EP1939336B1 - Fil frise, procede de fabrication correspondant et structure de fibre - Google Patents

Fil frise, procede de fabrication correspondant et structure de fibre Download PDF

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Publication number
EP1939336B1
EP1939336B1 EP06821902A EP06821902A EP1939336B1 EP 1939336 B1 EP1939336 B1 EP 1939336B1 EP 06821902 A EP06821902 A EP 06821902A EP 06821902 A EP06821902 A EP 06821902A EP 1939336 B1 EP1939336 B1 EP 1939336B1
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EP
European Patent Office
Prior art keywords
component
fiber
crimped yarn
preferable
sheath
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP06821902A
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German (de)
English (en)
Japanese (ja)
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EP1939336A4 (fr
EP1939336A1 (fr
Inventor
Katsuhiko c/o Mishima Plant Toray Industries Inc. MOCHIZUKI
Kousuke c/o Mishima Plant Toray Industries Inc. FUKUDOME
Shozo c/o Okazaki Plant Toray Industries Inc. INOUE
Toshiaki c/o Okazaki Plant Toray Industries Inc. KIMURA
Syusaku Seta Plant Toray Industries Inc. NARITA
Atsushi c/oHokuriku Branch Toray Industries Inc. SHINOZAKI
Hiroshi c/o Seta Plant Toray Industries Inc. KAJIYAMA
Kazuya c/o Osaka Head Office Toray Industries Inc. MATSUMURA
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Toray Industries Inc
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Toray Industries Inc
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Priority claimed from JP2005371657A external-priority patent/JP4872339B2/ja
Application filed by Toray Industries Inc filed Critical Toray Industries Inc
Publication of EP1939336A1 publication Critical patent/EP1939336A1/fr
Publication of EP1939336A4 publication Critical patent/EP1939336A4/fr
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Publication of EP1939336B1 publication Critical patent/EP1939336B1/fr
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/12—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyamide as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/36—Matrix structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D02G1/0206—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
    • D02G1/0266—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting false-twisting machines
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/12—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam
    • D02G1/161—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam yarn crimping air jets
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/20—Combinations of two or more of the above-mentioned operations or devices; After-treatments for fixing crimp or curl
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
    • D02J1/224—Selection or control of the temperature during stretching
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
    • D02J1/228—Stretching in two or more steps, with or without intermediate steps
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
    • Y10T428/2924—Composite

Definitions

  • the present invention relates to a crimped yarn constituted by a synthetic fiber comprising an aliphatic polyester resin and a thermoplastic polyamide resin in which exposed area ratio of the aliphatic polyester resin with respect to the fiber surface area is extremely small.
  • plant resources as starting materials which take in carbon dioxide from the air to grow, not only it is expected to be able to control the global warming by circulation of carbon dioxide, but also it may be possible to solve the problem of the shortage of resources. For that reason, plastics of which starting materials are plant resources, i.e., plastics made by biomass have been drawing attention.
  • biodegradable plastics made by biomass has problems that not only their mechanical properties and heat resistance are poor, but also their production cost is high, and they have not been used as general purpose plastics.
  • polylactic acid of which starting material is lactic acid obtainable by fermentation of starch is in the spotlight.
  • Aliphatic polyester resins represented by polylactic acid have been used for a long time, for example, in medical field as a sewing thread for surgical operation, but recently, by an improvement of its mass production technology, it became possible to compete in cost with other general purpose plastics. Accordingly, development of its commercial product as a fiber has been activated.
  • the fiber in case where polylactic acid fiber is used for apparel uses, the fiber have been found to be poor in practical durability such that a color staining occurs easily by a rubbing or the like or, and in a serious case, fiber becomes whitish by a fibrillation or, it is excessively stimulative to skin. And, in case where it is used for car interior, especially for carpet which suffers from hard rubbing, as well as a falling down of pile of polylactic acid easily occurs, weaving also occurs, and in a serious case, a hole may be opened. And, since aliphatic polyester (especially, polylactic acid) easily be hydrolyzed also, the fibrillation or weaving such as above-mentioned becomes serious with lapse of time, and it have been found that its product life is short.
  • aliphatic polyester especially, polylactic acid
  • methods for improving abrasion resistance of polylactic acid for example, there are methods by preventing hydrolysis, for example, a method of preventing hydrolysis at fiber production process by decreasing water content of polylactic acid as low as possible or, a method of improving hydrolysis resistance by adding a monocarbodiimide compound.
  • any method of them although the lowering of abrasion resistance is prevented from the view point that an embrittlement of polylactic acid with the lapse of time is prevented, any of them is not a method of changing the characteristic of polylactic acid that it is easily fibrillated, i.e., it was found that every of them can prevent an embrittlement with the lapse of time, but initial abrasion resistance has not been improved from the conventional one.
  • Patent reference 1 a technique of improving mechanical characteristics of resin composition by blending polyamide and aliphatic polyester is disclosed (Patent reference 1).
  • Patent reference 1 a technique of improving mechanical characteristics of resin composition by blending polyamide and aliphatic polyester is disclosed.
  • the polyamide is a minor component such that its blend ratio is 5 to 40%, the aliphatic polyester forms sea component, and furthermore, since the aliphatic polyester and the polyamide are incompatible and an adhesion force of the interface between these phases is poor, it was found there are problems that the interface is easily peeled off by an external force to become whitish by fibrillation and abrasion speed is also high.
  • a technique is disclosed that a high elongation polyamide fiber is prepared by micro-dispersing a polyester in a polyamide to prevent orientation (Patent reference 2).
  • Patent reference 2 By making it into said polymer alloy fiber, it becomes possible to impart a high bulkiness to a crimped yarn by mixing with a low elongation polyamide unstretched yarn at false twist processing.
  • said polymer alloy fiber is suitable for a sheath yarn at the false twist processing, when it is used for production of an air stuffer crimped yarn which is the object of the present invention, since fiber orientation is rather insufficient, heat shrinkage in the air stuffer crimping machine is insufficient and a 3 dimensional crimp is not developed and only a crimped yarn of which crimp elongation percentage is low can be obtained.
  • sheath split the sheath component is split (hereafter, referred to as sheath split), due to an abrasion between the core component and the sheath component and further, it grows to a fibrillation.
  • Patent reference 3 a composite fiber of which abrasion resistance is improved by having a thermoplastic polyamide of a specified thickness as sheath component is disclosed. Said composite fiber exhibits an effect in applications exposed only to relative weak abrasions such as apparel uses. However, in applications exposed to strong external force repeatedly such as carpet or the like, a pealing of the interface occurs easily and an appearance change was easy to occur. And, in Patent reference 3, a crimped yarn (false twisted yarn) in which said composite fiber is used, is disclosed, but it was found that, a crimped yarn comprising the composite fiber is easier to be peeled off at its sheath/core interface than an uncrimped yarn.
  • EP-A-1564315 discloses a polymer alloy fiber of islands-in sea structure in which the sea component is a high suitability polymer such as PLA.
  • the invention provides a method of producing a crimped yarn as defined in the accompanying Claim 13.
  • the invention provides a crimped yarn of sheath/core type as defined in the accompanying claim 18.
  • the invention provides a method for producing the crimped yarn of sheath/core type as defined in the accompanying claim 25.
  • a fifth aspect of the invention concerns a fiber structure containing a crimped yarn as claimed in claim 1 in at least a portion thereof.
  • the aliphatic polyester resin (A) (hereafter, may be referred to as "component A") mentioned in the present invention is a polymer of which aliphatic alkyl chain is connected with an ester bond.
  • component A a polymer of which aliphatic alkyl chain is connected with an ester bond.
  • the aliphatic polyester resin (A) used in the present invention it is preferable to be crystalline and it is more preferable that its melting point is 150 to 230°C.
  • the aliphatic polyester resin (A) used in the present invention for example, polylactic acid, polyhydroxybutyrate, polybutylene succinate, polyglycolic acid, polycaprolactone or the like are mentioned.
  • Polylactic acid is most preferable among the aliphatic polyesters since its melting point is high and excellent in thermal stability.
  • the above-mentioned polylactic acid is a polymer having -(O-CHCH 3 -CO) n - as its repeating unit, and it is a polymerization product of lactic acid or oligomer of lactic acid such as lactide. Since there are two kinds of optical isomer of lactic acid, D-lactic acid and L-lactic acid, as their polymers, there are poly(D-lactic acid) consisting only of D-type and poly(L-lactic acid) consisting only of L-type and polylactic acid consisting of both of them. Regarding the optical purity of D-lactic acid or L-lactic acid in polylactic acid, as it decreases, crystallinity decreases and melting point depression becomes large. In order to keep the heat resistance of fiber, it is preferable that the melting point is higher than 150°C or more, and to be 160°C or more is more preferable. Still more preferably, it is 170°C or more and especially preferably 180°C or more.
  • the melting point can be made as high as 220 to 230°C, and it is preferable.
  • the "component A” means a mixture of poly(L lactic acid) and poly(D lactic acid), and when its blend ratio is 40/60 to 60/40, it is best since it can increase ratio of the stereo complex crystal.
  • crystal nucleating agent at melt spinning in order to form said stereo complex crystal efficiently.
  • the crystal nucleating agents other than talc or stratified clay minerals, stearic acid or 12-hydroxystearic acid, stearic acid amide or oleic acid amide, erucic acid amide, methylene bisstearic acid amide, ethylene bisstearic acid amide, ethylene bisoleic acid amide, butyl stearate, stearic acid monoglyceride, calcium stearate, zinc stearate, magnesium stearate, lead stearate, etc., of which compatibility with polylactic acid is high can be applied.
  • the component A may, for example in a range which does not impair the property of polylactic acid, be a copolymer in which a component other than lactic acid is copolymerized.
  • a component to be copolymerized polyalkylene ether glycols such as polyethylene glycol, aliphatic polyesters such as polybutylene succinate or polyglycolic acid, aromatic polyesters such as polyethylene isophthalate, and ester bond formable monomers such as hydroxycarboxylic acid, lactone, dicarboxylic acid or diol, are mentioned.
  • polyalkylene ether glycols of which compatibility with the thermoplastic polyamide resin (B) (hereafter, may be referred to as “component B”) is good, is preferable.
  • a copolymerization ratio of such copolymerization component is, in a range not being impaired by a decrease of heat resistance due to a melting point depression, preferably 0.1 to 10 mol% with respect to the polylactic acid.
  • a particle, a color pigment, a crystal nucleating agent, a flame retardant, a plasticizer, an anti-static agent, an antioxidant, an ultraviolet absorber, a lubricant, etc. may further be added.
  • color pigments other than inorganic pigments such as carbon black, titanium oxide, zinc oxide, barium sulfate and iron oxide, organic pigments such as a cyanine-based, a styrene-based, a phthalocyanine-based, an anthraquinone-based, a perinone-based, an isoindolinone-based, a quinophthalone-based, a quinocridone-based and a thioindigo-based one can be used.
  • organic pigments such as a cyanine-based, a styrene-based, a phthalocyanine-based, an anthraquinone-based, a perinone-based, an isoindolinone-based, a quinophthalone-based, a quinocridone-based and a thioindigo-based one can be used.
  • modifiers such as particles such as various inorganic particles including calcium carbonate, silica, silicone nitride, clay, talc, kaolin, zirconic acid, etc., cross-linked polymer particles or various metallic particles can also be used.
  • polymers such as waxes, silicone oils, various surfactants, various fluororesins, polyphenylene sulfides, polyamides, polyacrylates including ethylene/acrylate copolymer and methyl methacrylate polymer, various rubbers, ionomers, polyurethanes and their thermoplastic elastomers, can be contained in a small amount.
  • aliphatic acid amides and/or aliphatic acid esters are mentioned.
  • aliphatic acid amides for example, lauric acid amide, palmitic acid amide, stearic acid amide, erucic acid amide, behenic acid amide, methylol stearic acid amide, methylol behenic acid amide, dimethylol oil amide, dimethyl lauric acid amide, dimethyl stearic acid amide, compounds containing two amide bond in one molecule such as saturated aliphatic acid bisamide, unsaturated aliphatic acid bisamide or aromatic-based bisamide are mentioned, for example, methylene biscaprylic acid amide, methylene biscapric acid amide, methylene bislauric acid amide, methylene bismyristic acid amide, methylene bispalmitic acid amide, methylene bisstearic acid amide, methylene bis
  • a substituent such as hydroxyl group may be introduced in its structure, for example, methylol stearic acid amide, methylol behenic acid amide, N-stearyl-12-hydroxystearic acid amide, N-oleyl 12-hydroxystearic acid amide or the like are included in the alkyl substituted type aliphatic acid monoamide of the present invention.
  • aliphatic acid esters for example, aliphatic monocarboxylic acid esters such as lauric acid cetyl ester, lauric acid phenacyl ester, myristic acid cetyl ester, myristic acid phenacyl ester, palmitic acid isopropylidene ester, palmitic acid dodecyl ester, palmitic acid tetradodecyl ester, palmitic acid pentadecyl ester, palmitic acid octadecyl ester, palmitic acid cetyl ester, palmitic acid phenyl ester, palmitic acid phenacyl ester, stearic acid, cetyl ester or behenic acid ethyl ester; monoesters of ethylene glycol such as glycol monolaurate, glycol monopalmitate or glycol monostearate, diesters of ethylene glycol such as glycol dilaurate, glycol dipalmitate or glycol di
  • Aliphatic acid bisamide or alkyl substituted type aliphatic acid monoamide has a low reactivity of its amide compared to ordinary aliphatic acid monoamide to thereby hardly cause a reaction with polylactic acid at melt molding, and further, since there are many such monoamides of high molecular weight, heat resistance is high and hardly sublimates, and accordingly, it exhibits an excellent slipperiness without impairing its function as a lubricant.
  • aliphatic acid bisamide has a lower reactivity of its amide, it can be more preferably used, and ethylene bisstearic acid amide is still more preferable.
  • aliphatic acid amide and the aliphatic acid ester may be used, and the aliphatic acid amide and the aliphatic acid ester may be used together.
  • a content of the aliphatic acid amide and/or aliphatic acid ester is 0.1 wt% or more with respect to fiber weight in order to exhibit the above-mentioned characteristics. And, it is preferable that the content is 5 wt% or less since, when the content is too high, mechanical properties of fiber may deteriorate or its color tone may turn worse such that it become yellowish when dyed. More preferable content of said aliphatic acid amide and/or aliphatic acid ester is, 0.2 to 4 wt%, and still more preferably, it is 0.3 to 3 wt%.
  • a molecular weight of polylactic acid polymer is high in order to improve abrasion resistance, but when the molecular weight is too high, moldability at melt spinning or stretchability may deteriorate.
  • the weight average molecular weight is 80,000 or more in order to keep abrasion resistance, 100,000 or more is more preferable. Still more preferably, it is 120,000 or more.
  • a weight average molecular weight is 350,000 or less, 300,000 or less is more preferable. Still more preferably, it is 250,000 or less.
  • the above-mentioned weight average molecular weight is a value measured by a gel permeation chromatography (GPC) and determined by being converted into the polystyrene equivalent.
  • a production method of polylactic acid preferably used as the component A of the present invention is not especially limited, but in concrete, a direct dehydrative condensation method in which lactic acid is subjected to a dehydrative condensation as it is under a presence of an organic solvent and a catalyst (refer to JP-H6-65360A ), a method of subjecting at least 2 kinds of homopolymer to a copolymerization and ester interchange reaction under a presence of polymerization catalyst (refer to JP-H7-173266A ), furthermore, an indirect polymerization method in which lactic acid is once dehydrated to be converted to cyclic dimer and subjected to a ring opening polymerization (refer to the specification of US Patent No. 2,703,316 ) are mentioned.
  • thermoplastic polyamide resin (B) used in the present invention is a polymer having an amide bond and as the thermoplastic polyamide resin (B) used in the present invention, for example, polycapramide (nylon 6), polytetramethylene adipamide (nylon 46), polyhexamethylene adipamide (nylon 66), polyundecane amide (nylon 11), polydodecane amide (nylon 12), polyhexamethylene sebacamide (nylon 610), polypentamethylene sebacamide (nylon 510), etc., can be mentioned.
  • nylon 6 is preferable, and in order to increase adhesion force of interface by increasing compatibility with the component A, it is preferable that methylene chain length of polyamide is long, and in that point, nylon 11, nylon 12, nylon 610 or nylon 510 are preferable. And, in view of providing a material for reducing environmental load, nylon 610 or nylon 510 of which monomer is sebacic acid which is a nonpetroleum raw material is preferable. And, the polyamide may be a homopolymer or a copolymer. And, to the component B, a particle, a flame retardant, an antistatic agent or the above-mentioned lubricant preferably used in the component A, etc., may be added.
  • solution viscosity of the thermoplastic polyamide can be measured by known methods, such that, in case of nylon 6, nylon 610 or the like, it is measured by using 98% sulfuric acid solution mentioned later, and an inherent viscosity of nylon 11 is measured by using m-crezol solution.
  • thermoplastic polyamide resin (B) in general, aliphatic polyesters cannot be said to be high in heat resistance such that, the melting point is usually 200°C or less even when it has a melting point, and when it is melted and stored at a temperature exceeding 250°C, its physical properties may deteriorate rapidly. For that reason, it is preferable that a melting point of the thermoplastic polyamide resin (B) to be blended is 150 to 250°C, and 150 to 225°C is more preferable. Still more preferably, it is 150 to 205°C. However, in consideration of heat resistance of crimped yarn, it is preferable that melting point of the thermoplastic polyamide resin (B) is higher than that of the aliphatic polyester (A). Said thermoplastic polyamide resin may be a copolymer as above-mentioned, but it is preferable to be crystalline since its abrasion resistance may be lowered with lowering of its crystallinity.
  • the polymer is crystalline when a melting peak can be observed by a differential scanning colorimeter (DSC). And, the higher the crystallinity, the more preferable, and it can be evaluated by crystal melting peak calorie in DSC, as its index.
  • the crystal melting peak calorie ⁇ H is preferably 30 J/g, more preferably 40 J/g and still more preferably, 60 J/g.
  • the crimped yarn of the present invention consists of the above-mentioned synthetic fiber comprising the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) and almost no aliphatic polyester resin (A) is exposed on fiber surface, and specifically that an exposed area ratio of the aliphatic polyester resin (A) with respect to fiber surface area is 5% or less.
  • structures having such fiber surface configuration can be achieved by any one of (1) or (2) of (1) "polymer alloy type synthetic fiber having an sea/island structure in which the aliphatic polyester resin (A) forms the island component and the thermoplastic polyamide resin (B) forms the sea component ", or (2) "sheath/core type composite fiber of which core component is the polymer alloy of the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B), and the sheath component is the thermoplastic polyamide resin (B)".
