraction. As stated, the difference of coefficient of contraction should be at least 3%
when tested by any one of these contraction test methods. Typically, the boiling water contraction method and the high-temperature dry contraction method are commonly used. In this specification, the contraction values referred to are often based on these test methods.
Thus, a filamentary type whose coefficient of contraction is small slackens relative to a filamentary type whose coefficient of contraction is large, thus making a bulky and puffy bundle of superfine filaments.
This puffiness may be brought about with the filament in , 1131~1~S
the form of a yarn, but it is more effective with the filament in the form of a fabric.
The relation between disposition of filamentary islands components A and B in the cross-sectional area of a composite filament and the difference in coefficient of contraction is important.
A second type of composite filament in accordance with the present invention is shown in Figures 11 - 26, in which filamentary islands of components A or s are separated by sea C.
In this type of composite filament, the filamentary islands may be a mixture of components A and s having a bicomponent-type or eccentric-type cross-sectional configuration, which are intended to be removed and separated from sea C. Also, the resultant bundle of superfine filaments may consist of a single component filamentary type of the component A or B in admixture with filamentary types of the remaining components of the original composite filament. For instance, in the case of Figure ll, there is shown a bicomponent-type composite superfine filament (a filamentary island) consisting of two adhering components A and B, and a superfine filament (the sea) of one component in admixture therewith arranged in the shape of a cross. In the case of, for example, Figure 13, the composite filament comprises a bundle of superfine filaments consisting of a bicomponent-type composite superfine filament consisting of adhering components A and B in combination with a cross-shaped superfine filament of sea C, as well as other superfine filaments consisting of the component A alone and the component B alone. When considered similarly, it may be easily understood what sorts of bundles of 1~3f~1~iS
superfine filaments are shown in each of the other figures.
Namely, throughout all the examples of Figures 11 - 26, combinations are shown each consisting of a bicomponent filamentary type or eccentric filamentary type composite superfine filament and super-fine filaments consisting of substantially a single component.
A third type of composite filament of the present invention is that in which, after sea C has been dissolved and removed, there remains a bundle of superfine filaments consisting of a combination of bicomponent filamentary types or eccentric filamentary types each consisting of components A and B, combined with superfine filaments of a single component type consisting of the components A or B or both. This combination of (a) bicomponent or eccentric and (b) single component superfine filaments is shown for example, in Figures 13, 16, 18, 20, 21, 22, 23 and 27 - 36.
Figures 27 - 36 particularly show examples of composite filaments in each of which the filamentary islands of components A and/or B are surrounded by sea C.
In each of these second and third types of filaments of the present invention utilizing bicomponent filamentary types, components A and B that are adherent to each other, yet have different coefficients of contr~action, are selected as the filamentary islands. Only when these conditions are met are very excellent effects, to be mentioned later, obtained. When all of the filamentary islands are composite, having roughly the same coefficient of contraction and the sea is removed, only crimp will be produced by heat and solvents as shown in Figure 37. In such crimping, loops of crimp often overlap and the feel of the resulting bundle or fabric is different than bundles or fabrics of this invention and ~ .~S~
~13~5 it is difficult to produce enough bulkiness in many cases.
sy contrast, in the use of the present invention, with the differential coefficients of contraction, as shown in Figure 38, a superfine crimped filament overlaps with another superfine straight filament, which is exactly the same result illustrated in Figure 2b. This is true, (even if each crimp does not make a complete loop, though the effect of the crimp in that case may be less).
In accordance with the present invention, compared with filaments where all reveal crimp, a very peculiar filament is produced having a voluminous feel, which is unexpected. This may be used to bloom naps of raised fabrics. Accordingly, compared with the crimp produced in a bundle of crimped superfine filaments as shown in Figure 37, which has heretofore been considered most excellent, a bundle of crimped superfine filaments of a superior structure may be obtained according to the present invention. In addition, such filaments may have no crimp while being processed into a woven fabric, knitted fabric or non-woven fabric, and are less bulky and easy to process. After a sheet-like fabric has been formed, said filaments may be rendered superfine by mechanical or chemical actions and said superfine filaments may be treated to produce crimp by further heat-treatment or chemical treatment.
Accordingly, in regard to the present invention, it should be noted that it is not necessary that a bundle or mixture consisting of crimpable superfine filaments and non-crimpable superfine filaments or contractable superfine filaments and non-contractible superfine filaments be made first, and then that such bundle or mixture be processed into filaments. Rather, superfine filaments having such 'J
, ~
~31~65 potential are readily processed in a fasciated state, namely, in aneasily processable condition like the filaments of an ordinary yarn.
Thereafter the respective superfine filaments are separated and made independent from such fasciated component, to produce particular effects of this invention.
As mentioned above, composite filaments used in the present invention are roughly divided into three types, the characteristics of each of which will be mentioned hereinafter.
In the first type, namely, in the case of each of the composite filaments shown in Figures 3 - 10, the contraction force is relatively strong, even in a restrained state, for example. As formed into a fabric, the product may become comparatively bulky.
In other words, with regard to the difference in coefficient of contraction of the superfine filaments, the loss of crimpability due to making the composite filament superfine is small. In addition, compared to ordinary filaments, such as super-fine multifilaments, according to the present invention, are mixed without being maldistributed. There is good affinity between the different superfine filaments, and the bundle of different super-fine filaments shows a good tendency to become puffy.
In the second type, namely, in composite filaments suchas those shown in Figures 11 - 26; a mechanical peeling method is applied and the chemical aid of a solvent is not necessary; accord-ingly there is no reduction of contractibility due to the action of the solvent; therefore, when a method of thermal contraction is adopted between two components A and B, crimp is very likely to be brought about. However, in this type of composite filament, peeling 1~ 1!Ei5 has to be carried out mechanically, and even when component C is unnecessary, for example, from the point of view of dyeing fastness, it may nevertheless be allowed to remain present. However, such composite filaments may peel at a stage when peeling is not wanted and this may be a drawback in that such a filament may have comparatively poor processability. On the other hand, there is, of course, no loss of components. These points become merits or demerits, depending upon the object at hand.
In the third type of composite filament in accordance with the present invention, as illustrated by Figures 27-36 of the draw-ings removal of one component is normally carried out by dissolution.
Owing to the use of a chemical solvent, crimpability due to difference of contraction between the two components A and B is often inferior.
The contraction power of one component is reduced by a crystalli-zation phenomenon caused by the solvent of sea C, which is called solvent crystallization. When heating is effected at the time of dissolution, loss of crimpability is even more likely. There are also other necessary drawbacks in removing one component by dissolution, including the loss of the component in solution.
; 20 However, as an advantage, the removal of the dissolved component creates spaces providing room among the superfine filaments, which contributes to a considerable feel-improving effect, which cannot be overlooked. In other words, this type of filament and procedure also has its merits and demerits.
Composite filaments of the third type having an "islands-in-sea" type cross-sectional configuration, as shown in Figures 27 -36, are especialiy important because in an "islands-in-sea" type '1-'' ,~' ,~
- : - , ~ :
.