  • core component is the polymer alloy of the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B)
  • sheath component is the thermoplastic polyamide resin (B)
  • blend ratio is not especially limited, but in order to make a polymer alloy having an sea/island structure in which the component A is the island component, and the component B is the sea component, it is preferable that a blend ratio (wt%) of component A/component B is in the range of 5/95 to 55/45. And, in case where the ratio of component A is increased, it is necessary to increase melt viscosity of the component A, ⁇ a, and in case where the ratio component B is increased, it is necessary to increase melt viscosity of the component B, ⁇ b.
  • a blend ratio of the component A and the component B is, since the higher the ratio of the component B, the easier to make the polymer alloy, more preferably, 10/90 to 45/55, still more preferably, 15/85 to 40/60, most preferably, 20/80 to 35/65.
  • method of measurement of the melt viscosity ⁇ is explained later in detail, but it is a value measured at the same temperature as the spinning temperature at a shear rate of 1216 sec -1 .
  • the component A and the component B are uniformly blended, but "uniformly blended" mentioned here means the following condition. That is, when a cross-section slice of said synthetic fiber is observed by a transmission electron microscope (TEM) (40,000 times ), as shown in Fig. 1 , it has a so-called sea/island structure in which the continuous matrix component (black portion) is the sea component, and the approximately circular and dispersed component (white portion) is the island component, and further, it is in a condition that a domain size of the component A constituting the island component is as small as 0.001 to 2 ⁇ m in diameter equivalent (diameter of hypothetical circle equivalent to the domain area).
  • TEM transmission electron microscope
  • the exposed area ratio of aliphatic polyester resin (A) in the polymer alloy type synthetic fiber can be determined by observing the above-mentioned TEM images for the entire peripheral to thereby respectively measure exposed length of the white portion exposed on fiber surface (aliphatic polyester resin) and entire peripheral length of fiber, and calculating a ratio of the lengths.
  • an adhesion force with the component B constituting the sea component is improved as the domain size becomes small, since stress concentration is dispersed, but on the other hand, when the domain size is a specified size or less, initial abrasion resistance is apt to decrease. Accordingly, it is preferable that the island domain size is 0.005 to 1.5 ⁇ m, and 0.02 to 1.0 ⁇ m is more preferable. And, in order to control a glossy texture of the crimped yarn, it is preferable to further control the domain size in a specified range.
  • the domain size is in the range of 0.08 to 0.8 ⁇ m.
  • the above-mentioned domain size of the present invention means, as mentioned later in item G of Examples, a distribution of 80 domains when 100 domains per 1 crimped yarn sample are measured and the largest 10 domain sizes and the smallest 10 domain sizes are excluded.
  • a material constituting the crimped yarn of the present invention is the polymer alloy type synthetic fiber, different from a block copolymer in which an aliphatic polyester block and a polyamide block are present alternatively in 1 molecular chain
  • the aliphatic polyester molecular chain (component A) and the polyamide molecular chain (component B) are present substantially independently.
  • This difference of conditions can be estimated by observing a melting point depression of the thermoplastic polyamide resin of before and after the compounding, that is, how the melting point based on the thermoplastic polyamide resin in the polymer alloy lowered from the melting point of the thermoplastic polyamide resin before the compounding.
  • the melting point depression of the thermoplastic polyamide resin is 3°C or less, the aliphatic polyester and the polyamide have hardly copolymerized (ester-amide interchange has hardly occurred), and it is a polymer alloy condition in which the aliphatic polyester molecular chain and the polyamide molecular chain are present substantially independently. And, since the fiber surface layer is substantially occupied by the thermoplastic polyamide resin which is the sea component, characteristics inherently pertaining to the above-mentioned thermoplastic polyamide resin are reflected to the fiber and the abrasion resistance is greatly improved. Accordingly, in the present invention, it is preferable that the melting point depression of the polyamide compounded is 2°C or less.
  • the material constituting the crimped yarn of the present invention is a polymer alloy type synthetic fiber
  • a sea/island structure is formed in which the aliphatic polyester resin forms the island component and the thermoplastic polyamide resin forms the sea component. And, by controlling the domain size of the island component, as well as the abrasion resistance is greatly improved, high quality glossiness is also exhibited.
  • component C is not especially limited as far as it increases the adhesion force of the interface between the component A and the component B, but it is preferable if it is a compound having two or more active hydrogen reactive groups in a molecule, since the adhesion force of interface is increased greatly.
  • the active hydrogen reactive group is a group having a reactivity with COOH terminal group, OH terminal group or NH 2 terminal group present at the terminal of polylactic acid resin or of the thermoplastic polyamide resin, for example glycidyl group, oxazoline group, carbodiimide group, aziridine group, imide group, isocyanate group, maleic acid anhydride group or the like are preferably used.
  • the melt spinning which is the production method of the crimped yarn of the present invention, since molding is carried out at a relatively low temperature as 250°C or less, a compound excellent in low temperature reactivity is selected.
  • glycidyl group, oxazoline group, carbodiimide group or acid anhydride group are preferably used, and especially, glycidyl group or carbodiimide group are preferably used.
  • group produced from maleic acid anhydride may be referred to as maleic acid anhydride group or the like
  • glycidyl group or carbodiimide group are preferably used.
  • the number of active hydrogen reactive groups in a molecule is 2 or more and 20 or less.
  • the compound having 2 or more of the above-mentioned active hydrogen reactive group is a compound of which weight average molecular weight is 250 to 30,000, it is preferable since it is excellent in heat resistance at melt molding and dispersibility. More preferably, it is 250 to 20,000.
  • a compound having these reactive groups if it is a copolymer graft copolymerized to the main chain of polymer with a side chain having a reactive group, it is preferable since not only it becomes possible to introduce many functional group in a molecule, but also, in general, thermal characteristic such as melting point becomes stable.
  • a polymer to be the main chain to be grafted with these reactive groups in view of easiness of its synthesis, it can be appropriately selected from the group consisting such as of polyester-based polymers, acrylate based polymers including polyacrylate, polymethyl methacrylate or poly(alkyl)methacrylate, polystyrene-based polymers and polyolefin-based polymers.
  • the compound having glycidyl group for example, a polymer of which monomer unit is a compound having glycidyl group or a compound of which polymer to be the main chain is graft copolymerized with glycidyl group, and furthermore, those having glycidyl group at terminal of polyether unit are mentioned.
  • the monomer units having the above-mentioned glycidyl group glycidyl acrylate, glycidyl methacrylate or the like are mentioned. And, other than these units, it is possible to control reactivity of glycidyl group by copolymerizing such as a long chain alkyl acrylate.
  • an average molecular weight of the polymer of which monomer unit is the compound having glycidyl group or the polymer to be the main chain is in the range of 250 to 30,000, it is preferable since a melt viscosity increase, when the component is added to be contained in a high concentration, can be prevented. It is more preferable that the weight average molecular weight is in the range of 250 to 20,000. And, other than that, a compound having 2 or more glycidyl units on triazine ring is also preferable since its heat resistance is high. For example, triglycidyl isocyanurate (TGIC), monoallyl diglycidyl isocyanurate (MADGIC) or the like are preferably used.
  • TGIC triglycidyl isocyanurate
  • MADGIC monoallyl diglycidyl isocyanurate
  • carbodiimide compounds mono or dicarbodiimide compounds such as diphenyl carbodiimide, di-cyclohexyl carbodiimide, di-2,6-dimethyl phenyl carbodiimide, diisopropyl carbodiimide, dioctyl decyl carbodiimide, di-o-toluyl carbodiimide, di-p-toluyl carbodiimide, di-p-nitrophenyl carbodiimide, di-p-aminophenyl carbodiimide, di-p-hydroxyphenyl carbodiimide, di-p-chlorophenyl carbodiimide, di-o-chlorophenyl carbodiimide, di-3,4-dichlorophenyl carbodiimide, di-2,5-dichlorophenyl carbodiimide, p-phenylene-bis-o-toluyl carbodi
  • polymers of N,N'-di-2,6-diisopropyl phenyl carbodiimide or 2,6,2',6'-tetraisopropyl diphenyl carbodiimide are preferable.
  • the 2 or more active hydrogen reactive groups may be the same or different reactive groups, but it is preferable to be the same reactive group in order to control reactivity.
  • polyalkylene ether glycols is preferable since it peculiarly improve abrasion resistance.
  • polyethylene glycol, polypropylene glycol, polybutylene glycol or the like are mentioned, but among them, polyethylene glycol of molecular weight 400 to 20,000 is preferable in view of heat resistance, dispersibility and cost. More preferred is a polyethylene glycol of molecular weight 600 to 6,000. And, it is more preferable if both terminals of said compound were modified to glycidyl group. And, it is also preferable to use it together with the above-mentioned compound having 2 or more active hydrogen reactive groups.
  • a heat resistance durable thereto is required. Accordingly, it is preferable that a heat loss ratio when arrived at 200°C in a thermogravimetric (TG) analysis is 3% or less. When the heat loss ratio exceeds 3%, since pyrolyzates bleed out at the time of spinning to thereby stain spinneret or spinning machine, not only spinnability is deteriorated but also, due to a smoke of gaseous pyrolyzate, a problem arises sometimes that working environment may be aggravated.
  • TG thermogravimetric
  • 200°C heat loss ratio is the weight loss ratio at 200°C when heated from a normal temperature (10 to 30°C) up to 300°C at a heating speed of 10 °C/min under nitrogen atmosphere in a thermogravimetric (TG) analysis.
  • An adding amount of the component C can be appropriately determined by an equivalency per unit weight of reactive group of the compound to be used, a dispersibility or reactivity when melted, domain size of the island component and blend ratio of the component A and the component B. In view of preventing a peeling off of the interface, it is preferable to be 0.005 wt% or more with respect to the total amount (100 wt%) of the component A, the component B and the component C. More preferably, it is 0.02 wt% or more, still more preferably, 0.1 wt% or more. When the adding amount of the component C is too small, its diffusion to and degree of reaction between the interface of the 2 components are not sufficient, and an increasing effect of adhesion force of the interface may be limited.
  • the adding amount of component C is 5 wt% or less, and 3 wt% or less is more preferable. Still more preferably, it is 1 wt% or less.
  • the component C by adding the component C, it is possible to end-cap terminal carboxyl group of the aliphatic polyester, and enhance hydrolysis resistance of the aliphatic polyester. Concentration of the terminal carboxyl group having a self-catalytic function is better to be low, and it is preferable that the total carboxyl terminal group concentration in the aliphatic polyester is 15 eq/ton or less, more preferably, 10 eq/ton or less and still more preferably, 0 to 7 eq/ton.
  • a catalyst of a metal salt of carboxylic acid in particular, of its metal is an alkali metal or alkali earth metal, in order to enhance reaction efficiency.
  • a catalyst based on lactic acid such as sodium lactate, calcium lactate or magnesium lactate.
  • a catalyst of which molecular weight is relatively high such as stearic acid metal salt, singly or in combination.
  • an adding amount said catalyst is, in view of controlling dispersibility and reactivity, preferably, 5 to 2000 ppm with respect to the synthetic fiber. More preferably, it is 10 to 1000 ppm and still more preferably, it is 20 to 500 ppm.
  • the crimped yarn of the present invention it is preferable that at least one kind crystal nucleating agent selected from talc, sorbitol derivative, metal salt of phosphoric acid ester, basic inorganic aluminum compound or salt of melamine compound is contained.
  • Said crystal nucleating agents are crystal nucleating agents effective mainly to the aliphatic polyester resin (A), especially, to polylactic acid.
  • an average particle diameter D 50 is 5 ⁇ m or less and the amount of talc of which particle diameter is 10 ⁇ m or more is 0 to 4.5 vol% or less with respect to the total talc.
  • the average particle diameter D 50 of the talc 5 ⁇ m or less an effect as a crystal nucleating agent greatly increase due to increase of apparent surface area. Accordingly, it is preferable that the particle diameter of talc is 4 ⁇ m or less and 3 ⁇ m or less is more preferable. Most preferred is 1.5 ⁇ m or less.
  • lower limit of the average particle diameter D 50 of talc is not especially limited, but if the particle diameter becomes small, its aggregation is promoted to cause a poor dispersion in the polymer and accordingly, it is preferable to be 0.2 ⁇ m or more. And, it is preferable that the talc of particle diameter 10 ⁇ m or more is 4.5 vol% or less with respect to the total amount of talc. When a coarse talc is contained, not only spinnability decreases, but also mechanical characteristics of fiber may deteriorate.
  • a content of talc of which particle diameter exceeds 10 ⁇ m is more preferably 0 to 3 vol% with respect to the total amount of the talc, still more preferably, it is 0 to 2 vol% and most preferably, 0 vol%.
  • the particle diameter of talc described in the above-mentioned items (1) and (2) is a value obtained from a particle diameter distribution measured by a laser diffraction method using SALD-2000J produced by Shimadzu Corp.
  • sorbitol derivatives preferably used as the crystal nucleating agent bisbenzylidene sorbitol, bis (p-methyl benzylidene) sorbitol, bis (p-ethyl benzylidene) sorbitol, bis (p-chlorobenzylidene) sorbitol, bis (p-bromobenzylidene) sorbitol, and furthermore, sorbitol derivatives obtained by chemically modifying the above-mentioned sorbitol derivatives are mentioned.
  • metal salt of phosphoric acid esters or as the basic inorganic aluminum compounds compounds described in JP2003-192883A are preferably used.
  • melamine compound melamine, substituted melamine compounds of which hydrogen of amino group is substituted with an alkyl group, an alkenyl group or phenyl group
  • substituted melamine compounds of which hydrogen of amino group is substituted with a hydroxyalkyl group, a hydroxyalkyl n (oxaalkyl) group or an aminoalkyl group JP-H5-202157A
  • deammonia condensates of melamine such as melam, melem, mellon or methone
  • guanamines such as benzoguanamine or acetoguanamine
  • organic acid salts or inorganic acid salts are mentioned.
  • organic acid salts isocyanuric acid salt, carboxylic acid salts such as of formic acid, acetic acid, oxalic acid, malonic acid, lactic acid or citric acid, aromatic carboxylic acid salts such as of benzoic acid, isophthalic acid or terephthalic acid, are mentioned. It is possible to use these organic acid salts singly or also as a mixture of 2 kinds or more of them.
  • melamine cyanurate is most preferable.
  • melamine cyanurate those surface treated with a metal oxide sol such as silica, alumina or antimony oxide ( JP-H7-224049A ), those surface treated with polyvinyl alcohol or cellulose ethers ( JP-H5- 310716A ) or those surface treated with a nonionic surface active agent of HLB 1 to 8 ( JP-H6-157820A ) can also be used.
  • Mol ratio of the melamine compound and the organic acid is not especially limited, but it is preferable that a free melamine compound or an organic acid which has not formed a salt is not contained in the salt compound.
  • a production method of the organic acid salt of melamine compound is not especially limited, but in general, it can be obtained as a crystalline powder, when a melamine compound and an organic acid are mixed and reacted in water, and then filtered off or distilled off the water and dried.
  • melamine polyphosphate melamine polyphosphate ⁇ melam ⁇ melem complex salt or p-toluene sulfonate are preferable.
  • Mol ratio of the melamine compound and the inorganic acid is not especially limited, but it is preferable that a free melamine compound or an inorganic acid which has not formed a salt is not contained in the inorganic acid salt compound.
  • Production method of the inorganic acid salt of melamine compound is not especially limited, but in general, it can be obtained as a crystalline powder when a melamine compound and an inorganic acid are mixed and reacted in water, and then filtered off or distilled off the water and by dried. And, production method of pyrophosphate or polyphosphate is described, for example, in the specification of US Patent No. 3,920,796 , JP-H10-81691A , JP-H10-306081A , etc.
  • the adding amount the crystal nucleating agent and the mechanical characteristics of fiber are in an inverse correlation, it is preferable that the adding amount is 0.01 to 2 wt% with respect to the aliphatic polyester (A). If the adding amount is 0.01 wt% or more, since the aliphatic polyester crystallize promptly at the cooling step after leaving the air jet stuffer machine, it is possible to obtain a crimped yarn excellent in crimp fastness. And, by making the adding amount into 2 wt% or less, a crimped yarn excellent in crimp fastness can be obtained while preventing a decrease of mechanical characteristics. It is more preferable that the adding amount of the crystal nucleating agent is 0.05 to 1.5 wt% and still more preferably, it is 0.2 to 1 wt%.
  • Cu salt, K salt, Mn salt, Cr salt, tannin or the like in order to improve fastness to light.
  • CuI or KI is effective to enhance fastness to light of the polyamide resin.
  • Compound to be added may be one kind, or two or more may be used together.
  • An adding amount may be 0.001 to 0.5 wt% with respect to the thermoplastic polyamide resin (B), more preferably, it is 0.005 to 0.2 wt%, still more preferably, 0.01 to 0.1 wt%.
  • grooves extending along fiber axis direction are formed on fiber surface of the crimped yarn of the present invention.
  • Said grooves means concave lines present on fiber surface as shown in Fig. 2 , and extend approximately in parallel along fiber axis direction (direction of 10° or less to fiber axis).
  • the width of grooves is, in order to effectively raise the diffusion, 0.01 to 1 ⁇ m, more preferably, it is 0.05 to 0.9 ⁇ m, and 0.08 to 0.8 ⁇ m is still more preferable.
  • an aspect ratio of the groove (longitudinal axis length of groove/width of groove) is approximately in the range of 3 to 50, a good glossy texture is exhibited without impairing abrasion resistance.
  • the grooves can be grasped by an observation by an electron microscope (SEM).
  • SEM electron microscope
  • width of groove in SEM images, by a photograph usually magnified 5,000 times, or magnified 1,000 to 10,000 times as required, and by defining maximum width of each groove as its width of groove, 10 widths of groove are measured and its average value is taken as the width of groove of the present invention.
  • respective both ends of the grooves are connected by straight lines and the respective length of the straight lines are taken as longitudinal axis length of the groove, and aspect ratios of the respective grooves were determined (refer to Fig. 3 ).
  • strength of the crimped yarn of the present invention is, in order to maintain processability or mechanical strength of product, 1 cN/dtex or more, and 1.5 cN/dtex or more is more preferable. Still more preferably, it is 2 cN/dtex or more and especially preferably, 3 cN/dtex or more.
  • An air stuffer crimped yarn (hereafter, referred to as "BCF yarn") having such strength can be produced by the melt spinning ⁇ stretching ⁇ bulking method mentioned later.