,':': ~' , :
` 1~3~1~5 filament, filaments are well fasciated. Such a filament has good processability because of the high degree of filament concentration in the non-bulked state. This cannot be overlooked. It is another characteristic that a treatment which forms spaces among filaments by removal of component C brings about an effect similar to that of removing sericin from silk consisting of sericin and fibroin by degumming. It is still another characteristic of composite filaments of the third type that it is possible to select components of the same kind such as, for example, polyesters having different contract-ibility and to make it possible to mix different kinds of components,such as a polyamide and polyethylene.
In the foregoing description; the merits and demerits of the respective embodiments of this invention have been mentioned so that different forms of the invention may be properly used in accordance with the user's intended objects. What may be said about them in common is that, as shown in Figure 38, a bundle is so made that a superfine filament (or a plurality of such superfine filaments) treatable to form a superfine crimp is interposed among other superfine filaments which, under the same treatment, do not form a superfine crimp. Therefore, effects in bulkiness, mutual dispersion among filaments and improvement in feel are brought about, depending on the selection of filamentary type and composition.
These composite filaments may be used for production of various kinds of fiber products such as woven fabrics, knitted fabrics and non-woven fabrics. Examples of woven fabrics include crepe, such as crepe de Chine, palace crepe, satin crepe, morocain crepe, striped crepe, oriental crepe, flat crepe, georgette crepe 1~3~1~;S
and silk crepe, or various kinds of crepe weaves, such as amundsen jersey. Other examples include habutae (glossy) silk, satins, silk gauzes, voiles, porous fabrics, twill weave, serges, taffetas, cord weaves, velvets, towel weaves, flannels, shirting and various other designs of weave. Above all, these composite filaments are preferably used for producing raised fabrics such as velvet, velveteen and corduroy and further fabrics of a type which is raised by use of a raising machine.
As to knitted fabrics, besides various conventional knitted fabrics, other knits, such as platen or tricot fabrics or two-ply fabrics, of which especially those which are raised or napped may be cited, may also be made from filaments of the present invention.
Among-non-woven fabrics, one should include needle punched non-woven fabrics, non-woven fabrics made by the paper making types of methods, and also spun bond non-woven fabrics.
From such woven, knitted or non-woven fabrics it is possible to make raised fabrics having good nap dispersibility by subjecting them to napping and/or buffing. It is also possible to make a raised fabric such as velveteen or velvet by cutting to make them into piled fabrics. In each of these instances, the suprisingly advantageous effects of the present invention are effectively revealed.
It is especially preferable that the deniers of filaments after being made superfine should be about 0.05-0.6 in the case of raised fabrics and about 0.6-2.0 in the case of non-raised fabrics.
It is preferaole that the denier of the composite filament before .~,.i ., - i : ~
, ~3~ iS
being made superfine should be within the range of about 15-1 denier. In the case of mixed denier, it is preferable that the difference of deviation of the various deniers of the filaments after being made superfine should not exceed about 1.0 denier.
AS regards treating the filaments for the purpose of imparting crimp thereto, heating is especially preferable.
The most preferable combination of the component A and B
is a combination of po1yesters, particularly a combination of poly-ethylene terephthalate with the product obtained by copolymerizing isophthalic acid or sodium sulfonate isophthalate with the same, with the products obtained by copolymerizing a small amount of a trifunctional component with the same, or with polybutylene terephthalate or other known polyesters with the same.
The amounts, components and draw conditions are so determined as to bring about a difference in coefficient of contraction. Also, various polyamides, namely, nylon 6, nylon 66, PACM-, IPA- and TPA- copolymerized nylon 66 and various other copolymers are preferable as the components A and B. It is a matter of course that combinations of polymers of different series are acceptable.
As the component C, there may be cited polymers of the polystyrene series, polymers of the polyvinyl series, copolyesters, polymers of the polyamide series and polymers of the polyolefin series. The component C may be properly used by dissolving and removing the same or by peeling the same.
It goes without saying that for use as the components A, B and C, all the known fabric-forming polymers are applicable as ~ ~1 - 1~3R1~5 well as those mentioned above.
When the remaining component is polyester, it is especially preferable for producing a silky, feel to treat poly-ester with an alkali solution. An original yarn may be also textured-processed, such as by false weave processing and made into a yarn having strong twist. For example, a combination with strong twist SZ is possible.
It is a matter of course that when the two components A
and B are different in dyeability, it is possible to dye them differently, and it is possible to subject them to resin processing and to process them by adding a feel-improving agent such as poly-urethane and silicone. When, for example, such filaments are needle punched, processed with polyurethane before the component C is removed and thereafter buffed, it is possible to make a fabric consisting of said filaments into suede-like artificial leather and to produce a product having excellent feel by so doing.
_ample A three-component "islands-in-sea" type composite filament having a cross sectional area as shown in Figure 4 was produced by using polyethylene terephthalate to form a filamentary island of one component and, as another filamentary island, a copolyethylene terephthalate containing 9.9 mol ~ of an isophthalic acid component. Specifically, by using a spinneret (for 42 filaments) for a composite filament which consisted of a number of cores embedded in the matrix, said cores being extremely fine and parallel to each other along the fiber axis as shown in Japanese Patent Application Publication No. 26723/1972, the aforementioned ~3~
composite filament was first spun in the usual way at 280C, then wound, and finally drawn with heating to obtain a 3.8 denier yarn.
The number of filamentary islands so obtained was equal to sixteen, eight of which consisted of polyethylene terephthalate and eight of which consisted of copolyethylene terephthalate; all such filament-ary islands accounted for 60% of the yarn.
This filamentary yarn was washed well with carbon tetra-chloride and dried to obtain a bundle of superfine filaments. At this point the bundle thus obtained was free from swelling; however, when the bundle was immersed in boiling water, filaments consisting of said copolyester having copolymerized isophthalic acid contracted greatly. As a result, a remarkable swelling was seen in the bundle of superfine filaments. The difference in coefficient of contract-ion between the highly contractable component and the slightly contractible component was not less than 5%. It is notable that the component having the higher coefficient of contraction appeared to have been drawn to the inside of the fiber.
Example 2 A drawn composite filament having a cross sectional area as shown in Figure 3 was produced, wherein the two kinds of the filamentary islands were the same as in Example 1, but the sea component thereof was polystyrene which had 22% by weight of co-polymerized 2-ethylhexyl acrylate, the island/sea ratio being 85/15.