  • elongation at break is 15 to 70% since processability for making fiber product is good. More preferably, it is 20 to 65%, still more preferably, 30 to 55%.
  • a boiling water shrinkage of the crimped yarn is 0 to 15%, since dimensional stability of fiber and fiber product are good. More preferably, it is 0 to 12%, still more preferably, 0 to 8%, most preferably, 0 to 3.5%.
  • the fiber of the present invention is stably formed by, as mentioned later, minimizing Barus effect by kind of polymer, best design of melt viscosity, control of linear discharge velocity from spinneret, optimization of cooling condition just beneath spinneret and control of spinning speed, and even when a swelling occurred by the Barus, as well as by controlling an elongational flow region as close as possible to the spinneret surface, and quick (shortening distance from discharging to completion of thinnig and deformation). Accordingly, yarn unevenness along the fiber longitudinal direction is also small.
  • yarn unevenness (Uster unevenness, U%, Normal value) of the crimped yarn of the present invention is, for its processability or for preventing dyeing unevenness after dyeing, 2% or less and 1.5% or less is more preferable. Still more preferably, it is 1 % or less.
  • the crimped yarn of the present invention is a "BCF yarn "(BCF : bulked continuous filament) obtained by an air jet stuffer machine mentioned later.
  • BCF yarn means a filament having an irregular entangled loop-like crimp configuration obtained by turbulent flow effect of hot fluid (dry air, etc.), and its configuration is explained in detail in the first chapter (pages 25 to 39) of "Filament Processing Technical Manual (2nd Bde)" edited by The Textile Machinery society of Japan . Examples of embodiment of BCF yarn are explained by photographs of fiber shape of Fig. 4 and Fig. 5.
  • Fig. 4 is a photograph observed by placing one embodiment of BCF yarn of the present invention on a black paper in multifilament state and Fig.
  • FIG. 5 is a photograph of the multifilament of Fig. 4 separated into single fibers and placed on a black paper.
  • loops of single fiber are formed in random direction, and has a crimp configuration in which 2 or more of single fibers are entangled.
  • amplitude and periodicity of loop of single fiber is irregular.
  • single fibers are respectively folded in loop state and amplitudes of the loop are irregular with no periodicity and have a configuration in which said single fibers are entangled with each other.
  • a crimp elongation percentage after boiling water treatment is 3 to 30%, more preferably it is 5 to 30%, still more preferably, 8 to 30% and especially preferably, 12 to 30%.
  • measurement of the crimp elongation percentage after boiling water treatment is carried out as follows.
  • sample length (L2) is measured.
  • crimp elongation percentage after boiling water treatment (%) is determined.
  • C ⁇ r ⁇ i ⁇ m ⁇ p e ⁇ l ⁇ o ⁇ n ⁇ g ⁇ a ⁇ t ⁇ i ⁇ o ⁇ n p ⁇ e ⁇ r ⁇ c ⁇ e ⁇ n ⁇ t ⁇ a ⁇ g ⁇ e % L ⁇ 2 - L ⁇ 1 / L ⁇ 1 ⁇ 100.
  • a crimp elongation percentage after boiling water treatment of such crimped yarn When a crimp elongation percentage after boiling water treatment of such crimped yarn is lower than 3%, it may be insufficient in crimp development , poor in bulkiness, and for example, when it is made into a carpet or the like, it may become a carped with no voluminous feeling. On the other hand, it is impossible to produce a crimped yarn of which crimp elongation percentage after boiling water treatment is 30% or more, and when said crimp elongation percentage is tried to increase over 30%, strength of crimped yarn may decrease significantly or it may cause a crimp unevenness or a yarn thickness unevenness.
  • a crimp elongation percentage under a load of 2 mg/dtex after boiling water treatment (hereafter, referred to as "elongation percentage under load") which is an index of crimp fastness is 2% or more.
  • the elongation percentage under load is more preferably, 3% or more, and still more preferably, 5% or more. There is especially no upper limit, but by the technique of the present invention, increasing to around 15% is the limit. Where, the elongation percentage under load can be measured by the method described in Examples.
  • cross-sectional shape of the polymer alloy type synthetic fiber constituting the crimped yarn of the present invention can be freely selected from circular cross-section, hollow cross-section, multi-hollow cross-section, multi-lobal cross-sections such as trilobal cross-section, flat cross-section, W type cross-section, X type cross-section and other non-circular cross-sections, but in order to enhance bulkiness of the crimped yarn to achieve a voluminous fiber structure, non-circular cross-section of its non-circularity (D1/D2) is 1.2 to 7 is preferable.
  • D1/D2 non-circularity
  • the non-circularity of the non-circular cross-section fiber is in the range of 1.3 to 5.5, and more preferably, it is in the range of 1.5 to 3.5.
  • Production method of a crimped yarn constituted by the polymer alloy type synthetic fiber which is one preferable embodiment of the present invention is not especially limited, but, for example, the following method can be employed by using a direct spinning ⁇ stretching ⁇ crimp processing machine shown in Fig. 6 .
  • the ratio of melt viscosity ( ⁇ b/ ⁇ a) is controlled into the range of 0.1 to 2.
  • melt viscosity ratio should be increased as 0.8 to 2
  • the ratio of melt viscosity should be 0.1 to 0.3, that is, it is necessary to lower the melt viscosity of the thermoplastic polyamide resin (component B) to 1/10 to 3/10 of the aliphatic polyester resin (component A).
  • the polymer alloy is made into a fiber by once palletized by using such as a twin screw kneading machine, or by kneading followed by a melt spinning.
  • adding timing of the compatibilizer (component C) it may be added at the timing of kneading of the component A and the component B, and as to its adding method, it may be mixed and kneaded at the same time with the component A and the component B by supplying the compatibilizer as it is to a kneading machine, or a master pellet containing the component C in a high concentration is prepared beforehand, and it may be supplied to a twin screw kneading machine by blending with pellet of the component A and the component B.
  • the master pellet is prepared with the component A of which molding temperature can be lowered.
  • jacket temperature at the time of kneading in melt extrusion it is preferable to be carried out , based on melting point of the thermoplastic polyamide (component B) (hereafter, referred to as Tmb), at Tmb+3°C to Tmb+30°C, and it is preferable that shear rate is 300 to 9800 sec -1 .
  • Tmb thermoplastic polyamide
  • shear rate is 300 to 9800 sec -1 .
  • the spinning temperature is also as low as possible, i.e., it is preferable to carry out spinning at Tmb+3°C to Tmb+40°C. More preferable spinning temperature is Tmb+3°C to Tmb+30°C, and still more preferably, it is Tmb+3°C to Tmb+20°C.
  • a high mesh filtering layer (#100 to #200), a porous metal, a nonwoven fabric filter of small filtering size (filtering size 5 to 30 ⁇ m) or a blend mixer in pack (static mixer or high mixer) may be built in.
  • a nonwoven fabric filter of filtering size 20 ⁇ m or less just before being discharged from spinneret to control the domain diameter.
  • polymer blend substance of aliphatic polyester and polyamide is an incompatible combination, and the molten polymer shows a strong behavior in elastic term, and swelling by Barus effect may become large. Accordingly, it is preferable that a linear discharge velocity at spinning hole of spinneret is, in order to prevent yarn swelling by Barus effect and also to stably extend and make fine to improve spinnability, 0.02 to 0.4 m/sec, 0.03 to 0.3 m/sec is more preferable and 0.04 to 0.2 m/sec is still more preferable. It is also effective to enlarge depth of spinning hole to prevent the Barus.
  • depth of spinning hole means the length from the lower end of inlet hole to discharge surface as shown in Fig. 7 (a) .
  • depth of spinning hole means the length from lower end of tapered portion to discharge surfaces shown in Fig. 7 (b) .
  • the depth of spinning hole is preferably 0.3 to 5 mm, more preferably, it is 0.4 to 5 mm, and still more preferably, 0.5 to 5 mm.
  • a discharged yarn has an elongational flow region as close as possible to the spinneret surface and quick (shortening distance from discharge to completion of thinnig and deformation). Accordingly, it is preferable that a starting point of cooling of the discharged yarn is close to the spinneret surface, i.e., it is preferable to start cooling from a position substantially vertically beneath 0.01 to 0.15 m from the spinneret surface. Where, the starting point of cooling substantially vertically beneath means, as shown in Fig.
  • the cooling method may be a uniflow type chimney which cools from one direction, or may also be a circular chimney which blows off cooling air from inside to outside of yarn or from outside to inside of yarn, but a circular chimney which cools from inside to outside of yarn is preferable, since a uniform and quick cooling is possible.
  • substantially right angle means that, as shown in Fig. 8 , flow line of the cooling air is substantially perpendicular on line "b" (inclination is 70 to 110°).
  • gas used as the cooling air is not especially limited, but a noble gas which is stable at normal temperature (reactivity is extremely low) such as argon, helium, nitrogen, or air are preferably used and among them, nitrogen or air which are cheaply available are especially preferably used.
  • a noble gas which is stable at normal temperature (reactivity is extremely low) such as argon, helium, nitrogen, or air are preferably used and among them, nitrogen or air which are cheaply available are especially preferably used.
  • the sea/island structure of the present invention is formed by a specific combination of polymers, and further, the sea/island structure can be discharged without a break by controlling spinning temperature, and further, the polymer alloy fiber of the present invention can be stably spun and taken up for the first time by controlling the linear discharge velocity at spinning hole of spinneret or, by controlling cooling method and other conditions.
  • Fig. 6 is a schematic view of an apparatus for carrying out 2 stage stretching ⁇ crimp processing after spinning, but in this case, taking up at 500 to 5000 m/min in 1 FR, and simultaneously heating the 1 FR to approximately 50 to 100°C, carrying out first stage stretching between the 1 FR (single hot roll) and 1 DR (tandem roll), and successively carrying out 2 nd stage stretching between the 1 DR and 2 DR (tandem roll). At this time, it is important that a stretching temperature (1 DR temperature of Fig.
  • 1 FR temperature is adjusted to 50 to 100°C
  • 1 DR temperature is adjusted to the range of 70 to 130°C and in 1 FR temperature +20°C or more.
  • a stretching ratio of the 1 FR to the final stretch roll may be controlled such that the elongation at break of the stretched yarn sampled at the exit of the final stretching roll becomes 15 to 65%, and preferably, it is 20 to 60%.
  • an air jet stuffer machine is used and the crimp processing is carried out at a nozzle temperature of said machine higher than the final stretch roll temperature by 5 to 100°C.
  • the air jet stuffer machine it is described in detail in the first chapter (pages 25 to 39) of "Filament Processing Technical Manual (2nd Bde)" edited by The Textile Machinery society of Japan . That is, it is a crimp processing machine widely used for production of crimped yarns for BCF carpet, and it is a machine which imparts an irregularly entangled loop-like bulkiness to a filament by using turbulent flow effect of air jet.
  • the machine several embodiments of the machine are described in Figs. 1 ⁇ 16 to 1 ⁇ 30 of the above-mentioned Filament Processing Technical Manual, and they can be appropriately selected in consideration of fiber thickness of multifilament, fiber thickness of constituting single filament, non-circularity, rigidity, etc.
  • said nozzle temperature should be low, and in order to make the crimp elongation percentage high, said nozzle temperature should be high.
  • upper limit of the nozzle temperature is Tmb+10°C.
  • a hot fluid introduced to the nozzle is not especially limited, e.g., dry air, dry nitrogen, air containing steam, etc., but hot air containing steam is preferable in view of thermal efficiency and running cost.
  • the yarn imparted with 3 dimensional crimp by an air jet stuffer machine is successively cooled rapidly by being contacted with a cooling drum, to thereby fix crimp structure.
  • crimp uniformity is improved by loading an appropriate tension to the crimped yarn, and wound into a package at a speed lower than the peripheral speed of the final stretch roll by 10 to 30%.
  • relax ratio between the final stretch roll in Fig.
  • winding tension would be in the range of 0.05 to 0.12 cN/dtex so that an excessive tension would not be loaded to the crimped yarn, i.e., a yarn with a high crimp elongation percentage is wound at a relax ratio of 20 to 30%, and a yarn of a low crimp elongation percentage is wound at a relax ratio of 10 to 20%.
  • sheath/core type composite fiber of which core component comprises the polymer alloy comprising the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B), and the sheath component comprises the thermoplastic polyamide resin (B)" which is the another preferable embodiment is explained.
  • sheath/core type composite fiber in order to prevent peeling off of the composite interface so that it can be applied to carpet uses to which a strong external force is added repeatedly, it is necessary to have a specified fiber structure.
  • the molecular orientation of the core component and the sheath component neighboring the sheath/core interface is apt to increase compared to other region than the interface. It was found that, by being the molecular orientation of the respective components neighboring the sheath/core interface high, the sheath/core interface is apt to have a residual stress, and when an external force is added, it triggers a growth of interface peeling while releasing the stress.
  • crimped yarns such as a false twisted yarn or a mechanically crimped yarn
  • molecular orientation of the above-mentioned core component and sheath component neighboring the sheath/core interface is apt to increase and a residual stress is generated in the sheath/core interface and an interface peeling may occur.
  • a multifilament comprising the sheath/core type composite fiber is used as a BCF yarn, different from the above-mentioned other processings, the generation of the residual stress of the sheath/core interface is greatly prevented to become an internal structure which hardly arise the interface peeling.
  • the core component and the sheath component of the respective single fibers can be heated uniformly in a short time close to the melting point of the thermoplastic polyamide resin (B) (Tmb), and simultaneously heat shrank under no tension condition, and in addition, by being cooled immediately and rapidly by a cooling roll, even in the region neighboring the sheath/core interface, it is possible to sufficiently release molecular orientation of the amorphous phase, and the history based on the difference of heat shrinking characteristics of the respective components is hardly remained.
  • the residual stress of the sheath/core interface is also stored when the molecular chain of the core component and the sheath component neighboring the sheath/core interface of which orientation condition is unstable is orientation relaxed in later stage processing steps such as dyeing or in a change with lapse of time when used as a product, in particular, in case where the aliphatic polyester (A) is used as the core component, not only in case where it is exposed to heat, but also by a change with lapse of time, the molecular orientation of the amorphous phase is easy to be released. Accordingly, a residual stress in the sheath/core interface is easy to generate and the interface is easy to be peeled off.
  • the lower the molecular orientation of the respective amorphous phases of the core component and sheath component of the crimped yarn the more excellent the peeling resistance, and it is preferable.
  • the more the crystal phases are present in the core component and sheath component the more the relaxation movement of the molecular chain of the amorphous phase is bound to render the peeling resistance excellent, and it is preferable.
  • the fiber structure of the crimped yarn is closely related to physical properties of the crimped yarn, and the crimped yarn comprising the sheath/core type composite fiber of the present invention is achieved by adjusting to a specified strength, boiling water shrinkage and single fiber thickness.
  • Strength of the crimped yarn may become high as the degree of orientation of amorphous phase inside the fiber becomes high. And in ordinary crimped yarn comprising single component, as the strength becomes high, it is more preferable in view of processability and durability when used as a product but in the crimped yarn in which the sheath/core type composite fiber of the present invention is used, since the lower the degree of orientation of amorphous phase, the more excellent in peeling resistance, it is preferable that the strength is 3 cN/dtex or less.
  • the strength of crimped yarn of the present invention By controlling the strength of crimped yarn of the present invention to 3 cN/dtex or less, the degree of orientation of amorphous phase inside the fiber becomes sufficiently low and a residual stress in the sheath/core interface hardly generates, it becomes a crimped yarn excellent in peeling resistance, and it is preferable. It is preferable that the strength is 2.8 cN/dtex or less since a crimped yarn more excellent in peeling resistance is obtained, to be 2.6 cN/dtex or less is more preferable, and to be 2.4 cN/dtex or less is still more preferable. On the other hand, when the strength is too low, spinnability, processability of later stage processing step and durability as a product may be poor.
  • the strength is 1.5 cN/dtex or more, to be 1.7 cN/dtex or more is preferable, to be 1.9 cN/dtex or more is more preferable and to be 2.1 cN/dtex or more is still more preferable.
  • the strength can be measured by the way indicated in Examples.
  • boiling water shrinkage becomes low as the degree of orientation of amorphous phase inside the fiber becomes low and the crystallinity becomes high. That is, in the crimped yarn of the present invention, as the boiling water shrinkage becomes low, the degree of orientation of amorphous phase inside the fiber becomes low and the crystallinity becomes high, and a residual stress in the sheath/core interface hardly generates and the peeling resistance becomes excellent and it is preferable.
  • the boiling water shrinkage of the crimped yarn of the present invention is 6% or less. It is more preferable that the boiling water shrinkage is 5% or less since the crimped yarn becomes more excellent in peeling resistance, to be 4% or less is still more preferable and to be 3% or less is especially preferable. The lower the boiling water shrinkage, the more preferable, and to be 0 to 2% is most preferable.
  • the boiling water shrinkage may be, ideally, 0%.
  • the sheath/core type composite fiber of the present invention has a single fiber thickness of 5 to 40 dtex.
  • the fiber is heated quickly and inside the cross-section of the single fiber is heated uniformly, an undue stress is unlikely to arise in the molecular chain of the core component and sheath component neighboring the sheath/core interface and in the sheath/core interface, a residual stress is hardly left. That is, it is excellent in peeling resistance.
  • peeling resistance can be maintained for a long term even after dyeing step or after a change with lapse of time.
  • the single fiber thickness is as fine as possible, to be 38 dtex or less is preferable, to be 35 dtex or less is more preferable, to be 33 dtex or less is still more preferable and to be 30 dtex or less is especially preferable.
  • the single fiber thickness is excessively fine, although it is easy to form 2 phase structure of a crystal phase and a random amorphous phase in crimping treatment, the crimped yarn is re-extended by a stretch tension added in later crimp extending step, winding tension added in winding step of the crimped yarn, or a tension added in later stage processing step, an undue stress is easily generated in the sheath/core interface. Accordingly, it is preferable that the single fiber thickness is 5 dtex or more. More preferably, it is 6 dtex or more and still more preferably, 8 dtex or more.
  • the problem of peeling off which was unavoidable in the crimped yarn constituted from the sheath/core type composite fiber of which core component comprises the aliphatic polyester resin (A) and the sheath component comprises the thermoplastic polyamide resin (B), has been overcome for the first time by controlling into strength : 1.5 to 3 cN/dtex, single fiber thickness : 5 to 40 dtex and boiling water shrinkage : 6% or less.
  • core Component comprises a polymer alloy comprising the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) (hereafter, referred to also as "component B").
  • component B thermoplastic polyamide resin
  • the above-mentioned 2 component constitutes 90 wt% or more of the core component, and to be 93 wt% or more is more preferable and to be 95 wt% or more is still more preferable.