Using a yarn consisting of such composite filament both as warp and weft, the following plain fabric was woven. Specifi-cally, in weaving the plain fabric for the warp, a total 50 denier D.' :~ ? ~ ~
' s of about 5.6 d/9 fil yarn was used, at a plain fabric density of 110 warps/in; for the weft, a total 73 denier of about 5.6 d/13 fil yarn was used at a plain fabric density of 83 wefts/in. Two such woven fabrics were prepared; one fabric was washed with carbon tetrachloride while the other fabric was washed with trichloro-ethylene. Each was dried and then immersed in boiling water. Both such treatments cause fabric swelling, but the swelling of the fabric washed with the carbon tetrachloride was superior to the swelling of the fabric washed with trichloroethylene. Said fabric was subsequently washed in a hot 2.5 g/liter aqueous bath of sodium hydroxide, the surface thereof finally treated with an alkali, washed with water, dried and finally passed through air at 180C for a short period of time. The product thus obtained was a pli~nt woven fabric having a silk-like luster and feel.
Example 3 A composite filament was produced which consisted of many cores embedded within the matrix, said cores being extremely fine parallel to each other along the fiber axis. The composite filament further had an "islands-in-sea" type cross sectional configuration with thirty six islands, of which half were polyethylene tere-phthalate and half were copolyethylene terephthalate containing 9.9 mol ~ of an isophthalic acid component as in Example l; the - sea component was polystyrene, and island/sea ratio was 95/5. The thus obtained drawn yarn consisting of total denier 100 d/25 filaments was used as the pile yarn when weaving velvet-like fabrics.
As both warp and weft of the base texture, a 50 D - 36 f bulky processed yarn having a T-shaped cross sectional configuration ~"~
-1~3~
(process for producing the same being disclosed in Japanese Patent Application Publications Nos. 18535/1976 and 47550/1972) was used and the length of the raising was made to equal 1.0 mm. Two such fabrics were prepared, each of which was washed with a sufficient amount of an alkali; then with a sufficient amount of water.
Thereafter, one fabric was washed with carbon tetrachloride and the other fabric was washed with trichloroethylene. It is necessary to sufficiently wash the fabric with water after the alkali treatment, but prior to the trichloroethylene washing in order to prevent the production of explosive dichloroacetylene.
Next, when the two fabrics were exposed in hot air at 180C and thereafter dyed in blue, very elegant raised fabrics (which might be well called velvets having suede effects) having different pile ~raising) lengths were obtained.
Example 4 A three-component composite filament having an "islands-in-sea" type cross sectional configuration as shown in Figure 27 (number of islands: 4) was made. Namely, as component A, poly-ethylene terephthalate was used, and as component B, copolyethylene terephthalate having copolymerized 10 mol % of isophthalic acid was used. The ratio of A/B was made 75/25. As component C, polystyrene was used. The ratio of component C to the entirety was made 20%.
;~ The composite filament having a cross sectional configuration was spun by a three-component filament spinning machine and drawn to 3.3 times. The obtained yarn was about 4 denier/12 fil. A skein consisting of a plurality of such yarns was made and thereafter, the component C consisting of polystyrene was dissolved with carbon tetrachloride and removed. Thereafter, when crimp was imparted by the treatment of boiling water, the skein became very bulky. When this skein was grabbed by hand, the bulkiness was high and a remarkable difference was recognized compared with the following comparative example.
Comparative Example A composite filament having an "island-in-sea" type cross sectional configuration similar to that of Figure 27 was produced, wherein the entire island components were polyethylene terephthalate only and the component C (sea component) was polystyrene. The denier and island/sea ratio were so adjusted as to become the same as in Example 1. Similarly, component C was dissolved with carbon tetrachloride and removed and thereafter what was obtained was treated in boiling water and dried.
On the other hand, using a composite filament whose cross sectional configuration was similar to that of Figure 27, with the exception that all the filamentary islands had an A/s component filamentary type composite structure, a skein was made by the same manner as in Example 4.
When the so obtained two samples were compared (after drying) with the product of the present invention obtained in Example 1, the product of the present invention was superior in bulkiness. Bulkiness was measured by strongly grabbing the skein many times by hand, and the state of each skein was checked after the hand had been removed. The skein of composite filaments wherein .D' 1~31~t1&5 all the filamentary islands were the same was lowest in bulkiness, followed by the skein of composite filaments wherein all filament-ary islands comprised a bicomponent filamentary type. The product of the present invention was the best in bulkiness properties.
This skein (present invention) comprised an aggregate of bundles of superfine filaments having a different hand when compared to the other two skeins.
Example 5 Using the same filament yarn as in Example 4, a plain fabric was woven. Its density was 115 warps/in and 83 wefts/in.
This fabric was dissolved with carbon tetrachloride. Thereafter, its surface was washed with hot alkali diluted with water, to slightly dissolve the surface. Thus, it was washed with water and dried. Crimp was imparted to an extent sufficient to separate one superfine filament from another inside the organization. A silk-like feel was evident on the fabric surface and said plain fabric ; exhibited very excellent, silk-like qualities.
Example 6 ,~.
Example 5 was repeated except polybutylene terephthalate was used instead of a copolyethylene terephthalate having copolymerized isophthalic acid as component B. Also trichloro-ethylene was used as a solvent in treating the plain fabric. The resulting fabric was somewhat different in hand from the woven fabric obtained in accordance with Example 5. The repulsion and bulkiness of this fabric also differed from the fabric produced in Example 5. However, this fabric also exhibited excellent woven :: ;: , ' , ~3t~ iS
silk-like qualities.
Example 7 A composite filament having an "island-in-sea" type cross sectional configuration of the type shown in Figure 29 was produced.
The total number of islands was sixteen and island component A
comprised a copolyester containing polyethylene terephthalate and 9.9 mol ~ of isophthalic acid. The island component B comprised polyethylene terephthalate. The ratio was (A/B=12/4), and the sea component was a styrene - octyl acrylate (78/22) copolymer present in an amount equal to 4% of the entire composite filament. The filament was spun as a composite filament consisting of many cores embedded with the matrix. Said cores were extremely fine, drawn and parallel to each other along the fiber axis. The total denier and number of filaments in the yarn produced therefrom were 104 D -42 f. Using the obtained yarn as the "nap" warp, a 50 D - 18 f united filament (100 D) as texture warp and as texture weft, a 2-ply velvet weave was produced. The length of the raising (naps) in the fabric was about 0.9 mm and the fabric density was 60 warps/
in and 90 wefts/in. This woven fabric was washed with trichloro-ethylene in a washing machine and dried. Thereafter, said wovenfabric was treated in boiling water under relaxed conditions and heat set at 170C for 5 minutes. Thereafter, it was dyed black in a liquid stream circular dyeing machine at 120C under pressure.
The resulting fabric had naps which could be well bloomed and there were intervals among the naps. Also, light fuzz was mixed in the naps and the overall hand of the fabric was that of a very soft Dj~
1~3fl~5 raised woven fabric. On the other hand, a fabric produced according to this example (with the exception of using a composite filament whose islands all comprised component A) is obviously different in appearance and luster compared to the fabric of this example.
consisting of the other two components. Furthermore, a fabric having a peculiar feel may be made from the new filament.
The novel composite filament drastically is improved with respect to the aforementioned drawbacks. In addition, this novel composite filament may have various other novel characteristics which have not been seen in prior composite filaments.