  • the sheath/core type composite fiber of the present invention it is preferable that, by using the polymer alloy of the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) as the core component, and by forming so-called sea/island or sea/sea structure in which the component A and the component B penetrate with each other, peeling of the sheath/core interface between the sheath component and the core component is prevented, and a fiber of which abrasion resistance is sufficiently high is obtained.
  • the component B to be used as the core component and the component B to be used as sheath component may be the same or different. And, even the content of the component A of the sheath/core type composite fiber is raised to 20 wt% or more, a fiber of which abrasion resistance and heat resistance are high can be obtained.
  • thermoplastic polyamide resin (B) constituting the core component constitutes the sea. Further, in order to raise the ratio of the aliphatic polyester resin (A) in the polymer alloy of the core component, it is important that a melt viscosity of the aliphatic polyester (A) at the time of melt spinning is made higher than the thermoplastic polyamide (B).
  • the sheath/core type composite fiber of the present invention in order to enhance abrasion resistance of fiber, it is important to prevent the peeling of the sheath/core interface.
  • the more the component B is contained in the core component the easier to form the polymer alloy structures (a) or (c) mentioned later which is considered to be preferable in the present invention, and it is preferable since abrasion resistance of fiber becomes excellent. Accordingly, it is preferable that the blend ratio of the component B in the core component is high.
  • the sheath/core type composite fiber of the present invention in order the sheath/core type composite fiber of the present invention to be a material having also an ability of reducing environmental load, it is preferable that plant derived component A is contained as much as possible, that is, it is preferable to lower the ratio of the component B.
  • component A/component B is 80/20 to 25/75, to be 70/30 to 30/70 is still more preferable and to be 60/40 to 35/65 is especially preferable.
  • the blend ratio (weight ratio) of component A/component B of the core component of the present invention can be calculated based on the weight ratio of the component A and the component B to be supplied to melt spinning.
  • the blend ratio (weight ratio) of the component A and the component B at the production is unclear, it can also be calculated by the following equation, for convenience. That is, the core component of sheath/core type composite fiber of the present invention may contain the component A and the component B and other small amount components, but in such cases, it can be considered that the core component substantially comprises the 2 components only of the component A and the component B, and the blend ratio (weight ratio) of component A/component B can be calculated.
  • sheath/core type composite fiber cross-section slice is observed by a transmission electron microscope (TEM) at a magnification of 40,000 times, and total area (Aa) of the component A and total area (Ab) of the component B constituting the core component are determined. And it was calculated by the following equation by putting as the specific gravity of component A 1.26, and as the specific gravity of component B 1.14.
  • Component A / component B Aa ⁇ 1.26 / Ab ⁇ 1.14 .
  • sheath component and core component in case where boundary line of sheath component and core component in the cross-section was difficult to decide, taking a similar figure in the cross-section to the fiber cross-section circumscribing the component A which is present at outermost layer and containing the component A in its inside only as boundary line, sheath component and core component was differentiated.
  • the polymer alloy structure of the core component in the single fiber cross-section the following (a) to (c) are mentioned, and any of these polymer alloy structures, by an effect of interaction between the component B in the core component and the component B in the sheath component, a good abrasion resistance is exhibited.
  • the polymer alloy structure of the core component is selected to be (a).
  • the "sea/island structure in which the component A is the island component and the component B is the sea component" which is the polymer alloy structure (a) constituting the core component of the present invention is explained with reference to the TEM photograph of Fig. 1 .
  • the dyed component is the thermoplastic polyamide resin (B) and the undyed component is the aliphatic polyester resin (A).
  • a structure in which the component A is divided by the component B, which is a continuous region, into a plural circular domains is defined as the sea/island structure of (a) the component A is the island component and the component B is the sea.
  • sea/island/lake structure in which the component B is present inside the component A which is the island component (approximately circular) is also included in the sea/island structure of the present invention.
  • "Island-in-sea structure in which the component A is the sea component and the component B is the island component" which is the polymer alloy structure (b) is a structure in which the component B is divided into a plurality of approximately circular region by the component A which is a continuous region.
  • sea component which is the polymer alloy structure (c) is defined as a structure in which both of the component A and the component B are not approximately circular, and the island component and the sea component cannot be differentiated.
  • the polymer alloy structure of the core component closely relates to the above-mentioned blend ratio (weight ratio) of the component A and the component B or the viscosity ratio of melt viscosity of the component A ( ⁇ a) and melt viscosity of the component B ( ⁇ b) mentioned later, and by respectively controlling to appropriate ranges, the alloy structure core component can be controlled.
  • melt viscosity of the component A ⁇ a high and melt viscosity of the component B ⁇ b low.
  • the polymer alloy structure is formed by being subjected to a shear deformation in a molten state, but a structure of which shear stress generated by the shear deformation is smallest is likely to be formed. This is because the energy level of the whole system becomes low and stable.
  • the ratio of melt viscosity ( ⁇ b/ ⁇ a) is small, and to be 2 or less is preferable, to be 1.5 or less is more preferable and to be 1 or less is still more preferable.
  • the ratio of melt viscosity is 0.10 or more, to be 0.15 or more is more preferable and to be 0.20 or more is still more preferable.
  • details of measurement of melt viscosity ⁇ is mentioned later, but it means a melt viscosity measured at a temperature of 240°C and at a shear rate of 1216 sec -1 .
  • the diameter of island component is 0.001 to 2 ⁇ m. It is preferable since by making the upper limit of the Island component diameter 2 ⁇ m, interface area formed by the component A and the component B greatly increases and fiber abrasion resistance greatly increases. On the other hand, if the diameter of island component is too small, the component A and the component B are compatibilized in a molecular level to impair crystallinity, and abrasion resistance, heat resistance and dyeing fastness of fiber may deteriorate. In view of this point, the lower limit of the island component diameter is 0.001 or more. From this point, it is preferable that diameter of the island component is 0.005 to 1 ⁇ m and 0.01 to 0.8 ⁇ m is more preferable. Still more preferably it is 0.02 to 0.5 ⁇ m.
  • the diameter of island component of the present invention is, as explained in detail in Examples, a cross-section slice of said sheath/core type composite fiber is observed by a transmission electron microscope (TEM) (40,000 times ), and for 100 islands per 1 sample of sheath/core type composite fiber, diameters of island component were measured (island was taken as a circle and diameter equivalent to area of the hypothetical circle is defined as the island component diameter).
  • TEM transmission electron microscope
  • a material constituting the core component of sheath/core type composite fiber is a polymer alloy, different from a block copolymer in which aliphatic polyester block and polyamide block are present alternatively in 1 molecular chain, it is important that the aliphatic polyester molecular chain (component A) and the polyamide molecular chain (component B) are present substantially independently.
  • This difference of conditions can be estimated by observing a melting point depressions of the thermoplastic polyamide resin of before and after the compounding, that is, how the melting point based on the thermoplastic polyamide resin in the polymer alloy decreased from the melting point of the thermoplastic polyamide resin before the compounding. If the melting point depression of the thermoplastic polyamide resin is 3°C or less, the aliphatic polyester and the polyamide have hardly copolymerized (ester-amide interchange has hardly occurred), and it is a polymer alloy condition in which the aliphatic polyester molecular chain and the polyamide molecular chain are present substantially independently.
  • thermoplastic polyamide resin (B) which forms the sheath component and the thermoplastic polyamide resin (B) which forms the core component easily arise an interaction to enhance adhesion force of the interface of the sheath component and the core component, and it is preferable.
  • characteristics which is inherent to the thermoplastic polyamide resin (B), the sheath component reflects to fiber characteristics to greatly improve abrasion resistance.
  • the melting point depression of the thermoplastic polyamide (B) is 2°C or less.
  • thermoplastic polyamide resin (B) used as the core component and the thermoplastic polyamide resin (B) used as the sheath component are polyamides of which main repeating unit is a same kind of monomer.
  • it may be a combination of nylon 6 and a co polyamide of which main component is nylon 6 or a combination of nylon 6 and nylon 610.
  • the melting points of said 2 components are as close as possible since, at the time of melt spinning, it becomes possible to select a spinning temperature at which respective polymers hardly decompose and the obtained fiber is excellent in abrasion resistance.
  • the melting point difference of the thermoplastic polyamide resins used for the core component and the sheath component, respectively is 30°C or less, to be 20°C or less is more preferable and to be 10°C or less is still more preferable.
  • the island component in the polymer alloy of the core component is in a fine and long streak-like configuration along the fiber axis. It is preferable since, by being the Island component streak-like, a composite interface area where one island component adheres to the sea component becomes large and fibrillation can be prevented. And, there is a merit that strength increases by forming the island component fine and long streaks. It is most preferable that, in case where the Island component is streak-like, it is perfectly parallel to fiber axis direction, but in the present invention, those inclined 5° or less from fiber axis are defined as fine and long streak-like configuration along fiber axis.
  • the content of the component A is high. It is preferable that the content of the component A is 20 wt% or more, to be 30 wt% or more is more preferable and to be 40 wt% or more is still more preferable. On the other hand, in view of excellence in peeling resistance, abrasion resistance or crimp fastness, it is preferable that the content of component A is 80 wt% or less, to be 75 wt% or less is more preferable and to be 70 wt% or less is still more preferable.
  • the content of component A (wt% of component A with respect to total fiber weight) can be calculated by the method described in Examples. That is, from difference between the fiber weight after dissolving off the component A only from the crimped yarn constituted from a sheath/core type composite fiber and the weight of the original crimped yarn is taken as the weight of component A, it is calculated by dividing said weight difference by the weight of the original crimped yarn.
  • the sheath component comprises the thermoplastic polyamide resin (B) only.
  • thermoplastic polyamide (B) As the sheath component, exposed area ratio of aliphatic polyester resin (A) with respect to fiber surface area becomes substantially zero, and abrasion resistance greatly increases, and it is preferable.
  • the component B constitutes 90 wt% or more of the sheath component, to be 93 wt% or more is more preferable, to be 95 wt% or more is still more preferable.
  • the thermoplastic polyamide resin (B) may be, as above-mentioned, a copolymer, but as more crystal phase is contained in the sheath/core type composite fiber of the present invention, an orientation relaxation of amorphous phase can be prevented more in later stage processing step or with lapse of time in product use, and it is preferable since a residual stress is hardly generated in the sheath/core interface and excellent in peeling resistance. Accordingly, in the thermoplastic polyamide resin (B), since it is preferable that the crystallinity is as high as possible, it is preferable that a crystal melting peak calorie ⁇ H is 10 J/g or more, to be 20 J/g or more is more preferable and to be 30 J/g or more is still more preferable.
  • the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) of the present invention hardly react, in order to enhance the adhesion force of the sheath/core interface formed by the above-mentioned 2 polymers, it is also preferable to add the above-mentioned compatibilizer (component C).
  • component C the above-mentioned compatibilizer
  • the difference of melting point between the component B and the component C is 30°C or less, to be 20°C or less is more preferable and to be 10°C or less is still more preferable.
  • the adding amount of the component C can be appropriately determined according to an equivalency per unit weight of reactive group of a compound to be used, dispersibility and reactivity at the time of melting or content of the component A, but in order to prevent peeling of the sheath/core interface, it is preferable to be 0.005 wt% or more with respect to the total amount of component A, component B and component C. More preferably, it is 0.02 wt% or more and still more preferably, 0.1 wt% or more. When the adding amount of the component C is too small, an amount of reaction at the sheath/core interface is small, and the effect of enhancing the adhesion force at the sheath/core interface may be limited.
  • the adding amount of component C is 5 wt% or less and to be 3 wt% or less is more preferable. Still more preferably, it is 1 wt% or less.
  • a metal salt of carboxylic acid especially, a catalyst of which metal is alkali metal or alkali earth metal, since it can enhance reaction efficiency.
  • a metal salt of carboxylic acid especially, a catalyst of which metal is alkali metal or alkali earth metal, since it can enhance reaction efficiency.
  • a lactic acid-based catalyst such as sodium lactate, calcium lactate or magnesium lactate.
  • a catalyst of a relatively high molecular weight such as stearic acid metal salt can be used singly or in combination.
  • an adding amount of said catalyst is, for controlling dispersibility and reactivity, 5 to 2000 ppm with respect to the synthetic fiber. More preferably, it is 10 to 1000 ppm, and still more preferably, 20 to 500 ppm.
  • the sheath/core ratio (weight ratio) is 10/90 to 65/35.
  • the ratio of core component becomes high, the area of sheath/core interface increases and when the ratio of core component is high, the component A, which is low in crystallinity and easy to change with lapse of time, is contained in much amount, a residual stress at the sheath/core interface is likely to arise, and peeling resistance may deteriorate. Accordingly, in order to enhance peeling resistance, it is preferable that an area of the sheath/core interface per unit volume of the core component is large, from this view point, it is preferable that the ratio of core component is low.
  • the sheath/core ratio is in the above-mentioned range, to be 10/90 to 50/50 is more preferable and to be 10/90 to 45/55 is still more preferable.
  • the sheath/core ratio of the present invention can be calculated by, taking sum of weight of the core component and the sheath component to be supplied to melt spinning as 100, calculating respective ratios of the core component and the sheath component with respect to the sum.
  • the weight ratio of the component A and the component B at the time of production is unclear, it can also be calculated by the following equation, for convenience.
  • the core component of sheath/core type composite fiber of the present invention may contain the component A and other small amount components, and the sheath component may contain the component B and other small amount components, but even in such cases, it can be considered that the core component substantially comprises the component A only, and the sheath component comprises the component B only, and the sheath/core ratio as weight ratio of the core component and the sheath component can be calculated.
  • sheath/core type composite fiber cross-section slice is observed by a transmission electron microscope (TEM) at a magnification of 4,000 times, and total area (Aa) of the component A and total area (Ab) of the component B constituting the core component are determined.
  • TEM transmission electron microscope
  • Sheath / core ratio weight ratio core component / weight ratio of sheath component
  • Weight ratio of core component Aa ⁇ 1.26 / Aa ⁇ 1.26 + Ab ⁇ 1.14 ⁇ 100
  • Weight ratio of sheath component Ab ⁇ 1.14 / Aa ⁇ 1.26 + Ab ⁇ 1.14 ⁇ 100.
  • cross-sectional shape of the sheath/core type composite fiber of the present invention various cross-sectional shapes can be employed such as circular type, Y type, multi-lobal type, polygonal type, flat type or hollow type. And, in case of multifilament, respective single fiber cross-sectional shapes may be the same or different.
  • One embodiment of single fiber cross-sectional shape of the sheath/core type composite fiber of the present invention is shown in Fig. 10 .
  • respective 42s denote component A and 43s denote component B.
  • Fig. 10 respective embodiments of circular type, Y type and multi-global type are illustrated.
  • the cross-sectional shape is, in concrete, Y type, multi-lobal type or flat type, and Y type or flat type is further preferable.
  • the non-circularity (D3/D4) of single fiber is 1.3 to 4.
  • the non-circularity of single fiber increases, fiber surface area becomes large, and fiber is rapidly heated in crimp processing step and inside the cross-section of fiber is heated uniformly and, an undue stress is hardly added to molecular chain of the core component and the sheath component neighboring the sheath/core interface, and a fiber excellent in peeling resistance can be obtained, so it is preferable.
  • the non-circularity of single fiber is 1.3 or more, to be 1.5 or more is more preferable, to be 1.8 or more is still more preferable and to be 2.0 or more is especially preferable.
  • the non-circularity when the non-circularity is excessively high, cross-sectional shape may have an acute angle portion, and abrasion resistance may deteriorate by an external force being concentrated to said acute angle portion. And, there also is a problem in production process that the core component becomes hard to be coated with the sheath component uniformly in longitudinal direction.
  • the non-circularity is 4 or less, to be 3.8 or less is more preferable, to be 3.5 or less is still more preferable and to be 3.3 or less is especially preferable.
  • a single fiber cross-section is observed by using TEM in the same method as Examples, and it is defined as the ratio of diameter D3 of the circumscribed circle and diameter D4 of the inscribed circle (D3/D4) of the cross-section.
  • D3/D4 diameter of the inscribed circle
  • the inscribed circle is a circle inscribing to outlined curve of the single fiber cross-section
  • the circumscribed circle is a circle circumscribing to outlined curve of the single fiber cross-section.
  • a circle inscribing at least two points with outlined curve of the single fiber and being present inside of the fiber only and having maximum radius which does not intersect with the outlined curve of the single fiber is defined as the inscribed circle.
  • a circle circumscribing at least 2 points with outlined curve of the single fiber, being present outside of the single fiber cross-section only, and having minimum radius in the range that circumference of the circumscribed circle and outline of the single fiber does not intersect is defined as the circumscribed circle.
  • the non-circularity of core component is 1.3 to 4.
  • the sheath/core interface area per unit volume of the core component becomes large, and it is preferable since a fiber excellent in peeling resistance is obtained.
  • the non-circularity of core component is 1.3 or more, to be 1.5 or more is more preferable, to be 1.8 or more is still more preferable and to be 2 or more is especially preferable.
  • the non-circularity of core component is 4 or less, to be 3.8 or less is more preferable, to be 3.5 or less is still more preferable and to be 3.3 or less is especially preferable.
  • the non-circularity of core component of the present invention is determined in the same way as above-mentioned non-circularity of single fiber in which the sheath/core composite interface is taken as the cross-sectional shape.
  • Cross-sectional shapes of preferable crimped yarns in the present invention are exemplified in Fig. 10 .
  • Cross-sectional shape of core component of the single fiber constituting the crimped yarn is optional, but it is preferable that the cross-sectional shape of core component is similar to the cross-sectional shape of single fiber in view of enhancement of adhesion force of the sheath/core interface, and in view of excellence of peeling resistance even when the core component ratio of the crimped yarn, and further, even the content of the component A is high.
  • the similar shape does not mean a mathematically precise similarity, for example, even a case where a cross-sectional shape of single fiber is Y type and a cross-sectional shape of core component is Y type and both non-circularities are different, they should be understood as similar shapes.
  • the sheath/core type composite fiber of the present invention is not limited to the cross-sectional shapes of Fig. 10 .
  • number of core component of sheath/core type composite fiber of the present invention is optional and a single fiber may have one core component inside or may have a plural number of core components.
  • the center of gravity of outlined shape of single fiber cross-section and the center of gravity of outlined shape of core component may be same or different, but since as the fiber surface is covered more uniformly with the sheath component, abrasion resistance becomes more excellent, it is preferable that the center of gravity of the outlined shape of single fiber and the center of gravity of the outlined shape of core component is same. And, outlined shapes of core component of respective single fiber cross-sections in a multifilament, may be same or different.
  • sheath/core type composite fiber of the present invention is a sheath/core type composite fiber of so-called sea/island type composite fiber in which a plural core components is present in a single fiber cross-section
  • sheath/core interface area per unit volume of core component increases and peeling resistance is improved.
  • the core component is 3 islands or more, to be 9 islands or more is more preferable and 24 islands or more is still more preferable.
  • the fiber surface is substantially constituted by the sheath component entirely in its longitudinal direction of the fiber, in particular, it is preferable that the component A is not exposed on fiber surface.
  • the sheath/core type composite fiber of the present invention is excellent in peeling resistance, and in addition, by being the fiber surface substantially covered with the sheath component, abrasion resistance is greatly improved.
  • the sheath component is thick in entire fiber cross-section, and it is preferable that the minimum value of thickness of sheath component is 0.4 ⁇ m or more.
  • thickness of sheath is 10 ⁇ m or less, to be 7 ⁇ m or less is more preferable and to be 5 ⁇ m or less is still more preferable.
  • sheath/core ratio in order to thicken the minimum value of thickness of the sheath component, it is preferable to control sheath/core ratio, single fiber thickness and non-circularity of single fiber into the above-mentioned range, and it is preferable to control melt viscosity ratio of component A and component B and spinning temperature into the range mentioned later.
  • the orientation relaxation movement of amorphous phase of the core component and the sheath component can be prevented more easily, and it is preferable since a crimped yarn excellent in peeling resistance can be obtained. Furthermore, as the crystallinity increases, abrasion resistance, heat resistance, dyeing or crimp fastness, etc., become more excellent, and it is preferable.
  • the crystallinity in the present invention can be evaluated by a total heat capacity of melting peak of a differential calorimetric curve measured at heating rate 16 °C/min, and it is preferable that said total heat capacity of melting peak is 50 J/g or more, more preferably, it is 60 J/g or more and still more preferably, 70 J/g or more.
  • it is preferable to control production conditions such as stretch ratio, heat treatment temperature after stretching, and crimp nozzle temperature at crimp processing step.
  • the crimp elongation percentage after boiling water treatment which is an index of bulkiness of crimped yarn is high. Accordingly, it is preferable that the crimp elongation percentage after boiling water treatment is 5% or more, to be 10% or more is more preferable and to be 15% or more is especially preferable. It is especially not limited as to the upper limit of the crimp elongation percentage after boiling water treatment, but when it is too high, single fiber apt to be folded and peeling resistance may deteriorate. At this point, it is preferable that the elongation percentage after boiling water treatment is 35% or less, to be 33% or less is more preferable and to be 30% or less is especially preferable.
  • the sheath/core type composite fiber of the present invention in dyeing step or later stage processing step, or in a long term use after being made into a fiber structure, it is preferable that crimp is hardly lost (crimp fastness is high) and voluminous feeling of product can be maintained for a long term. Accordingly, it is preferable that the crimp elongation percentage after boiling water treatment under a load of 2 mg/dtex which is an index of crimp fastness (hereafter, crimp elongation percentage after boiling water treatment under a load of 2 mg/dtex may be simply referred to as "elongation percentage under load”) is 2% or more.
  • elongation percentage under load can be measured by the method indicated in Examples.
  • the elongation of the sheath/core type composite fiber of the present invention is 15 to 70%, since processability for making into fiber product is good.
  • a crimped yarn having such elongation can be produced by adjusting stretch ratio into a preferable range in the production method mentioned later. More preferably, it is 20 to 60%, still more preferably, 30 to 50%.
  • a yarn unevenness of the sheath/core type composite fiber of the present invention is small. By reducing yarn unevenness, it becomes possible to prevent a local concentration of an external force when exposed to an abrasion, and it is preferable since peeling resistance can be enhanced. Accordingly, it is preferable that yarn unevenness (uster U%) (Normal) which is an index of yarn unevenness is 2.5% or less, 2.0% or less is more preferable, 1.5 or less is still more preferable and 1.0 or less is especially preferable.
  • the sheath/core type composite fiber of the present invention Compared to conventional simple polymer alloy fiber of an aliphatic polyester and a polyamide, in the sheath/core type composite fiber of the present invention, since it has a sheath component on fiber surface, the Barus is prevented and thinnig behavior is stabilized, yarn unevenness is small and also has a merit to be excellent in abrasion resistance.
  • a production method of the crimped yarn constituted by the sheath/core type composite fiber which is one of a preferable embodiment of the present invention is not especially limited, but for example the following method can be employed by using the direct spinning stretching crimp processing machine shown in Fig. 9 .
  • melt viscosity ( ⁇ b) of the thermoplastic polyamide resin (B) By raising melt viscosity ( ⁇ b) of the thermoplastic polyamide resin (B) to be used, it becomes possible to raise fiber temperature close to the melting point of the thermoplastic polyamide resin (B) (Tmb) at heat treatment and crimp processing step after stretching, without causing a fusion bond between single fibers.
  • Tmb melting point of the thermoplastic polyamide resin
  • a polarization is progressed to a molecular chain which is crystallized and to a molecular chain which is orientation relaxed to random arrangement, and it is preferable since peeling resistance becomes excellent.
  • the melt viscosity of the thermoplastic polyamide resin (B) ( ⁇ b) is 10 to 300 Pa ⁇ sec -1 , to be 20 to 250 Pa ⁇ sec -1 is more preferable and to be 30 to 200 Pa ⁇ sec -1 is still more preferable.
  • melt viscosity of the aliphatic polyester resin (A) ( ⁇ a) and the melt viscosity of the thermoplastic polyamide resin (B) ( ⁇ b) are close, and it is preferable that the melt viscosity ratio ( ⁇ b/ ⁇ a) which is the ratio of melt viscosity of the component A and the component B is 0.2 to 2. More preferably, it is 0.4 to 1.7, still more preferably, 0.6 to 1.4.
  • melt viscosities ⁇ a and ⁇ b in the present invention are, melt viscosity (Pa ⁇ sec) of the polymer used for the crimped yarn at temperature 240°C and shear rate 1216 sec -1 , and they can be measured by the method described in Examples. And, in case where the component A and the component B used for the crimped yarn cannot be obtained, they can be measured, for convenience, by measuring relative viscosity ( ⁇ ra) of the component A in the crimped yarn, and measuring relative viscosity ( ⁇ rb) of the component B in the crimped yarn, ⁇ a and ⁇ b can be determined for convenience. As indicated by plots of Fig.
  • the relative viscosity can be measured by the method shown in Examples. That is, by using an Ostwald viscometer, and for the component A o-chlorophenol solution, and for the component B sulfuric acid solution are used, and they are expressed by ratios of drop time of solutions prepared by dissolving at specified concentration, temperature and time respectively and solvents in which respective components are not dissolved, and it is an index indicating solution viscosity.
  • a polymer alloy prepared by blending the aliphatic polyester (A) and the thermoplastic polyamide resin (B) is used as the core component, while the respective polymers being separately metered, they are mixed and kneaded at melting point of the component B (Tmb) to melting point of the component B (Tmb)+40°C by using a twin screw extruding/kneading machine or single screw extruding/kneading machine and once a polymer alloy resin is prepared. At this time, it is preferable to use a twin screw extruding/kneading machine in view of easiness of controlling diameter of island component.
  • a method for controlling polymer alloy structure and diameter of island component it is possible to control by adjusting blend ratio of the above-mentioned 2 components (component A and component B) and melt viscosity ratio in the above-mentioned range, and by kneading in the range of shear rate 200 to 20,000 sec -1 and residence time 0.5 to 30 min. in particular, as a method for making the diameter of island component smaller, it is better that the kneading temperature is low, the shear rate is high and the residence time is short in the above-mentioned range.
  • polymer alloy resin which constitutes the core component of fiber containing the component A and the component B those prepared beforehand by an extruding/kneading machine different from a spinning machine may also be used after drying, or may be prepared continuously at the time of spinning by an extruding/kneading machine equipped to a spinning machine.
  • all polymer alloy to be used as the core component may be a chip prepared beforehand, or a master chip in which the component A or the component B is mixed/kneaded in a high concentration is prepared and said master chip and the component A and/or component B may be chip blended and used.
  • the component A and the component B Since it is easier to uniformly disperse the component A and the component B, and it is easier to prevent a thermal degradation of the component A, it is also preferably employed to continuously prepare a polymer alloy of the component A and the component B by a single screw kneading machine and/or twin screw extruding/kneading machine equipped to a spinning machine and supply it to a spinning pack.
  • a spun yarn is formed at linear discharge velocity 1 to 20 m/min in the spinning hole of spinneret. Said spun yarn is cooled from vertically beneath 0.01 to 0.15 m from spinneret surface as starting point of cooling, by a gas of wind speed 0.3 to 1 m/sec and wind temperature 15 to 25°C from the right angle to
  • Said multifilament is stretched in 2 stages in total stretching ratio 2 to 5 and then, at being subjected to a crimp processing, heat set by setting first stage stretching roll to 50 to 90°C, the second stage stretching roll to 90 to 150°C and final roll after the stretching to 160 to 220°C, and at being supplied to a air jet stuffer crimp processing machine, subjected to a crimp processing by setting nozzle temperature of said machine to a temperature higher than the final roll temperature by 5 to 100°C to form a crimped yarn, taken up by contacting with a cooling drum, and wound at a speed lower than the final roll after stretching by 10 to 30%.
  • aliphatic polyester resin, polymer alloy (blend of component A and component B) and the thermoplastic polyamide resin such as nylon 6 (component B) are respectively dried to prepare beforehand a component A of which water content is 10 to 100 ppm and a component B of which water content is 100 to 500 ppm.
  • component A and the component B are molten by separate twin screw extruding/kneading machines or single screw extruding/kneading machines, metered by separate gear pumps into a sheath/core ratio (weight ratio) 65/35 to 10/90 and then, by assembling spinnerets as shown in Fig.
  • a spinneret constructed inside the spinning pack, joined the component A and the component B and discharged to obtain a spun yarn.
  • a device such as assembling a high mesh filtering layer (#100 to #200) or porous metal, nonwoven fabric filter of small filtering size (filtering size 5 to 30 ⁇ m), blend mixer in pack (static mixer or high mixer) is necessary.
  • the aliphatic polyester and the polyamide in the polymer alloy is an incompatible combination, and since the molten polymer exhibits a strong elastic behavior, a swelling called the Barus occurs and thinnig/deformation may become unstable.
  • the polyamide (component B) which is the sheath component of the present invention has an effect of preventing the Barus, and it is effective to control a melt viscosity of the component B and a thickness of the sheath component into the above-mentioned range.
  • Fig. 12 is a longitudinal-section schematic view showing one embodiment of spinneret used in a method of the present invention, and the spinneret is constituted by an assembly of spinneret 2 (46) which is a spinneret just before discharge and spinneret 1 (45) which positioned just before spinneret 2 and has separate flow channels for core component and sheath component.
  • the component A and the component B are melted by a kneading machine, it is preferable that the component A is melted at a temperature of melting point of the component A (Tma) to melting point of the component A (Tma) + 40°C, for example, in case where the component A is polylactic acid of which melting point is 170°C, it is preferable to melt the component A in the range of 170 to 210°C.
  • the component B it is preferable to melt the component B at a temperature of melting point of the component B (Tmb) to melting point of the component B (Tmb) + 40°C, for example, in case where the component B is nylon 6 of which melting point is 225°C, it is preferable to melt it in the range of 225 to 265°C.
  • Spinning temperature can be determined by the melting point of the component B (polyamide), and best range is melting point of the component B Tmb to Tmb+30°C (for example, in case where melting point of the component B Tmb is 225°C, it is 225 to 255°C).
  • heat resistance of the component A is not so high, if it exceeds 250°C when stored in molten state, its physical properties may deteriorate rapidly. Accordingly, as above-mentioned, it is preferable that a thermoplastic polyamide resin (B) of which melting point is 250°C or less is selected as sheath component and setting a spinning temperature to 260°C or less.
  • the linear discharge velocity at spinning hole of spinneret is 1 to 20 m/min.
  • the linear discharge velocity 20 m/min or less it becomes possible to uniformly add shear stress in cross-section of single fiber to make a uniform orientation of molecular chain of the core component and the sheath component, and therefore, an undue stress is hardly added to the sheath/core interface by heat shrinkage at a later crimp processing, and a crimped yarn excellent in peeling resistance can be obtained, and therefore, it is preferable.
  • linear discharge velocity 1 m/min or more it is possible to prevent a rapid thinnig of spinline, and spinnability, or uniformity of crimped yarn becomes better, and therefore, it is preferable.
  • linear discharge velocity in the present invention is calculated by the following equation based on spinning hole area, total output and number of holes.
  • average of discharge area of all holes is calculated and by employing an discharge area of a hole closest to the average area, the linear discharge velocity is calculated by the following equation.
  • Fig. 7 is a spinneret longitudinal-sectional view explaining depth of spinning hole, hole diameter, slit length and slit width and a schematic view of spinning hole, and slit length and slit width of Y hole, multi-lobal hole and flat hole are shown in (a) right drawing of non-circular hole and schematic view of spinning hole.
  • spinneret hole shape is Y hole (refer to Fig. 7 (a) non-circular hole)
  • a (cm 2 ) 3 ⁇ slit width (cm) ⁇ slit length (cm)+ (center triangle surrounded by slits)
  • UD which is ratio of hole diameter (D) and depth of spinning hole (L) of spinning hole of spinneret, 0.6 to 10.
  • D hole diameter
  • L depth of spinning hole
  • UD 10 or less core component is easily disposed to the center of fiber, and a crimped yarn excellent in peeling resistance can be obtained, and therefore, it is preferable.
  • L/D 0.6 or more the core component and sheath component are uniformly distributed to respective holes and sheath/core ratios become uniform between single fibers, i.e., all fibers constituting multifilament are uniformly excellent in peeling resistance, and therefore, it is preferable.
  • UD is 0.7 to 8
  • to be 0.8 to 6 is still more preferable and to be 0.9 to 4 is especially preferable.
  • the depth of spinning hole in the present invention means the depth of spinning hole in the spinneret longitudinal-sectional view shown in Fig. 7 , and it is the length of which hole shape is maintained in the same shape as the spinning hole, and it is a portion which controls flow rate when polymer is extruded.
  • the hole diameter means the diameter of circular hole in the spinning hole schematic view shown in Fig. 7 .
  • discharge area A (cm 2 ) is calculated by the method described in the explanation of the linear discharge velocity, and the diameter of hypothetical circle equivalent to said discharge area is taken as the hole diameter.
  • the starting point of cooling it is preferable to make vertically beneath 0.01 to 0.15 m from spinneret surface as starting point of cooling.
  • the starting point of cooling 0.15 m or less, spinline is rapidly cooled, and the core component and the sheath component are easy to be molecularly oriented, and therefore, it is preferable.
  • the starting point of cooling 0.01 m or more, disadvantages such as discharge abnormality by containing an unmelted polymer in spun yarn by spinneret surface being cooled hardly occurs, and processability in production process is improved, and therefore, it is preferable. Accordingly, it is more preferable that the starting point of cooling is 0.02 to 0.13 m and to be 0.03 to 0.12 m is still more preferable.
  • a method of positively heating spinneret surface is also preferable, by arranging a ring heater around the spinneret surface so that the temperature spinneret surface does not lower.
  • the cooling air is blown off to spun yarn from a right angle to perpendicular direction on spinneret surface, at wind speed 0.3 to 1 m/sec and wind temperature 15 to 25°C so that temperature of spinneret surface does not lower.
  • the fiber of the present invention when the fiber of the present invention is left in a state of an unstretched yarn or a stretched yarn, orientation relaxation is likely to occur, and when there is a time difference between unstretched yarn packages before stretching, or there is a time difference between stretched yarn packages before crimp processing, in particular, the molecular orientation of amorphous phase of the core component, which is easy to be orientation relaxed, relaxes earlier, and difference of heat shrinking characteristics of the core component and the sheath component becomes large, and as a result, a residual stress is easy to be generated at the sheath/core interface of crimped yarn obtained by crimp processing.
  • a direct spinning ⁇ stretching ⁇ crimp processing in which spinning, stretching, crimping are carried out continuously in one step. That is, it is preferable, after spun yarn is taken up by a take-up roll, to carry out continuously, without winding, stretching and heat treatment and then direct crimp processing.
  • An unstretched yarn is obtained by taking up a spun yarn, and a stretched yarn obtained by stretching said unstretched yarn is subjected to a crimping, but in order to enhance peeling resistance of the sheath/core type composite fiber of the present invention, it is important, at the crimping, without generating an undue stress at the sheath/core interface, to form a fiber structure polarized to a crystal phase and a random amorphous phase.
  • Best spinning speed differs according to melt viscosity ratio of component A and component B and sheath/core ratio, but making spinning speed 3000 m/min or less, spinning tension can be kept low, and it is possible to make degree of molecular orientation of core component and sheath component in unstretched yarn uniform, and therefore, it is preferable.
  • spinning speed 300 m/min or more spinning tension becomes moderately high, fiber oscillation of spinline is prevented to stabilize thinnig behavior, and therefore, it is preferable.
  • the spinning speed is 350 to 2500 m/min, to be 400 to 2000 m/min is still more preferable and to be 450 to 1500 m/min is especially preferable.
  • Unstretched yarn of which molecular orientations of core component and sheath component are low is molecularly oriented in a later stretching step, but at this time, by carrying out stretching stepwise in 2 stages or more, in addition, by raising stretching temperature stepwise, it becomes possible to uniformly increase molecular orientation of the core component and the sheath component, and therefore, it is preferable.
  • it is 170°C or more and still more preferably, 180°C or more.
  • the final roll temperature 220°C or less a disadvantage that the sheath component melts, single fiber cross-section deforms and the core component is exposed to surface can be avoided, therefore, it is preferable. More preferably, it is 210°C or less and still more preferably, 200°C or less.
  • a method of shortening the distance from the final roll to the crimp nozzle a method of keeping fiber temperature by a heat insulation box or a method of heating by a noncontact heater are preferably employed.
  • the final roll temperature is important for controlling "crimp elongation percentage after boiling water treatment" which is an index of bulkiness of the crimped yarn comprising the sheath/core type composite fiber of the present invention, or "elongation percentage under load” which is an index of crimp fastness, and as the final roll temperature is raised high, the crimp elongation percentage after boiling water treatment and the elongation percentage under load can be raised high.