According to the present invention, there is provided a multi-component composite filament having an "islands-in-sea" type cross-sectional configuration and convertible into a bundle of superfine filaments, said composite filament comprising (A) at least two different kinds of filamentary islands having different contracting or crimping properties each dispersed - independently in said sea without maldistribution of such filamen-tary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the respective kinds of filamentary islands having different coefficients of free contraction of at least 5%, or (2) one of said filamentary islands comprising a one component filamentary type and the other of said filamentary islands comprising (a) a bicomponent filamentary type in which a plurality of different polymers are adhered together or (b) an eccentrically shaped filamentary type having at least two components, the sum of the weights of said filamentary islands being greater than the weight of said sea, said filamentary islands being convertible, upon separation from said sea and upon differential contraction, into a bundle of puffy superfine filaments, or (B) filamentary islands and a sea having different .~.................................................. .
;-contracting or crimping properties, the filamentary islands dispersed independently in the sea without maldistribution of such filamentary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the filamentary islands and the sea having different coefficients of free contraction of at least 5%, or (2) the filamentary islands being a member selected from the group consisting of a bicomponent filamentary type in which a plurality of different polymers are adhered together and an eccentrically shaped filamentary type having at least two components, and the sea being a member selected from the group consisting of a one component filamentary type and a multicomponent filamentary type having one major component, with the proviso that said filamentary islands are of a different filamentary type from said sea, said filamentary islands and said sea being convertible, upon separation from each other and upon differential contraction, into a bundle of puffy superfine filaments.
In another aspect of the present invention, there is provided a method of forming a fabric from the multi-component 61!~'nc~ 0.~9~C
composite filament o'f claim 1, said fabric being composed of an aggregation of a plurality of bundles of superfine filaments, said method comprising taking a plurality of said composite filaments and forming a sheet-like fabric, separating said filamentary islands from said sea and then differentially contracting the filamentary islands or the filamentary islands and the sea to form said bundles of superfine filaments in which each type of superfine filament is dispersed wichout maldistribution in a said bundle.
In yet a further aspect, the invention provides a fabric ~ ., ' ~ .' :
1~3~
composed of an aggregation of a plurality of bundles of superfine filaments, each such bundle being obtained by separating said superfine filaments from a multi-component composite filament, each such bundle comprising at least two different types of superfine filaments which have different coefficients of free contraction, each type of superfine filament being dispersed without maldistri-bution in said bundle, and wherein either (a) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type and a multi-component filamentary type having one major component and the other superfine filament comprises (1) a bicomponent filamentary type in which a plurality of different polymers are adhered together or (2) an eccentrically shaped fila-mentary type having at least two components, or (b) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type, a bicomponent filamentary type in which a plurality of different polymers are adhered together, and an eccentrically shaped filamentary type having at least two components and the other of said superfine filaments is a member selected from the group consisting of a one component filamentary type and a multi-component filamentary type having one major component, with the proviso that said superfine filaments and said other superfine filaments are of different filamentary types.
Thus two particular types of multi-component composite filament of the present invention may be stated as follows:
(1) A multi-component composite filament having an "islands-in-sea" type cross-sectional configuration in which at least two different kinds of filamentary islands are dispersed ~:' independently without maldistribution to one side in a sea component (i.e., the different filamentary islands are not unevenly distri-buted such that the weight of any one component predominates on any one side of the composite filament), wherein the respective filamentary islands have different coefficients of free contraction of at least 5%, and wherein the sum of the weights of these filamentary islands exceeds the weight of the sea.
(2) A multi-component composite filament having an "islands-in-sea" type cross-sectional configuration in which at least two different kinds of filamentary islands are dispersed independently without maldistribution of any one component to one side in a sea component, wherein one individual kind of filamentary island consists of an island of the usual type and the other individual kind of filamentary island comprises a binary bi-component-type or eccentric-type composite superfine filament, and wherein the sum of the weights of these filamentary islands exceeds the weight of the sea.
Particular embodiments will now be described in detail with reference to the acoompanying drawings, in which:
Figure 1 is a schematic view showing a bundle of super-fine filaments obtained from a conventional composite filament.
Figures 2a and b are explanatory views showing the principle by which superfine filaments become bulky.
Figures 3 - 36 are cross-sectional views of various embodiments of composite filaments according to the present invention.
Figure 37 is a schematic view showing overlap of crimps .: ~
.
1~31~1~i5 (at the time of free crimping) of a bundle of conventional super-fine filaments.
Figure 38 is a schematic view showing bulkiness and peculiarity of a bundle of superfine filaments (at the time of free crimping) according to the present invention.
Figure 1 is a schematic view of a bundle of superfine filaments, illustrative of the present invention, as well as a conventional bundle of superfine filaments. Selected filaments of such a bundle, enlarged, are also shown in Figure 2(a). However, when this bundle is subjected to contraction, in accordance with the present invention, it appears as shown in Figure 2(b), wherein a superfine filament is contracted and is crimped, while other superfine filaments which are less contracted are properly inter-posed among the contracted superfine filaments and the resulting superfine filament bundle becomes puffy. Accordingly, when filamentary islands of components A or B are maldistributed in sea C and A and B are not mixed at least somewhat symmetrically, there is little uniformity of puffiness. This is not preferred. It is preferable that these filamentary islands of components A or B
should be well mixed and mutually interposed. In this sense, it is important that the multi-component composite filament of the present invention be convertible to a bundle of puffy superfine filaments.
The composite filament according to the present invention is convertible to a superfine multifilament bundle, wherein crimped or slack superfine filaments and straight superfine filaments co-exist without maldistribution, by dividing and contracting !
.
~ ' ~319~i5 treatments to be described in detail hereinafter. The superfine filament bundles of the present invention may be roughly divided into three types.
A first type has at least two different kinds of filamentary islands of components A or B, both A and B being independently dispersed in a sea C of another component.
Filamentary islands of components A or B may have various types of cross-sectional areas, examples of which are shown in Figures 3 - 10.
Filamentary islands of components A or B in Figure 3 are shown to be dispersed in a regularly interposed pattern in sea C.
When the deniers of these islands are within the range of 2 - 0.6 d, this composite filament is very useful as a material for producing silk-like and wool-like fabrics in a manner to be described in detail hereinafter. This composite filament is also effective as a starting material for making plush, velveteen and corduroy.
Figure 4 is an example wherein two filamentary islands of components A or B are in a regularly dispersed but random mixed arrangement. The islands of components A and B are mutually, but randomly interposed.
In Fi-gure 5, filamentary islands of components A or B are disposed in a manner similar to the filamentary islands in Figure 3.
However, a composite filament of this type may be called a peeling type o~ an exposed surface type because the other surfaces of the islands are exposed. When the islands are separated and become independent, the sea C remains as a fiber, requiring separate consideration.
Figure 6 shows an example wherein one of the filamentary t ,i ~3~65 islands of components A or B, the inner grouping of islands of component A in the example illustrated, is surrounded by the outer grouping of the other island of component B. In this case, too, one island is interposed with respect to the other.