  • first stage stretching roll it is preferable to heat set by setting first stage stretching roll to 50 to 90°C, the second stage stretching roll to 90 to 150°C and final roll after stretching to 160 to 220°C. More preferably, first stage stretch roll is set to 60 to 80°C, second stage stretch roll to 100 to 140°C and final roll after stretching to 170 to 210°C.
  • first stage stretching roll it is preferable to set first stage stretching roll to 50 to 90°C, second stage stretch roll to 90 to 130°C, third stage stretch roll to 130 to 160°C and final roll after stretching to 160 to 220°C. More preferably, first stage stretch roll is set to 60 to 80°C, second stage stretch roll to 100 to 120°C, third stage stretch roll to 140 to 150°C and final roll after stretching to 170 to 210°C.
  • the stretched yarn heat set by the final roll after stretching is imparted with a crimp by a nozzle in an air jet stuffer crimp processing machine.
  • crimp processing machines for forming a BCF yarn which is a preferable crimp configuration of the present invention crimp imparting machines which carries out an ordinary hot fluid processing treatment may be used, for example, various crimp imparting methods such as a jet nozzle type, a jet stuffer type and further a gear system are employed.
  • a jet nozzle system is preferable, for example a crimp nozzle such as disclosed in the specification of US Patent No. 3,781,949 is preferably used.
  • the crimp nozzle In order to enhance peeling resistance of the crimped yarn, it is preferable to raise fiber temperature in the crimp nozzle, to immediately and uniformly heat the core component and the sheath component of respective single fibers to a high temperature state to be heat shrunken, and it is preferable to raise the crimp nozzle temperature higher than the final roll temperature after stretching by 5 to 100°C.
  • the temperature of re-heat treatment is 160 to 220°C, to be 170 to 210°C is more preferable, and to be 180 to 200°C is especially preferable.
  • the contact length is 20 cm or more, to be 30 cm or more is more preferable and to be 40 cm or more is still more preferable.
  • the crimped yarn is wound in a speed lower than that of the final roll after stretching without adding an excessive stress to the crimped yarn.
  • the temperature of the cooling drum is usually 20 to 35°C. At this time, in case where the winding speed is lower than the final roll speed by 10 to 30%, by this, the fiber structure fixed by the cooling drum is not changed again, boiling water shrinkage can be kept low, a residual stress at the sheath/core interface is hardly generated and a crimped yarn excellent in peeling resistance can be obtained, and therefore, it is preferable.
  • the tension for stretch is 0.02 to 0.2 cN/dtex and to be 0.04 to 0.15 cN/dtex is more preferable.
  • the crimped yarn in an arbitrary step of before or after winding the crimped yarn by the winder, it is preferable to subject the crimped yarn to an interlacing treatment.
  • the number and pressure of the interlacing treatment may be controlled such that the CF value of the crimped yarn would be 5 to 30, but since an interlace imparted before the stretching step is loosened sometimes by the stretching, it is preferable to interlace just before winding.
  • the yarn just before winding is under a low tension, it is easy to be interlaced by a compressed air of a low pressure. Accordingly, it is preferable since the crimped yarn is not imparted with an undue stress, and peeling resistance can be improved, and therefore, it is referable.
  • the compressed air for the treatment is 0.05 to 0.5 MPa.
  • the obtained crimped yarn can be used for fiber structure. Further, the obtained crimped yarn can be processed by ordinary way to a carpet to use as a carpet for a car interior.
  • Configuration of the crimped yarn of the present invention may be a filament as it is, or the obtained crimped yarn may be cut in an appropriate length to handle as a staple.
  • the crimped yarn is a filament
  • CF value can be measured in the way described in Examples, and it is an index indicating a degree of being interlaced.
  • the CF value is 5 or more and 7 or more is still more preferable.
  • CF value when CF value is too high, single fibers are too much bound with each other, crimp is bound (crimp elongation percentage after boiling water treatment becomes low), or in bulking up step by heat (for example, dyeing treatment, boiling water treatment or steam treatment), crimp unevenness appears, etc., and for avoiding such adverse effects, it is preferable that the CF value is 30 or less. More preferably, it is 25 or less and still more preferably, 20 or less.
  • total fiber thickness fiber thickness as multifilament
  • the total fiber thickness is 3000 dtex or less, to be 2500 dtex or less is more preferable and to be 2000 dtex or less is still more preferable.
  • the total fiber thickness is 500 dtex or more, to be 600 dtex or more is more preferable and to be 700 dtex or more is still more preferable.
  • number of single fibers (number of filaments) constituting the crimped yarn can be freely selected such that the single fiber thickness would be in the range of the present invention.
  • the crimped yarn of the present invention can be applied to a woven fabric, a knitted fabric, a nonwoven fabric, a pile, cotton, etc., and other fibers may be contained.
  • it may be a paralleled yarn, a twisted yarn, a mixed yarn with a natural fiber, a regenerated fiber, a semi-synthetic fiber or a synthetic fiber.
  • natural fibers such as cotton, linen, wool, silk or regenerated fibers such as rayon or cupra
  • semi-synthetic fiber such as acetate
  • synthetic fibers such as nylon, polyester (polyethylene terephthalate, polybutylene terephthalate, etc.), polyacrylonitrile and polyvinyl chloride can be applied.
  • abrasion resistance is required
  • outdoor wear or sports wears such as golf wear, athletic wear, ski wear, snow board wear and pants thereof
  • casual wears such as boulzon, outers for ladies/gentlemen such as coat, winter clothes and rain wear.
  • a uniform, futons or pillow such as kakefuton (a comforter) or shikifuton (futon mattress), hadakakefuton (thin futon), kotatsu (wooden table frame covered by a futon.
  • Underneath is a heat source) futon, zabuton (cushion for sitting), baby comforter and blanket, sheets or coverings of cushion or the like, mattress or bed pad, sheets for hospital, medical care, hotel and baby or the like, and further, bedding materials such as covering of sleeping-bag, cradle, baby car, etc, and can also be preferably used in these applications. Furthermore, it can also preferably be used for interior materials of automobile, and among them, car carpet which require a high abrasion resistance and moisture degradation resistance are the best applications. Where, it is not limited to these applications and it may be used for, for example, anti-grass sheet for agriculture or waterproof sheet for construction materials.
  • car carpet which is a use of preferable fiber structure in the present invention
  • its processed structure is not limited, for example, carpets having piles represented by woven carpets such as dantsu, wilton, double face, Axminster, tufting, embroidery carpet such as hook do rag, bonded carpets such as bonded, electro-deposition or code, knit carpet such as knit or raschel, compressed carpets such as needle punch, or combinations thereof can be used.
  • a tufting carpet constituted by at least a front yarn which is pile fiber, a base cloth to which the front yarn is tufted and a backing material laminated to the base cloth is preferable.
  • Example 6 is a Reference Example included for information only.
  • Tetrahydrofuran was mixed to a sample (aliphatic polyester polymer) solution in chloroform to prepare a solution to be measured. This was measured by gel permeation chromatography (GPC), and determined weight average molecular weight in polystyrene equivalent. Where, in case where a weight average molecular weight of aliphatic polyester in a fiber was measured, a sample was dissolved in chloroform, polyamide residue was removed by filtration, and aliphatic polyester was taken out by drying said chloroform solution to thereby provide it to a measurement.
  • GPC gel permeation chromatography
  • method of extracting aliphatic polyester from polymer alloy fiber (synthetic fiber) or sheath/core type composite fiber is not especially limited, but in the present invention, by using chloroform, aliphatic polyester was dissolved and filtered to remove polyamide, and then the filtrate was dried to extract.
  • thermoplastic polyamide D. Sulfuric acid relative viscosity and inherent viscosity of the thermoplastic polyamide
  • Relative viscosity of nylon 6 was measured at 25°C by preparing 0.01 g/mL solution in 98% sulfuric acid.
  • Inherent viscosity of nylon 11 was measured at 20°C by preparing 0.5 wt% solution in m-crezol.
  • Relative viscosity of aliphatic polyester was measured at 25°C by preparing 0.01 g/mL solution in o-chlorophenol.
  • a melting point of original polymer is decided.
  • a melting peak of differential calorimetric curve of fiber is decided by the following way.
  • a crimped yarn (fiber 1 : crimped yarn containing the component A and the component B) was subjected, as sample, to a DSC measurement in the same measurement condition as above described, to obtain a differential calorimetric curve 1.
  • the component A in sheath/core type composite fiber (fiber 1) is removed by solvent (chloroform), washed with water and vacuum dried for 24 hours at room temperature.
  • the component B in sheath component in sheath/core type composite fiber was removed by solvent (solution in sulfuric acid), washed with water and vacuum dried for 24 hours at room temperature.
  • a DSC measurement was carried out in the same condition as above-mentioned to obtain a differential calorimetric curve 3.
  • the melting point of the component B in sheath component was decided.
  • a solvent treatment condition solvent temperature and immersing time
  • sheath/core type composite fiber was immersed in solvent (solution in sulfuric acid) of a specified temperature for a specified time, and then taken out, and the obtained fiber was washed with water and vacuum dried for 24 hours at room temperature. For this fiber, fiber surface is observed by an optical microscope, and confirmed whether the sheath component is removed or not.
  • solvent treatment conditions solvent temperature and immersing time
  • differential calorimetric curve was obtained in the same condition as item F. Peaks which show extreme values in endothermic side which are present in the differential calorimetric curve are decided as melting peaks, and heat capacities obtained from the areas of the respective melting peaks were totalized and it was taken as the total heat capacity.
  • melt viscosities of the aliphatic polyester resin and the thermoplastic polyamide resin at shear rate 1216 sec -1 were measured. The measurements were carried out three times and their average value was taken as the melt viscosity. It was measured, in case of sheath/core type composite fiber and for a resin of which melting point is 240°C or less, at 240°C, and in case of a resin of which melting point is 240°C or more, at melting point +20°C.
  • One single fiber constituting a crimped yarn is taken out, and an ultrathin section was cut out in a direction perpendicular to fiber axis (fiber cross-section direction), polyamide component of said cross-section is metal-dyed with phosphotungstic acid, and by a transmission electron microscope (TEM) of a magnification of 40,000 times, blend state of all over the outer surface was observed and taken into a photograph. From this image taken, fiber peripheral length is measured, and further, all exposed lengths of white portions (aliphatic polyester resin) exposed on fiber surface are measured, and exposed area ratio of aliphatic polyester resin was obtained from the total exposed length of the white portions with respect to the fiber periphral length.
  • TEM transmission electron microscope
  • WinROOF image analyzing software
  • TEM image TEM image
  • a diameter (equivalent to diameter) (2r) calculated from the domain area was taken as its domain size.
  • number of domains to be measured is 100, and 80 domains, excluding 10 domains of largest domain size and 10 domains of smallest domain size, were provided to determine the distribution.
  • blend ratio of the component A and the component B in fiber was determined as weight ratio by correcting the cross-sectional areal ratio obtained from the above-mentioned TEM image (5.93 ⁇ 4.65 ⁇ m) by specific gravities of the respective components.
  • specific gravities of the respective components in this invention are, polylactic acid : 1.24, nylon 6 : 1.14, nylon 11 : 1.04, nylon 610 : 1.08 and nylon 6/66copolymer : 1.14.
  • TEM instrument H-7100FA model produced by Hitachi, Ltd. Condition : Acceleration voltage 100kV.
  • One single fiber constituting crimped yarn was taken out, and its fiber surface condition was observed and taken into a photograph by electron microscope ESEM-2700 produced by Nikon Instech Co., at a magnification of 5,000 times, and from this image taken, by using an image analyzing software "WinROOF" of Mitani Corp., arbitrarily selected 10 widths of groove (maximum width) were measured and its average value was taken as the width of grooves. In addition, respective lengths of the groove were measured and the aspect ratio (length of groove/width of groove) was determined. As number of grooves, grooves present in arbitrarily selected 10 ⁇ m ⁇ 10 ⁇ m were counted.
  • a weight of core component (comprises only the component A) and a weight of sheath component (comprises only the component B) were weighed respectively and, provided that total weight of the core component and the sheath component was 100, respective weights of the core component and the sheath component thereto were calculated.
  • core component of the crimped yarn of the present invention may contain the component A and a small amount of other component
  • sheath component may contain the component B and a small amount of other component, but even in such a case, it is possible to consider that the core component substantially comprises the component A only and the sheath component substantially comprises the component B only, and it is possible to calculate the sheath/core ratio as the weight ratio of the core component and the sheath component.
  • a cross-sectional slice of crimped fiber was prepared, polyamide component of said slice was metal dyed with phosphotungstic acid, and the cross-sectional area of the crimped fiber was observed by a transmission electron microscope (TEM) at a magnification of 4,000 times and a photograph was taken.
  • TEM transmission electron microscope
  • sheath/core interface was decided by considering the undyed region as the component A and the dyed region as the component B, and by image analyzing by the image analyzing software, "WinROOF" of Mitani Corp, total area of the region constituting the core component (Aa) and total area of the region constituting the sheath component (Ab) were determined.
  • the island component diameter was determined from hypothetical diameter calculated from area of the island component, provided that the island component is a circle. Where, number of islands to be measured was 100 islands per one sample, and its distribution was taken as the island component diameter distribution.
  • Blend ratio weight ratio of component A/component B in core component (polymer alloy) in sheath/core type composite fiber
  • Weights of the component A and the component B were respectively metered at providing them to a melt spinning, and a blend ratio of the component A and the component B was calculated.
  • the blend ratio (weight ratio) of component A/component B was calculated from sheath/core type composite fiber.
  • the core component of sheath/core type composite fiber of the present invention may contain the component A, the component B and other small amount component, but in such a case, it is possible to calculate the blend ratio (weight ratio) of component A/component B by considering that the core component substantially comprises only 2 components of the component A and the component B.
  • the blend ratio was calculated by the following equation, provided that the specific gravity of the component A was 1.26 and the specific gravity of the component B was 1.14.
  • Component A / the component B Aa ⁇ 1.26 / Ab ⁇ 1.14
  • a thickness was measured at portion where, in said cross-section, thickness of the sheath component is smallest.
  • 10 sheets of image were prepared, and the above-mentioned measurement was carried out for the respective images, and an average value was taken as the minimum value of thickness of sheath component.
  • a sample (crimped yarn) was measured by Tensilon UCT-100 of Orientech Inc. in accordance with the constant rate elongation method defined in JIS L1013 (chemical fiber filament yarn test method, 1998). Grip length (sample length) was 200 mm. Where, elongation at break was determined by the elongation at which maximum strength in S-S curve was shown.
  • Boiling water shrinkage % L 0 - L 1 / L 0 ⁇ 100
  • a sample (crimped yarn) was subjected to a U% (Normal) measurement by using UT4-CX/M produced by Zellweger uster Inc., at yarn speed : 200 m/min and measurement time : 1 minute.
  • Crimp elongation percentage was determined in the same way as in the item M except changing to a load of 2 mg/dtex to the crimped yarn when it was subjected to a boiling water treatment, and the value was taken as the elongation percentage under load.
  • a cross-section of a sample (crimped yarn) was cut out, and the non-circularity was determined by the following equation from diameter D1 of circumscribed circle of the single fiber cross-section and diameter D2 of inscribed circle of the single fiber cross-section.
  • Non - circularity D ⁇ 1 / D ⁇ 2.
  • a sandpaper (# P600) was wound and fixed to a roller rotating at a constant speed, and one end of a stretched yarn was fixed to a wall and the other end was loaded as shown in Fig. 3 , and the stretched yarn was abraded by rotating the roller while traversing the stretched yarn at a constant speed to thereby count a number of roller rotations at which the stretched yarn was broken. Measuring conditions are shown in the following.
  • Two crimped yarns subjected to S-twist and Z-twist were paralleled and twisted and wound.
  • a backing material was coated on reverse side of base fabric and dried to thereby obtain a tufting carpet (weight 1200g/m 2 ).
  • the above-mentioned tufting carpet was cut out in a circular shape of diameter 120 mm, and made a 6 mm hole at its center to make a test piece. After measuring weight W0 of said test piece, it was fixed to a taber abrasion tester (Rotary Abaster) prescribed in ASTM D 1175 (1994) with its surface upside, and carried out an abrasion test with H#18 abrasion wheel at compressive load 1 kgf (9.8N), sample holder rotation speed 70 rpm and number of abrasion 5500 times, and sample weight W1 after the abrasion test was measured. The abrasion loss ratio was calculated from these data and by the following equation.
  • a touch (softness) when said dyed carpet was pushed with palm and glossy texture or gloss unevenness was confirmed under sunlight by visual inspection to thereby evaluate touch and appearance in 4 classes, respectively.
  • An abrasion loss ratio was determined in the same way as above-mentioned item HH for a carpet after being treated under atmosphere of temperature 50°C and humidity 95% for 1200 hours. However, the number of rations was 1000 times.
  • Appearance change was evaluated by pressing at molding temperature 150°C by 300t press machine produced by Miura Press Seisakusho.
  • a carpet in which the dyed yarn was used was visually inspected and evaluated in the following criteria.
  • strip method According to the labeled strip method of JIS L 1096 : 1999 8.12.1 A method (strip method), at atmospheric temperature 20°C, 3 test pieces for longitudinally and transversely, respectively, were sampled, yarns were removed from both sides of width to adjust to a width of 30 mm, and a strength at break was measured by constant speed stretch type (Autograph (AG-G) produced by Shimadzu Corp.) tester when tested at grip distance 150 mm and tensile speed 200 mm/min, and calculated an average value of the 6 sheets.
  • a method strip method
  • 3 test pieces for longitudinally and transversely, respectively were sampled, yarns were removed from both sides of width to adjust to a width of 30 mm, and a strength at break was measured by constant speed stretch type (Autograph (AG-G) produced by Shimadzu Corp.) tester when tested at grip distance 150 mm and tensile speed 200 mm/min, and calculated an average value of the 6 sheets.
  • Weight average molecular weight of the obtained polylactic acid (P4) was 210,000.
  • amount of residual lactide was 0.13 wt%.
  • melting point was 170°C
  • heat capacity of melting peak was 45 J/g
  • melt viscosity was 200 Pa ⁇ sec -1
  • relative viscosity was 3.42.
  • Weight average molecular weight of the obtained polylactic acid (P5) was 260,000.
  • amount of residual lactide was 0.14 wt%.
  • melting point was 170°C and heat capacity of melting point peak was 45 J/g. Melt viscosity was 300 Pa ⁇ sec -1 . Relative viscosity was 3.76.
  • Weight average molecular weight the obtained polylactic acid (P6) was 150,000.
  • amount of residual lactide was 0.10 wt%.
  • melting point was 170°C
  • heat capacity of melting peak was 48 J/g
  • melt viscosity 120 Pa ⁇ sec -1
  • relative viscosity was 3.04.