Figure 7 shows another example in which the grouping of filamentary islands of component A extends through the grouping of islands of component B.
Figure 8 is a peeling type composite filament, with both types of filamentary islands having exposed surfaces. In this case, after mechanically peeling the islands of components A or B
from the sea C, it is possible to further halve the islands.
Figure 9 is a hollow type composite filament wherein four islands of component A and four islands of component s are provided and wherein it is possible to peel away the interposing sea C, or otherwise to remove the sea C.
Figure 10 is an example of another form of composite filament wherein filamentary islands of components A or B are regularly but differently disposed. In this example, a denier mix is accompanied by a mixing of heterogeneous cross sections. When a wool-like composite filament is to be made, a filament of the type shown in Figure 10 is especially preferable as a starting material. In this case, a multi-lobal cross section (at least trilobal) is especially preferable.
In the cases illustrated in Figures 3 - 10, it is necessary that there be a difference in coefficient of contraction between the two filamentary islands of components A and B
respectively. That difference should be at least 3~, but 1~381~S
preferably is at least 5%. This is especially true in the case of filaments in which the sea C is peeled away but is allowed to remain in the admixture with the filamentary islands. The difference in coefficient of contraction as referred to herein, means a difference in the coefficient of free contraction without hinderance. Ordinarily, the coefficient of contraction of a filament in a knitted or woven fabric is often lower than its unhindered coefficient of free contraction due to restrictions in the fabric. Even though the difference of the respective coefficients is small, it still greatly affects fabric bulkiness.
Accordingly, the respective coefficients of contraction are measured after separating or peeling the filamentary islands of components A and B from the sea C by use of a solvent or decompo-sition agent which has the least effect upon the filamentary islands of components A and B. Contraction may be measured by any one of a variety of procedures including boiling water contraction, solvent contraction and high-temperature heating contraction. As stated, the difference of coefficient of contraction should be at least 3%
when tested by any one of these contraction test methods. Typically, the boiling water contraction method and the high-temperature dry contraction method are commonly used. In this specification, the contraction values referred to are often based on these test methods.
Thus, a filamentary type whose coefficient of contraction is small slackens relative to a filamentary type whose coefficient of contraction is large, thus making a bulky and puffy bundle of superfine filaments.
This puffiness may be brought about with the filament in , 1131~1~S
the form of a yarn, but it is more effective with the filament in the form of a fabric.
The relation between disposition of filamentary islands components A and B in the cross-sectional area of a composite filament and the difference in coefficient of contraction is important.
A second type of composite filament in accordance with the present invention is shown in Figures 11 - 26, in which filamentary islands of components A or s are separated by sea C.
In this type of composite filament, the filamentary islands may be a mixture of components A and s having a bicomponent-type or eccentric-type cross-sectional configuration, which are intended to be removed and separated from sea C. Also, the resultant bundle of superfine filaments may consist of a single component filamentary type of the component A or B in admixture with filamentary types of the remaining components of the original composite filament. For instance, in the case of Figure ll, there is shown a bicomponent-type composite superfine filament (a filamentary island) consisting of two adhering components A and B, and a superfine filament (the sea) of one component in admixture therewith arranged in the shape of a cross. In the case of, for example, Figure 13, the composite filament comprises a bundle of superfine filaments consisting of a bicomponent-type composite superfine filament consisting of adhering components A and B in combination with a cross-shaped superfine filament of sea C, as well as other superfine filaments consisting of the component A alone and the component B alone. When considered similarly, it may be easily understood what sorts of bundles of 1~3f~1~iS
superfine filaments are shown in each of the other figures.
Namely, throughout all the examples of Figures 11 - 26, combinations are shown each consisting of a bicomponent filamentary type or eccentric filamentary type composite superfine filament and super-fine filaments consisting of substantially a single component.
A third type of composite filament of the present invention is that in which, after sea C has been dissolved and removed, there remains a bundle of superfine filaments consisting of a combination of bicomponent filamentary types or eccentric filamentary types each consisting of components A and B, combined with superfine filaments of a single component type consisting of the components A or B or both. This combination of (a) bicomponent or eccentric and (b) single component superfine filaments is shown for example, in Figures 13, 16, 18, 20, 21, 22, 23 and 27 - 36.
Figures 27 - 36 particularly show examples of composite filaments in each of which the filamentary islands of components A and/or B are surrounded by sea C.
In each of these second and third types of filaments of the present invention utilizing bicomponent filamentary types, components A and B that are adherent to each other, yet have different coefficients of contr~action, are selected as the filamentary islands. Only when these conditions are met are very excellent effects, to be mentioned later, obtained. When all of the filamentary islands are composite, having roughly the same coefficient of contraction and the sea is removed, only crimp will be produced by heat and solvents as shown in Figure 37. In such crimping, loops of crimp often overlap and the feel of the resulting bundle or fabric is different than bundles or fabrics of this invention and ~ .~S~
~13~5 it is difficult to produce enough bulkiness in many cases.
sy contrast, in the use of the present invention, with the differential coefficients of contraction, as shown in Figure 38, a superfine crimped filament overlaps with another superfine straight filament, which is exactly the same result illustrated in Figure 2b. This is true, (even if each crimp does not make a complete loop, though the effect of the crimp in that case may be less).
In accordance with the present invention, compared with filaments where all reveal crimp, a very peculiar filament is produced having a voluminous feel, which is unexpected. This may be used to bloom naps of raised fabrics. Accordingly, compared with the crimp produced in a bundle of crimped superfine filaments as shown in Figure 37, which has heretofore been considered most excellent, a bundle of crimped superfine filaments of a superior structure may be obtained according to the present invention. In addition, such filaments may have no crimp while being processed into a woven fabric, knitted fabric or non-woven fabric, and are less bulky and easy to process. After a sheet-like fabric has been formed, said filaments may be rendered superfine by mechanical or chemical actions and said superfine filaments may be treated to produce crimp by further heat-treatment or chemical treatment.
Accordingly, in regard to the present invention, it should be noted that it is not necessary that a bundle or mixture consisting of crimpable superfine filaments and non-crimpable superfine filaments or contractable superfine filaments and non-contractible superfine filaments be made first, and then that such bundle or mixture be processed into filaments. Rather, superfine filaments having such 'J
, ~
~31~65 potential are readily processed in a fasciated state, namely, in aneasily processable condition like the filaments of an ordinary yarn.
Thereafter the respective superfine filaments are separated and made independent from such fasciated component, to produce particular effects of this invention.
As mentioned above, composite filaments used in the present invention are roughly divided into three types, the characteristics of each of which will be mentioned hereinafter.
In the first type, namely, in the case of each of the composite filaments shown in Figures 3 - 10, the contraction force is relatively strong, even in a restrained state, for example. As formed into a fabric, the product may become comparatively bulky.