  • Weight average molecular weight of the obtained polylactic acid (P7) was 210,000.
  • amount of residual lactide was 0.12 wt%.
  • melting point was 130°C
  • heat capacity of melting peak was 38 J/g and melt viscosity was 200 Pa ⁇ sec -1 .
  • MADGIC monoallyl diglycidyl isocyanuric acid
  • first stage stretching (stretch ratio : 2.7 times) was carried out at 1890 m/min
  • second stage stretching (stretch ratio : 1.37 times) was carried out at 2590 m/min, successively, subjected to a hot and compressed air treatment by the air stuffer 14 at nozzle temperature 220°C to carry out crimp processing to form a 3-dimensional crimp, and after taking up by contacting with the cooling drum 15, via the tension measuring detector 16, taken up by the take-up roll 17, and while interlacing by the interlacing nozzle 18, wound by the winder 19 under winding tension 120g
  • the obtained polylactic acid crimped yarn was 1500 dtex, 96 filaments.
  • the melt spinning condition was as follows. Where, linear discharge velocity in spinneret hole under the following conditions is 0.184 m/sec. And, elongation at break of the stretched yarn samples at the exit of 2 DR was 35%.
  • the crimped yarn was sampled approximately 100 kg but in all processes of spinning, stretching and bulking processing, a yarn break and a single fiber break did not occur and the processes were very stable.
  • the obtained fiber showed good fiber physical properties that tensile strength was 2.8 cN/dtex, residual elongation : 48%, boiling water shrinkage : 2.8%, yarn unevenness U% : 0.8%, crimp elongation percentage : 12% and non-circularity : 2.5.
  • melting points by DSC were around 175°C (polylactic acid) and around 225°C (nylon 6), i.e., melting peaks based on the respective components were observed.
  • carboxyl group terminal concentration of polylactic acid extracted from said fiber was 18 eq/ton. Further, number of rotations up to yarn break by the abrasion test was 101 rotations, i.e., a good abrasion resistance was shown.
  • a BCF yarn was obtained in the same way as Example 1 except changing the blend ratio of P1/the component B to 10/90.
  • the spinnability in Example 2 was very stable as Example 1.
  • an observation by TEM of cross-section of the obtained fiber was carried out, it was found that a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 0.1 %.
  • an island domain size was 0.01 to 0.15 ⁇ m in diameter equivalent, i.e., dispersion size of island component was smaller than that of Example 1.
  • a section of said fiber cross-section was subjected to an alkali etching to thereby dissolve out polylactic acid and observed, it was confirmed that the island component was dropout and polylactic acid constituted the island component.
  • non-circularity of the obtained fiber was 2.4 and fiber physical properties were also good.
  • melting points by DSC were around 175°C (polylactic acid) and around 225°C (nylon 6), i.e., melting peaks based on the respective components were observed.
  • Number of rotations up to yarn break by the abrasion test of the obtained multifilament was 185 rotations and it was superior to that of Example 1.
  • Example 1 when a carpet was prepared by using said crimped yarn and evaluated, it was more excellent than that of Example 1 in abrasion resistance, and a carpet having a soft touch was obtained. However, glossy texture was inferior to that of Example 1.
  • a BCF yarn was obtained in the same way as Example 1 except changing the blend ratio of P1/the component B to 40/60.
  • Spinnability in Example 3 was very stable as Example 1.
  • Example 1 When an observation by TEM of cross-section of the obtained fiber was carried out, a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 3.2%.
  • island domain size was 0.03 to 0.8 ⁇ m in diameter equivalent and dispersion size of the island component was smaller than that of Example 1.
  • a carpet was prepared by using said crimped yarn and evaluated, it was found that the carpet of Example 1 was superior in abrasion resistance, but the carpet of this example was more excellent than that of conventional one in both of touch and appearance.
  • Example 4 A BCF yarn was obtained in the same way as Example 1 except changing the blend ratio of P1/the component B to 5/95. Spinnability in Example 4 was very stable as Example 1.
  • Example 1 When an observation by TEM of a cross-section of the obtained fiber was carried out, it was found that a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 0%. And, island domain size was 0.01 to 0.1 ⁇ m in diameter equivalent, i.e., dispersion size of the island component was extremely small, and number of islands was also small. And, almost no groove was formed on fiber surface of said crimped yarn.
  • a carpet was prepared by using said crimped yarn and evaluated, similar to Example 1, although it has a high softness and an excellent touch, its glossy texture was in the same level as that of conventional one.
  • a BCF yarn was obtained in the same way as Example 1 except using nylon 6 of relative viscosity in sulfuric acid 2.05 (melting point 225°C) as the component B and changing the blend ratio of P1/the component B to 47/53.
  • Example 5 due to Barus effect just beneath spinneret, swelling of extruded flow was slightly large. And, when crimped yarn was sampled 100 kg, yarn break occurred 2 times and its spinnability was slightly inferior to that of Example 1.
  • an observation by TEM of a cross-section of the obtained fiber was carried out, it was found that a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 5.0%.
  • island domain size was 0.03 to 0.8 ⁇ m in diameter equivalent and dispersion size of island component was slightly larger than that of Example 1.
  • a BCF yarn was obtained in the same way as Example 1 except using only the component A (polylactic acid P1). Spinnability of comparative example 1 was stable as that of Example 1.
  • number of rotations up to yarn break by the abrasion test was 9 rotations, i.e., its abrasion resistance was extremely poor.
  • abrasion loss ratio was 89% and it was in a level of which application was considerably limited.
  • a BCF yarn was obtained in the same way as Example 1 except using the polylactic acid P3 (melting point 178°C) as the component A and except changing spinning condition as follows.
  • Example 6 thinnig point just beneath spinneret was not stable, and discharged flow was slightly unstable. And, when crimped yarn was sampled 100 kg, yarn break occurred 3 times and spinnability was slightly inferior to that of Example 1.
  • crimped yarn was sampled 100 kg, yarn break occurred 3 times and spinnability was slightly inferior to that of Example 1.
  • island domain size in diameter equivalent was 0.3 to 2.5 ⁇ m, i.e., dispersion size of island component was large and its distribution was wide.
  • Uster unevenness U% which indicates yarn unevenness was high as 2.1 %, and it was found that there was a thickness unevenness along the longitudinal direction of the yarn.
  • an abrasion loss ratio was approximately 2 times compared to that of Example 1. And, its touch was of partially hard and coarse feeling, and glossy texture was also in the same level as conventional one.
  • a BCF yarn was obtained in the same way as Example 1 except using the polylactic acid P3 (melting point 178°C) as the component A and nylon 6 (melting point 225°C) of relative viscosity in sulfuric acid 2.90 as the component B.
  • the polylactic acid P3 melting point 178°C
  • nylon 6 melting point 225°C
  • an extremely large swelling was occurred due to Barus effect just beneath spinneret and a wave phenomena in which thinnig point goes up and down occurred and it was an unstable condition.
  • crimped yarn was sampled 100 kg, yarn break frequently occurred as 17 times, and spinnability was considerably bad.
  • the island component was dyed.
  • Example 7 A BCF yarn was obtained in the same way as Example 1 except using nylon 11 of inherent viscosity 1.45 as the component B. Spinnability in Example 7 was extremely stable as that of Example 1.
  • Example 1 When an observation by TEM of a cross-section of the obtained fiber was carried out, it was found that a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 0.9%. Island domain size in diameter equivalent was 0.05 to 0.5 ⁇ m. And, when a section of said fiber cross-section was subjected to an alkali etching to thereby dissolve out polylactic acid and observed, it was confirmed that the island component was dropout and polylactic acid constituted the island component.
  • Example 1 when a carpet was prepared by using said crimped yarn and evaluated, it was bulkier and of a higher quality than that of Example 1, and its abrasion resistance was also excellent. And, both of touch and appearance were very excellent as those of Example 1.
  • Example 8 A BCF yarn was obtained in the same way as Example 1 except using nylon 610 (melting point 225°C) of relative viscosity in sulfuric acid 2.15 as the component B. Spinnability of Example 8 was extremely stable as that of Example 1.
  • Example 1 When an observation by TEM of a cross-section of the obtained fiber was carried out, a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 1.2%. Island domain size in diameter equivalent was 0.03 to 0.3 ⁇ m.
  • the island component was dropout and polylactic acid constituted the island component.
  • a carpet was prepared by using said crimped yarn and evaluated, it was found that both of touch and appearance were excellent as those of Example 1.
  • Spinnability in Example 9 was extremely stable as that of Example 1.
  • a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 1.4%.
  • Island domain size in diameter equivalent was 0.03 to 0.26 ⁇ m.
  • Example 1 when a section of said fiber cross-section was subjected to an alkali etching to thereby dissolve out polylactic acid and observed, it was confirmed that the island component was dropout and polylactic acid had constituted the island component. Further, when a carpet was prepared by using said crimped yarn and evaluated, it was bulkier than that of Example 1. And, both of touch and appearance were very excellent as those of Example 1.
  • Spinnability of Example 10 was extremely stable as that of Example 1.
  • an observation by TEM of a cross-section of the obtained fiber was carried out, a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 1.1%. Island domain size in diameter equivalent was 0.03 to 0.3 ⁇ m.
  • a carpet was prepared by using said crimped yarn and evaluated, its abrasion resistance was more excellent than that of Example 1 as well as both of touch and appearance were very excellent as those of Example 1.
  • a BCF yarn was obtained in the same way as Example 1 except carrying out melt spinning by changing the spinning temperature to 270°C (Tmb+45°C).
  • a swelling occurred due to Barus effect just beneath spinneret and discharged flow was slightly unstable.
  • a spinning was carried out in the same way as Example 3, except changing the spinneret to a spinneret with a Y type hole of which slit width 0.43 mm, slit length 2.15 mm and depth of hole 0.6 mm. Although swelling just beneath spinneret did not occur, but thinnig was not stable and it was impossible to spin. Where, linear discharge velocity in spinneret hole in Comparative example 4 was 0.0195 m/sec.
  • a spinning was carried out in the same way as Example 3 except changing the spinneret to a spinneret with a Y type hole of which slit width 0.09 mm, slit length 0.45 mm and depth of hole 0.6 mm.
  • a wave phenomena in which thinnig point goes up and down occurred and it was impossible to spin In Comparative example 5, an extremely large swelling occurred due to Barus effect just beneath the spinneret, and accordingly, a wave phenomena in which thinnig point goes up and down occurred and it was impossible to spin.
  • a BCF yarn was obtained in the same way as Example 1 except changing the cooling air speed of the circular chimney to 0.1 m/sec.
  • Example 11 swelling occurred due to Barus effect just beneath spinneret, and a slight wave phenomena occurred. Accordingly, in sampling of 100 kg, yarn break occurred 2 times.
  • strength was 1.3 cN/dtex which is approximately a half of that of Example 1 as well as Uster unevenness U% which indicates yarn unevenness was high as 3.3%.
  • an abrasion loss ratio was slightly low as 46.8% and it had a slightly hard and coarse touch, but had a silky glossy texture and appearance was good.
  • a BCF yarn was obtained in the same way as Example 1 except changing the out put to 277g/min, carrying out second stage stretching (stretch ratio : 1.15 times) with 2 DR speed of 2173 m/min and changing the winding speed to 1847 m/min (a speed lower than 2 DR speed by 15%). Elongation at break of stretched yarn samples at the exit of 2 DR was 76%.
  • strength was 1.8 cN/dtex which was approximately 64% of the strength of Example 1 and Uster unevenness U% which indicates yarn unevenness was slightly high as 1.6%.
  • an abrasion loss ratio was slightly high as 41.1%, but it was a level which could be used in limited applications.
  • Example 13 A BCF yarn was obtained in the same way as Example 1 except changing the set temperature at 2 DR to 130°C. Spinnability in Example 13 was extremely stable as that of Example 1.
  • Example 1 An observation by TEM of a cross-section of the obtained fiber was carried out, it was found that a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 1.5%.
  • Island domain size in diameter equivalent was 0.03 to 0.3 ⁇ m which was the same level as Example 1, but almost no groove was formed on fiber surface of said crimped yarn. And, crimp elongation percentage was also a half or less of Example 1.
  • a carpet was prepared by using said crimped yarn and evaluated, although it had more excellent touch than that of conventional one, glossy texture was the same as that of conventional one.
  • Example 14 A BCF yarn was obtained in the same way as Example 1 except changing the set temperature at 2 DR to 110°C. Spinnability of Example 14 was stable as that of Example 1. In the obtained fiber, crimp elongation percentage was 2.5%, i.e., crimp development was weak. And, boiling water shrinkage was high as 11.1 %, i.e., Example 1 was better in dimensional stability than this example. When a carpet was prepared by using said crimped yarn and evaluated, it was found that both of touch and glossy texture were same level as those of conventional one.
  • Example 15 A BCF yarn was obtained in the same way as Example 13 except changing the spinneret to a spinneret with circular holes of diameter 0.62 mm and depth of hole 1.0 mm. Spinnability of Example 15 was extremely stable as that of Example 1. Cross-section of the obtained fiber was approximately perfect circle (non-circularity 1.0), and when cross-section was observed by TEM, a uniformly dispersed sea/island structure was formed, and exposed area ratio of polylactic acid with respect to fiber surface area was 1.7%. Island domain size in diameter equivalent was 0.03 to 0.3 ⁇ m, i.e., the same level as Example 1. When a carpet was prepared by using said crimped yarn and evaluated, although it had an excellent touch similar to that of Example 1, but as to glossy texture, Example 1 was better than this example.
  • a BCF yarn was obtained in the same way as Example 1 except subjecting hot compressed air treatment by an air jet stuffer machine at nozzle temperature 150°C.
  • crimp elongation percentage was low as 2.7%, i.e., crimp development was weak.
  • a carpet was prepared by using said crimped yarn and evaluated, it was found that although glossy texture was excellent, it had somewhat hard and coarse touch.
  • a BCF yarn was obtained in the same way as Example 1 except dry blending 1 wt% (0.3 wt% to whole fiber) of talc "SG-2000" (average particle diameter D50 : 0.98 ⁇ m, particle of 10 ⁇ m or more : 0 vol%) produced by Nippon Talc Co. to the polylactic acid P1 (component A).
  • Spinnability in Example 17 was extremely stable as that of Example 1.
  • said crimped yarn showed an elongation percentage under load which was 1.4 times of that of Example 1, and crimp fastness was high.
  • a BCF yarn was obtained in the same way as Example 1 except dry blending 1 wt% (0.3 wt% to whole fiber) of melamine cyanurate "MC-600" (average particle diameter 1.6 ⁇ m, particle of 10 ⁇ m or more : 0 vol%) produced by Nissan Chemical Industries, Ltd. to the polylactic acid P1 (component A).
  • Spinnability in Example 18 was extremely stable as that of Example 1.
  • said crimped yarn showed an elongation percentage under load which was approximately 1.8 times of that of Example 1, and crimp fastness was extremely high.
  • a BCF yarn was obtained in the same way as Example 1 except dry blending respectively 0.03 wt% of copper iodide and potassium iodide to nylon 6 (component B) (0.021 wt% to whole fiber, respectively).
  • the crimped yarn obtained in Example 1and the crimped yarn obtained in Example 19 were taken as hanks, and subjected to a light resistance test by using UV Auto-fade-meter (type : U48AU) produced by Suga Test Instrument Co. Strength retentions were determined from strengths of before and after the light resistance test under the following condition. As a result, as compared to the strength retention of crimped yarn of Example 1 of 5%, strength retention of crimped yarn of Example 19 was 91 %, i.e., which was a crimped yarn extremely excellent in light resistance.
  • nylon 6 of relative viscosity in sulfuric acid 2.15 (N6-5, melting point 225°C, melt viscosity 60 Pa ⁇ sec -1 ) and as the component B to be used as sheath component, nylon 6 of relative viscosity in sulfuric acid 2.60 (N6-6, melting point 225°C, melt viscosity 150 Pa ⁇ sec -1 ), were respectively dried and adjusted to water contents from 50 to 100 ppm.
  • a continuous spinning and crimping machine equipped with a twin screw kneading machine shown in Fig. 14 was used, and an air stuffer crimped yarn was obtained by continuously subjecting to a melt spinning, stretching, heat treatment and crimping.
  • melt spinning, stretching, heat treatment and crimping conditions were as follows.
  • a carpet was prepared by using said crimped yarn and as a result of carrying out an abrasion resistance test, it showed an excellent abrasion resistance as an abrasion loss ratio 10%. Furthermore, a circular knit of said crimped yarn was prepared and as a result of evaluation of iron heat resistance, it showed an excellent heat resistance as exhibiting no appearance change at all. Melting points of said crimped yarn by DSC were around 170°C (peak based on the component A) and around 225°C (peak based on the component B), i.e., melting peaks based on respective components were observed, and total heat capacity of melting peak based on the respective components was 74 J/g which indicated a sufficient crystallinity.
  • Air stuffer crimped yarns of Examples 54 to 57 were obtained in the same way as Example 53 except changing, in Example 53, the blend ratio of the component A and the component B to be fed to the core component hopper.
  • Examples 56 and 57 are included for information only; they do not contain a polymer alloy in which aliphatic polyester resin (A) forms an island component and thermoplastic polyamide (B) forms a sea component. (weight ratio) of the component A and the component B are described below.
  • Air stuffer crimped yarns of Examples 58 to 60 were obtained in the same way as Example 53 except, in Example 53, by changing the composite ratio of the core component and the sheath component and changing the thickness of sheath component of the stretched yarn.
  • Example 58 to 59 spinnability was excellent as there was no yarn break and, on the other hand, in Example 60, yarn break occurred 2 times in 100 kg spinning.
  • Results of Examples 58 to 60 are shown in Table 6, and the respective compositing ratio of the core component and the sheath component (weight ratio) are shown below.
  • Example 53 As can be understood by comparing Example 53 (Table 5) and Examples 58 to 60 (Table 6), as the thickness of sheath component becomes large, a crimped yarn of which crimp elongation percentage is high, elongation percentage under load is high and excellent in abrasion resistance can be obtained. And, as the sheath component becomes thick, a high quality crimped yarn not only excellent in abrasion resistance, but also of which elongation percentage under load is high, that is, crimp is hardly lost, can be obtained.
  • Air stuffer crimped yarns were obtained by subjecting to the spinning, stretching, heat treatment and crimping in the same way as Example 53 except changing, in Example 53, the fourth roll temperature.
  • spinnings were extremely stable as Barus effects of the spun yarn were small and there was no yarn break, but regarding Example 65, a slight oscillation of yarn on the fourth roll occurred and yarn break arose 1 time. Results of Examples 61 to 65 are shown in Table 7. And, the fourth roll temperatures of Examples 61 to 65 are shown below.