In other words, with regard to the difference in coefficient of contraction of the superfine filaments, the loss of crimpability due to making the composite filament superfine is small. In addition, compared to ordinary filaments, such as super-fine multifilaments, according to the present invention, are mixed without being maldistributed. There is good affinity between the different superfine filaments, and the bundle of different super-fine filaments shows a good tendency to become puffy.
In the second type, namely, in composite filaments suchas those shown in Figures 11 - 26; a mechanical peeling method is applied and the chemical aid of a solvent is not necessary; accord-ingly there is no reduction of contractibility due to the action of the solvent; therefore, when a method of thermal contraction is adopted between two components A and B, crimp is very likely to be brought about. However, in this type of composite filament, peeling 1~ 1!Ei5 has to be carried out mechanically, and even when component C is unnecessary, for example, from the point of view of dyeing fastness, it may nevertheless be allowed to remain present. However, such composite filaments may peel at a stage when peeling is not wanted and this may be a drawback in that such a filament may have comparatively poor processability. On the other hand, there is, of course, no loss of components. These points become merits or demerits, depending upon the object at hand.
In the third type of composite filament in accordance with the present invention, as illustrated by Figures 27-36 of the draw-ings removal of one component is normally carried out by dissolution.
Owing to the use of a chemical solvent, crimpability due to difference of contraction between the two components A and B is often inferior.
The contraction power of one component is reduced by a crystalli-zation phenomenon caused by the solvent of sea C, which is called solvent crystallization. When heating is effected at the time of dissolution, loss of crimpability is even more likely. There are also other necessary drawbacks in removing one component by dissolution, including the loss of the component in solution.
; 20 However, as an advantage, the removal of the dissolved component creates spaces providing room among the superfine filaments, which contributes to a considerable feel-improving effect, which cannot be overlooked. In other words, this type of filament and procedure also has its merits and demerits.
Composite filaments of the third type having an "islands-in-sea" type cross-sectional configuration, as shown in Figures 27 -36, are especialiy important because in an "islands-in-sea" type '1-'' ,~' ,~
- : - , ~ :
.
,':': ~' , :
` 1~3~1~5 filament, filaments are well fasciated. Such a filament has good processability because of the high degree of filament concentration in the non-bulked state. This cannot be overlooked. It is another characteristic that a treatment which forms spaces among filaments by removal of component C brings about an effect similar to that of removing sericin from silk consisting of sericin and fibroin by degumming. It is still another characteristic of composite filaments of the third type that it is possible to select components of the same kind such as, for example, polyesters having different contract-ibility and to make it possible to mix different kinds of components,such as a polyamide and polyethylene.
In the foregoing description; the merits and demerits of the respective embodiments of this invention have been mentioned so that different forms of the invention may be properly used in accordance with the user's intended objects. What may be said about them in common is that, as shown in Figure 38, a bundle is so made that a superfine filament (or a plurality of such superfine filaments) treatable to form a superfine crimp is interposed among other superfine filaments which, under the same treatment, do not form a superfine crimp. Therefore, effects in bulkiness, mutual dispersion among filaments and improvement in feel are brought about, depending on the selection of filamentary type and composition.
These composite filaments may be used for production of various kinds of fiber products such as woven fabrics, knitted fabrics and non-woven fabrics. Examples of woven fabrics include crepe, such as crepe de Chine, palace crepe, satin crepe, morocain crepe, striped crepe, oriental crepe, flat crepe, georgette crepe 1~3~1~;S
and silk crepe, or various kinds of crepe weaves, such as amundsen jersey. Other examples include habutae (glossy) silk, satins, silk gauzes, voiles, porous fabrics, twill weave, serges, taffetas, cord weaves, velvets, towel weaves, flannels, shirting and various other designs of weave. Above all, these composite filaments are preferably used for producing raised fabrics such as velvet, velveteen and corduroy and further fabrics of a type which is raised by use of a raising machine.
As to knitted fabrics, besides various conventional knitted fabrics, other knits, such as platen or tricot fabrics or two-ply fabrics, of which especially those which are raised or napped may be cited, may also be made from filaments of the present invention.
Among-non-woven fabrics, one should include needle punched non-woven fabrics, non-woven fabrics made by the paper making types of methods, and also spun bond non-woven fabrics.
From such woven, knitted or non-woven fabrics it is possible to make raised fabrics having good nap dispersibility by subjecting them to napping and/or buffing. It is also possible to make a raised fabric such as velveteen or velvet by cutting to make them into piled fabrics. In each of these instances, the suprisingly advantageous effects of the present invention are effectively revealed.
It is especially preferable that the deniers of filaments after being made superfine should be about 0.05-0.6 in the case of raised fabrics and about 0.6-2.0 in the case of non-raised fabrics.
It is preferaole that the denier of the composite filament before .~,.i ., - i : ~
, ~3~ iS
being made superfine should be within the range of about 15-1 denier. In the case of mixed denier, it is preferable that the difference of deviation of the various deniers of the filaments after being made superfine should not exceed about 1.0 denier.
AS regards treating the filaments for the purpose of imparting crimp thereto, heating is especially preferable.
The most preferable combination of the component A and B
is a combination of po1yesters, particularly a combination of poly-ethylene terephthalate with the product obtained by copolymerizing isophthalic acid or sodium sulfonate isophthalate with the same, with the products obtained by copolymerizing a small amount of a trifunctional component with the same, or with polybutylene terephthalate or other known polyesters with the same.
The amounts, components and draw conditions are so determined as to bring about a difference in coefficient of contraction. Also, various polyamides, namely, nylon 6, nylon 66, PACM-, IPA- and TPA- copolymerized nylon 66 and various other copolymers are preferable as the components A and B. It is a matter of course that combinations of polymers of different series are acceptable.
As the component C, there may be cited polymers of the polystyrene series, polymers of the polyvinyl series, copolyesters, polymers of the polyamide series and polymers of the polyolefin series. The component C may be properly used by dissolving and removing the same or by peeling the same.
It goes without saying that for use as the components A, B and C, all the known fabric-forming polymers are applicable as ~ ~1 - 1~3R1~5 well as those mentioned above.
When the remaining component is polyester, it is especially preferable for producing a silky, feel to treat poly-ester with an alkali solution. An original yarn may be also textured-processed, such as by false weave processing and made into a yarn having strong twist. For example, a combination with strong twist SZ is possible.
It is a matter of course that when the two components A
and B are different in dyeability, it is possible to dye them differently, and it is possible to subject them to resin processing and to process them by adding a feel-improving agent such as poly-urethane and silicone. When, for example, such filaments are needle punched, processed with polyurethane before the component C is removed and thereafter buffed, it is possible to make a fabric consisting of said filaments into suede-like artificial leather and to produce a product having excellent feel by so doing.
_ample A three-component "islands-in-sea" type composite filament having a cross sectional area as shown in Figure 4 was produced by using polyethylene terephthalate to form a filamentary island of one component and, as another filamentary island, a copolyethylene terephthalate containing 9.9 mol ~ of an isophthalic acid component. Specifically, by using a spinneret (for 42 filaments) for a composite filament which consisted of a number of cores embedded in the matrix, said cores being extremely fine and parallel to each other along the fiber axis as shown in Japanese Patent Application Publication No. 26723/1972, the aforementioned ~3~
composite filament was first spun in the usual way at 280C, then wound, and finally drawn with heating to obtain a 3.8 denier yarn.
The number of filamentary islands so obtained was equal to sixteen, eight of which consisted of polyethylene terephthalate and eight of which consisted of copolyethylene terephthalate; all such filament-ary islands accounted for 60% of the yarn.
This filamentary yarn was washed well with carbon tetra-chloride and dried to obtain a bundle of superfine filaments. At this point the bundle thus obtained was free from swelling; however, when the bundle was immersed in boiling water, filaments consisting of said copolyester having copolymerized isophthalic acid contracted greatly. As a result, a remarkable swelling was seen in the bundle of superfine filaments. The difference in coefficient of contract-ion between the highly contractable component and the slightly contractible component was not less than 5%. It is notable that the component having the higher coefficient of contraction appeared to have been drawn to the inside of the fiber.
Example 2 A drawn composite filament having a cross sectional area as shown in Figure 3 was produced, wherein the two kinds of the filamentary islands were the same as in Example 1, but the sea component thereof was polystyrene which had 22% by weight of co-polymerized 2-ethylhexyl acrylate, the island/sea ratio being 85/15.
Using a yarn consisting of such composite filament both as warp and weft, the following plain fabric was woven. Specifi-cally, in weaving the plain fabric for the warp, a total 50 denier D.' :~ ? ~ ~
' s of about 5.6 d/9 fil yarn was used, at a plain fabric density of 110 warps/in; for the weft, a total 73 denier of about 5.6 d/13 fil yarn was used at a plain fabric density of 83 wefts/in. Two such woven fabrics were prepared; one fabric was washed with carbon tetrachloride while the other fabric was washed with trichloro-ethylene. Each was dried and then immersed in boiling water. Both such treatments cause fabric swelling, but the swelling of the fabric washed with the carbon tetrachloride was superior to the swelling of the fabric washed with trichloroethylene. Said fabric was subsequently washed in a hot 2.5 g/liter aqueous bath of sodium hydroxide, the surface thereof finally treated with an alkali, washed with water, dried and finally passed through air at 180C for a short period of time. The product thus obtained was a pli~nt woven fabric having a silk-like luster and feel.
Example 3 A composite filament was produced which consisted of many cores embedded within the matrix, said cores being extremely fine parallel to each other along the fiber axis. The composite filament further had an "islands-in-sea" type cross sectional configuration with thirty six islands, of which half were polyethylene tere-phthalate and half were copolyethylene terephthalate containing 9.9 mol ~ of an isophthalic acid component as in Example l; the - sea component was polystyrene, and island/sea ratio was 95/5. The thus obtained drawn yarn consisting of total denier 100 d/25 filaments was used as the pile yarn when weaving velvet-like fabrics.
As both warp and weft of the base texture, a 50 D - 36 f bulky processed yarn having a T-shaped cross sectional configuration ~"~
-1~3~
(process for producing the same being disclosed in Japanese Patent Application Publications Nos. 18535/1976 and 47550/1972) was used and the length of the raising was made to equal 1.0 mm. Two such fabrics were prepared, each of which was washed with a sufficient amount of an alkali; then with a sufficient amount of water.
Thereafter, one fabric was washed with carbon tetrachloride and the other fabric was washed with trichloroethylene. It is necessary to sufficiently wash the fabric with water after the alkali treatment, but prior to the trichloroethylene washing in order to prevent the production of explosive dichloroacetylene.
Next, when the two fabrics were exposed in hot air at 180C and thereafter dyed in blue, very elegant raised fabrics (which might be well called velvets having suede effects) having different pile ~raising) lengths were obtained.
Example 4 A three-component composite filament having an "islands-in-sea" type cross sectional configuration as shown in Figure 27 (number of islands: 4) was made. Namely, as component A, poly-ethylene terephthalate was used, and as component B, copolyethylene terephthalate having copolymerized 10 mol % of isophthalic acid was used. The ratio of A/B was made 75/25. As component C, polystyrene was used. The ratio of component C to the entirety was made 20%.
;~ The composite filament having a cross sectional configuration was spun by a three-component filament spinning machine and drawn to 3.3 times. The obtained yarn was about 4 denier/12 fil. A skein consisting of a plurality of such yarns was made and thereafter, the component C consisting of polystyrene was dissolved with carbon tetrachloride and removed. Thereafter, when crimp was imparted by the treatment of boiling water, the skein became very bulky. When this skein was grabbed by hand, the bulkiness was high and a remarkable difference was recognized compared with the following comparative example.
Comparative Example A composite filament having an "island-in-sea" type cross sectional configuration similar to that of Figure 27 was produced, wherein the entire island components were polyethylene terephthalate only and the component C (sea component) was polystyrene. The denier and island/sea ratio were so adjusted as to become the same as in Example 1. Similarly, component C was dissolved with carbon tetrachloride and removed and thereafter what was obtained was treated in boiling water and dried.
On the other hand, using a composite filament whose cross sectional configuration was similar to that of Figure 27, with the exception that all the filamentary islands had an A/s component filamentary type composite structure, a skein was made by the same manner as in Example 4.
When the so obtained two samples were compared (after drying) with the product of the present invention obtained in Example 1, the product of the present invention was superior in bulkiness. Bulkiness was measured by strongly grabbing the skein many times by hand, and the state of each skein was checked after the hand had been removed. The skein of composite filaments wherein .D' 1~31~t1&5 all the filamentary islands were the same was lowest in bulkiness, followed by the skein of composite filaments wherein all filament-ary islands comprised a bicomponent filamentary type. The product of the present invention was the best in bulkiness properties.
This skein (present invention) comprised an aggregate of bundles of superfine filaments having a different hand when compared to the other two skeins.
Example 5 Using the same filament yarn as in Example 4, a plain fabric was woven. Its density was 115 warps/in and 83 wefts/in.
This fabric was dissolved with carbon tetrachloride. Thereafter, its surface was washed with hot alkali diluted with water, to slightly dissolve the surface. Thus, it was washed with water and dried. Crimp was imparted to an extent sufficient to separate one superfine filament from another inside the organization. A silk-like feel was evident on the fabric surface and said plain fabric ; exhibited very excellent, silk-like qualities.
Example 6 ,~.
Example 5 was repeated except polybutylene terephthalate was used instead of a copolyethylene terephthalate having copolymerized isophthalic acid as component B. Also trichloro-ethylene was used as a solvent in treating the plain fabric. The resulting fabric was somewhat different in hand from the woven fabric obtained in accordance with Example 5. The repulsion and bulkiness of this fabric also differed from the fabric produced in Example 5. However, this fabric also exhibited excellent woven :: ;: , ' , ~3t~ iS
silk-like qualities.
Example 7 A composite filament having an "island-in-sea" type cross sectional configuration of the type shown in Figure 29 was produced.
The total number of islands was sixteen and island component A
comprised a copolyester containing polyethylene terephthalate and 9.9 mol ~ of isophthalic acid. The island component B comprised polyethylene terephthalate. The ratio was (A/B=12/4), and the sea component was a styrene - octyl acrylate (78/22) copolymer present in an amount equal to 4% of the entire composite filament. The filament was spun as a composite filament consisting of many cores embedded with the matrix. Said cores were extremely fine, drawn and parallel to each other along the fiber axis. The total denier and number of filaments in the yarn produced therefrom were 104 D -42 f. Using the obtained yarn as the "nap" warp, a 50 D - 18 f united filament (100 D) as texture warp and as texture weft, a 2-ply velvet weave was produced. The length of the raising (naps) in the fabric was about 0.9 mm and the fabric density was 60 warps/
in and 90 wefts/in. This woven fabric was washed with trichloro-ethylene in a washing machine and dried. Thereafter, said wovenfabric was treated in boiling water under relaxed conditions and heat set at 170C for 5 minutes. Thereafter, it was dyed black in a liquid stream circular dyeing machine at 120C under pressure.
The resulting fabric had naps which could be well bloomed and there were intervals among the naps. Also, light fuzz was mixed in the naps and the overall hand of the fabric was that of a very soft Dj~
1~3fl~5 raised woven fabric. On the other hand, a fabric produced according to this example (with the exception of using a composite filament whose islands all comprised component A) is obviously different in appearance and luster compared to the fabric of this example.
Claims (20)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A multi-component composite filament having an "islands-in-sea" type cross-sectional configuration and convertible into a bundle of superfine filaments, said composite filament comprising (A) at least two different kinds of filamentary islands having different contracting or crimping properties each dispersed independently in said sea without maldistribution of such filamentary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the respective kinds of filamentary islands having different coefficients of free contraction of at least 5%, or (2) one of said filamentary islands comprising a one component filamentary type and the other of said filamentary islands comprising (a) a bicomponent filamentary type in which a plurality of different polymers are adhered together or (b) an eccentrically shaped filamentary type having at least two components, the sum of the weights of said filamentary islands being greater than the weight of said sea, said filamentary islands being convertible, upon separation from said sea and upon different-ial contraction, into a bundle of puffy superfine filaments, or (B) filamentary islands and a sea having different contracting or crimping properties, the filamentary islands dispersed independently in the sea without maldistribution of such filamentary islands to any one side of said sea as viewed in said cross-sectional configuration, said composite filament being further characterized by (1) the filamentary islands and the sea having different coefficients of free contraction of at least 5%, or (2) the filamentary islands being a member selected from the group consisting of a bicomponent filamentary type in which a plurality of different polymers are adhered together and an eccentrically shaped filamentary type having at least two components, and the sea being a member selected from the group consisting of a one component filamentary type and a multicomponent filamentary type having one major component with the proviso that said filamentary islands are of a different filamentary type from said sea, said filamentary islands and said sea being convertible, upon separation from each other and upon differential contraction, into a bundle of puffy superfine filaments.
2. A multi-component composite filament according to claim 1, wherein the denier of said filamentary islands is between about 0.05 - 0.6 d.
3 A multi-component composite filament according to claim 1, wherein the denier of said filamentary islands is between about 0.6 - 2.0 d.
4. A multi-component composite filament according to claim 1, wherein the denier of said filament is between about 1 - 15 d.
5. A multi-component composite filament according to claim 1, wherein said filamentary islands is dispersed in a mutually inter-posed pattern.
6. A multi-component composite filament according to claim 1, wherein said filamentary islands are disposed concentrically.
7. A multi-component composite filament according to claim 1, wherein said filamentary islands are exposed on the surface of said composite filament.
8. A multi-component composite filament according to claim 1, wherein said filamentary islands are converted by said sea.
9. A multi-component composite filament according to claim 1, wherein said filamentary islands are formed of polymers of the polyester series.
10. A multi-component composite filament according to claim 1 or 5 wherein said filamentary islands are seperable upon solvent treatment for removal of said sea.
11. A multi-component composite filament according to claim 1 or 7 wherein said filamentary islands are separable from said sea upon mechanical treatment.
12. A method of forming a fabric from the multi-component composite filament of claim 1, said fabric being composed of a plurality of bundles of superfine filaments, said method comprising taking a plurality of said composite filaments and forming a sheet-like fabric, separating said filamentary islands from said sea and then differentially contracting the filamentary islands or the filamentary islands and the sea to form said bundles of superfine filaments in which each type of superfine filament is dispersed witnout maldistribution in a said bundle.
13. A method according to claim 12, wherein the denier of said separated superfine filaments is between about 0.05 - 0.6 d.
14. A method according to claim 12, wherein the denier of said separated superfine filaments is between about 0.6 - 2.0 d.
15. A method according to claim 12 wherein the separation is effected by removal of said sea upon addition of a solvent to said composite filament.
16. A method according to claim 12 wherein the separation is effected by mechanical stripping of the filamentary islands from said sea.
17. A fabric composed of a plurality of bundles of superfine filaments, each such bundle being obtained by separating said superfine filaments from a multi-component composite filament, each such bundle comprising at least two different types of superfine filaments which have different coefficients of free contraction, each type of superfine filament being dispersed without maldistribution in said bundle, and wherein either (A) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type and a multi-component filamentary type having one major component and the other superfine filament comprises (1) a bicomponent filamentary type in which a plurality of different polymers are adhered to-gether or (2) an eccentrically shaped filamentary type having at least two components, or (B) one of said superfine filaments is a member selected from the group consisting of a one component filamentary type, a bicomponent filamentary type in which a plurality of different polymers are adhered together, and an eccentrically shaped filamentary type having at least two components and the other of said superfine filaments is a member selected from the group con-sisting of a one component filamentary type and a multi-component filamentary type having one major component, with the proviso that said superfine filaments and said other superfine filaments are of different filamentary types.
18. A fabric according to claim 17 wherein at least one type of superfine filament has a denier of between about 0.05 - 0.6d.
19. A fabric according to claim 17 wherein at least one type of superfine filament has a denier of between about 0.6 - 2.0d.
20. A fabric according to claim 17 wherein at least one type of superfine filament is a polymer of the polyester series.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000338914A CA1138165A (en) | 1979-10-31 | 1979-10-31 | Multi-component composite filament |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000338914A CA1138165A (en) | 1979-10-31 | 1979-10-31 | Multi-component composite filament |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1138165A true CA1138165A (en) | 1982-12-28 |
Family
ID=4115503
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000338914A Expired CA1138165A (en) | 1979-10-31 | 1979-10-31 | Multi-component composite filament |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1138165A (en) |
-
1979
- 1979-10-31 CA CA000338914A patent/CA1138165A/en not_active Expired
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