  • Example 53 Table 5
  • Examples 62 to 63 Table 6
  • Examples 61 and 65 Table 7
  • abrasion resistance is greatly improved. Since the crimped yarns of Examples 53 and 62 to 63 are crimped yarns having moderate crimp elongation percentages, the crimped yarns are hardly fall down when abraded by an external force, and since they have moderate flections or entanglements, external force was dispersed to respective single fibers and the crimped yarns exhibited excellent abrasion resistances.
  • Air stuffer crimped yarns of Examples 66 to 68 were obtained by subjecting to spinning, stretching, heat treatment and crimping in the same way as Example 53 except changing, in Example 53, the specification of spinneret hole used and the non-circularity of air stuffer crimped yarn to be obtained. Results of Examples 66 to 68 are shown in Table 8. And, the specifications of spinneret used in Examples 66 to 68 are shown below.
  • spinneret 2 spinneret just before polymer discharge: slit length 0.18 mm, slit width 1.0 mm and number of holes 120
  • spinneret 2 spinneret just before polymer discharge: slit length 0.12 mm, slit width 1.8 mm and number of holes 120
  • Example 53 (Table 5) and Examples 66 to 68, in the present invention, by making an air stuffer crimped yarn of which non-circularity is high, abrasion resistance becomes excellent. That is, in the present invention, as the non-circularity of crimped yarn becomes high, diameter of island component becomes easy to be fine in spinning step and since it has a polymer alloy structure of which islands are uniformly dispersed, adhesion force in the interface of component A/component B of the core component and the component B of the of the sheath component increases, and an excellent crimped yarn excellent in abrasion resistance with no fibrillation is obtained.
  • Example 66 Example 67
  • Example 68 the component A - P4 P4 P4 Melting point of the component A (Tma) °C 170 170 170 Melt viscosity of the component A ( ⁇ a) Pa ⁇ sec -1 200 200 the component B to be blended in core component - N6-5 N6-5 N6-5 Melting point of the component B (Tmb) to be blended in core component °C 225 225 225 Melt viscosity of the component B ( ⁇ b) blended in core component Pa ⁇ sec -1 60 60 60
  • Polylactic acid P4 as the component A and nylon 6 (melt viscosity 580 poise, melting point 225°C) as the component B are kneaded in an extruding machine at kneading mass ratio (polylactic acid : nylon) 30 : 70 at kneading temperature 230°C, and supplied to a spinning machine.
  • Spinning temperature in the spinning machine was adjusted to 230°C, and after the molten polymer mixture was filtered in a spinning pack by a metallic nonwoven fabric filter of mesh size 20 ⁇ m, it was discharged as a yarn from a spinneret having Y type hole of number of holes 54.
  • the spun yarn discharged from the spinneret was, after cooled and solidified by a chimney wind, imparted with an oiling agent liquid of 25 % by weight diluted with low viscosity mineral oil and then contacted around a take-up roll (Nelson type roll, rotation speed 700 m/min, roll temperature 65°C).
  • the yarn was not wound and successively subjected to first stretching by contacting around first stretch roll (Nelson type roll, rotation speed 600 m/min, roll temperature 110°C). Furthermore, the yarn was, without winding, successively subjected to second stretching by contacting around second stretch roll (Nelson type roll, rotation speed 1800 m/min, roll temperature 150°C).
  • the stretched yarn was successively introduced to a crimp processing machine and subjected to a crimp processing by hot compressed air of 170°C and 0.8 MPa, and ejected on a rotating conveyor and cooled.
  • plug-like crimped yarn piece was stretched by a pair of separate roll to unravel the piece.
  • Said crimped yarn was interlaced, wound into a cheese to obtain a crimped yarn of 2000 dtex-94fil.
  • domain size of the island structure was 25 to 400nm (average 180nm).
  • non-circularity of the Y type fiber cross-section was 1.34.
  • the above-mentioned crimped yarn was twisted at 160 t/m S-twist as first twist, furthermore 2 yarns were paralleled and twisted at 160 t/m Z-twist as second twist, and heat set at 105°C.
  • nylon 6 forms the covering component
  • the dyeing treatment was carried out in the following way.
  • a dyeing bath of bath ratio 1 : 15 was prepared in a dyeing machine, IRGALAN (R) Black RBLN 2.0% owf as a metal-complex dye, acetic acid 0.5 g/l and ammonium sulfate 0.5 g/l as a dyeing auxiliary agent were added, and in said dyeing bath, the above-mentioned twisted yarn was put and subjected to a dyeing treatment at 90°C for 20 minutes.
  • a spunbond nonwoven fabric of single fiber thickness 5.5 dtex and weight 100g/m 2 was obtained from the polylactic acid P4 as the base cloth of carpet.
  • the above-mentioned twisted yarn was tufted to the above-mentioned base cloth at 1/8 gauge and 6.8 stitch/mm to thereby obtain a loop carpet for car option mat of pile weight 700g/m 2 .
  • Abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 3.5%, at 5500 rotation abrasion, 33.3%, and an abrasion loss ratio after wet heat degradation was 5.2%, i.e., it exhibited an excellent abrasion resistance. And, the obtained carpet for option mat exhibited a deep excellent color.
  • Example 69 The same one as Example 69 was used as the base cloth of carpet.
  • the above-mentioned twisted yarn was tufted to the above-mentioned base cloth, at 1/8 gauge and 7.5 stitch/mm and the pile ends were cut to obtain a saxony carpet for car option mat of which pile length was 10 mm and pile weight was 1100g/m 2 .
  • the abrasion loss ratio of the obtained carpet for option mat was, at 300 rotation abrasion, 2.2%, at 5500 rotation abrasion, 20.8% and abrasion loss ratio after wet heat degradation was 3.1%, i.e., it exhibited a good abrasion resistance. And, the obtained carpet for option mat exhibited a deep and excellent color.
  • Spinning ⁇ stretching ⁇ crimping processing was carried out in the same way as Example 69 except changing the total output of polymer and the number of holes of spinneret, and obtained a crimped yarn of 1450 dtex-54fil.
  • domain size of the island structure was 25 to 400nm (average 200nm).
  • Example 69 The same one as that of Example 69 was used as a base cloth of carpet.
  • the above-mentioned crimped yarn was tufted to the above-mentioned base cloth at 1/10 gauge and 12 stitch/mm, and the pile ends were cut to obtain a velour carpet for car line mat of which pile length was 6 mm and pile weight was 450g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 2.6% and abrasion loss ratio after wet heat degradation was 4.2%, i.e., it exhibited a good abrasion resistance. And, the obtained carpet exhibited a deep excellent color. And, heat resistance of the obtained carpet was good as there was no thermal bond.
  • a crimped yarn was obtained in the same way as Example 69 except changing the kneading mass ratio of polylactic acid and nylon to 100 : 0.
  • a dyeing bath of bath ratio 1 : 15 was prepared in a dyeing machine and, as disperse dyes, Disperse Yellow KT-1, Disperse Red KT-1, Disperse Blue KT-1 5%owf as total dye concentration, as dyeing auxiliary agent, acetic acid 0.5 g/l and Nicca Sunsalt RM-340 (produced by Nicca Chemical Co.) 0.5 g/l were added, and the above-mentioned twisted yarn was put in said dyeing bath and subjected to a dyeing treatment at 110°C for 30 minutes.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the crimped yarn was tufted in the same way as Example 69 to thereby obtain a loop carpet of pile weight 700g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 6.3%, at 5500 rotation abrasion, 95.2% and abrasion loss ratio after wet heat degradation was 25.2%, i.e., every value was inferior to those of Example 69.
  • a crimped yarn was obtained in the same way as Example 69 except changing the kneading mass ratio of polylactic acid and nylon to 70 : 30.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the above-mentioned twisted yarn was tufted to the above-mentioned base cloth at 1/8 gauge and 7.5 stitch/mm and the pile ends were cut to thereby obtain a saxony carpet of which pile length was 10 mm and pile weight was 1100g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 3.2%, at 5500 rotation abrasion, 75.1%, and abrasion loss ratio after wet heat degradation was 18.8%, i.e., it was inferior to that of Example 70.
  • a crimped yarn was obtained in the same way as Example 69 except changing the kneading mass ratio of polylactic acid and nylon to 100 : 0.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the above-mentioned twisted yarn was tufted to the above-mentioned base cloth at 1/8 gauge and 7.5 stitch/mm, and the pile ends were cut to thereby obtain a saxony carpet of which pile length was 10 mm and pile weight was 1100g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 2.4%, at 5500 rotation abrasion, 85.6%, and abrasion loss ratio after wet heat degradation was 19.9%, i.e., it was inferior to that of Example 70.
  • a spinning ⁇ stretching ⁇ crimping processing was carried out in the same way as Example 69 except changing the total output of polymer and the number of holes of spinneret and the kneading mass ratio of polylactic acid and nylon to 70 : 30, and obtained a crimped yarn of 1450 dtex-54fil.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the above-mentioned crimped yarn was tufted to the above-mentioned base cloth at 1 /10 gauge and 12 stitch/mm, and the pile ends were cut to thereby obtain a velour carpet of which pile length was 6 mm and pile weight was 450g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 40.2%, and abrasion loss ratio after wet heat degradation was 50.3%, i.e., it was inferior to that of Example 71. And, heat resistance of the obtained carpet was inferior to that of Example 71, as a fusion bond of the pile occurred in said test.
  • a spinning ⁇ stretching ⁇ crimping processing was carried out in the same way as Example 69 except changing the total output of polymer, the spinneret and the kneading mass ratio of polylactic acid and nylon to 100 : 0, and obtained a crimped yarn of 1450 dtex-54fil.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the above-mentioned crimped yarn was tufted to the above-mentioned base cloth at 1/10 gauge and 12 stitch/mm, and pile ends were cut to obtain a velour carpet of which pile length was 6 mm and pile weight was 450g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 43.4%, and abrasion loss ratio after wet heat degradation was 70.2%, i.e., it was inferior to that of Example 71.
  • a spinning ⁇ stretching ⁇ crimping processing was carried out in the same way as Example 69 except changing the total output of polymer, the spinneret and the kneading mass ratio of polylactic acid and nylon to 0 : 100 to thereby obtain a crimped yarn of 1560 dtex-96fil.
  • the above-mentioned crimped yarn was twisted at 140 t/m S-twist as first twist and 2 yarns were paralleled and furthermore, twisted at 140 t/m Z-twist as second twist, and heat set at 125°C.
  • Example 69 The same one as that of Example 69 was used as a base cloth for carpet.
  • the above-mentioned twisted yarn was tufted to the above-mentioned base cloth at 1/10 gauge and 8.5 stitch/mm, and pile ends were cut to thereby obtain a saxony carpet of which pile length was 10 mm and pile weight was 1100g/m 2 .
  • the abrasion loss ratio of the obtained carpet was, at 300 rotation abrasion, 1.0%, at 5500 rotation abrasion, 9.2%, and abrasion loss ratio after wet heat degradation was 2.1%, i.e., it exhibited a good abrasion resistance. And, the obtained carpet was inferior in color brightness to those of Examples.
  • Polylactic acid P4 as the component A and nylon 6 (melt viscosity 580 poise, melting point 225°C) as the component B were mixed and kneaded by an extruding machine at kneading mass ratio (polylactic acid : nylon) 30 : 70 and kneading temperature 230°C, and supplied to a spinning machine.
  • Spinning temperature in the spinning machine was adjusted to 230°C, and after the polymer mixture was filtered in the spinning pack by a metallic nonwoven fabric filter of mesh size 20 ⁇ m, it was discharged as a yarn from a spinneret having circular holes of which number of holes was 26.
  • an unstretched yarn of 252 dtex-26fil was wound and, after that, subjected to a one stage stretching by a vertical type stretching machine in a condition of stretch ratio 3.0 times, stretching temperature 90°C and set temperature 130°C to thereby obtain a stretched yarn of 84 dtex-26fil.
  • domain size of the island structure was 15 to 200nm (average 100nm).
  • a dyeing bath of bath ratio 1 : 15 was prepared in a dyeing machine, by adding IRGALAN (R) Black RBLN 2.0% owf as metal-complex dyes, acetic acid 0.5 g/l and ammonium sulfate 0.5 g/l as dyeing auxiliary agent, and the above-mentioned twisted yarn was put into said dyeing bath, and a dyeing treatment was carried out at 90°C for 20 minutes.
  • the obtained car sheet had a strength having no problem in practical use, and strength retention at 90°C atmosphere was also of no problem in practical use as 67.9%, and abrasion resistance was also good.
  • a stretched yarn of 84 dtex-26fil was obtained in the same way as Example 72 except changing the kneading mass ratio of polylactic acid and nylon (polylactic acid : nylon) to 20 : 80.
  • nylon 6 formed the covering component, in order to dye nylon 6 with a metal-complex dye, dyeing was carried out in the same way as Example 72.
  • the obtained fabric had strength of no problem in practical use, and, strength retention in 90°C atmosphere was also of no problem in practical use as 75.8%, and abrasion resistance was also good.
  • a stretched yarn of 84 dtex-26fil was obtained in the same way as Example 72 except changing the kneading mass ratio of polylactic acid and nylon (polylactic acid : nylon) to 70 : 30.
  • the obtained fabric was low in strength retention at 90°C atmosphere as 29.3%, and abrasion resistance was also inferior to that of Example 72, and its practical use was difficult as a result.
  • a stretched yarn was obtained in the same way as Example 72 except changing the kneading mass ratio of polylactic acid and nylon to 100 : 0.
  • Example 72 4 of the obtained stretched yarn were assembled, and a double jersey was prepared in the same way as Example 72.
  • Example 72 Example 73 Comparative example 22 Comparative example 23 Fiber thickness dtex 84 84 84 84 Raw Yarn Yarn component PLA/N6 PLA/N6 PLA/N6 PLA Sea component N6 N6 PLA PLA Weight ratio PLA/N6 30/70 20/80 70/30 100/0 N6 melt viscosity poise 580 580 580 - PLA melt viscosity poise 1210 1210 1210 Tensile strength cN/dtex 4.3 4.5 3.2 4.3 Yarn unevenness U% 1.1 0.9 1.6 0.8 Fabric Knit structure double jersey mocro cloth double jersey mocro cloth double jersey mocro cloth double jersey mocro cloth double jersey mocro cloth Wale W/inch 29 29 30 29 Course C/inch 48 42 40 42 Weight g/m 2 618 498 512 498 Dyeing condition °C ⁇ min 90
  • a crimped yarn and a fiber structure constituted by a synthetic fiber comprising an aliphatic polyester resin and a thermoplastic polyamide resin excellent in abrasion resistance as well as aesthetic appearance after dyeing it is possible to provide a synthetic fiber and a fiber structure most suitable for general apparel applications or industrial material applications.

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Abstract

Cette invention concerne un fil frisé comprenant une fibre synthétique contenant une résine de polyester aliphatique (A) et une résine de polyamide thermoplastique (B) et dont le rapport de la surface apparente de la résine de polyester aliphatique (A) à la surface de la fibre est inférieur ou égal à 5 %, un fil multifilament composé d’une pluralité des fibres synthétiques étant frisé, et une structure de fibre constituée au moins partiellement du fil frisé. Plus précisément, cette invention concerne un fil frisé comprenant une fibre synthétique en alliage polymère contenant une résine de polyester aliphatique (A) et une résine de polyamide thermoplastique (B) ; un fil frisé comprenant une fibre composite à âme enrobée, l’élément âme contenant une résine de polyester aliphatique (A) ou un alliage polymère formé de la résine de polyester aliphatique (A) et d’une résine de polyamide thermoplastique (B) et l’élément gaine contenant la résine de polyamide thermoplastique (B) ; et une structure de fibre constituée au moins partiellement du fil frisé.

Claims (28)

  1. Fil frisé en fibres synthétiques de type alliage polymère contenant une résine de polyester aliphatique (A) et une résine de polyamide thermoplastique (B), dans lequel l'alliage polymère a une structure en îlots dans la mer dans laquelle la résine de polyester aliphatique (A) forme un composant îlot et la résine de polyamide thermoplastique (B) forme un composant mer, et la taille de domaine du composant îlot est de 0,001 à 2 µm, et la résine de polyester aliphatique (A) est exposée sur la surface des fibres, de façon que le rapport de la surface exposée de la résine de polyester aliphatique (A) à la superficie des fibres soit de 5 % ou moins, et une frisure est conférée au multifilament comprenant lesdites fibres synthétiques.
  2. Fil frisé selon la revendication 1, caractérisé en ce que le fil frisé est un film BCF.
  3. Fil frisé selon la revendication 1 ou 2, dans lequel la résine de polyester aliphatique (A) est une résine cristalline et a un point de fusion de 150 à 230°C.
  4. Fil frisé selon l'une quelconque des revendications précédentes, dans lequel la résine de polyamide thermoplastique (B) est une résine cristalline et a un point de fusion de 150 à 250°C.
  5. Fil frisé selon l'une quelconque des revendications précédentes, dans lequel le rapport de mélange (rapport en poids) de la résine de polyester aliphatique (A) à la résine de polyamide thermoplastique (B) est de 5/95 à 55/45.
  6. Fil frisé selon l'une quelconque des revendications précédentes, dans lequel l'alliage polymère contenant la résine de polyester aliphatique (A) et la résine de polyamide thermoplastique (B) est obtenu par addition en outre d'un composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif.
  7. Fil frisé selon la revendication 6, dans lequel le groupe réactif contenant de l'hydrogène actif est au moins un groupe réactif choisi dans l'ensemble constitué par un groupe glycidyle, un groupe oxazoline, un groupe carbodiimide et un groupe anhydride d'acide.
  8. Fil frisé selon la revendication 6, dans lequel la teneur en le composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif par rapport à la quantité totale de la résine de polyester aliphatique (A), de la résine de polyamide thermoplastique (B) et du composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif est de 0,005 à 5 % en poids.
  9. Fil frisé selon l'une quelconque des revendications précédentes, dans lequel des rainures s'étendant le long de la direction de l'axe des fibres sont formées sur la surface des fibres, et la largeur desdites rainures est de 0,01 à 1 µm.
  10. Fil frisé selon la revendication 9, dans lequel le rapport d'aspect de la rainure (longueur de l'axe longitudinal de la rainure / largeur de la rainure) est de 10 à 500.
  11. Fil frisé selon l'une quelconque des revendications précédentes, lequel fil frisé satisfait aux propriétés physiques suivantes :
    résistance : 1 cN/dtex ou plus,
    pourcentage d'allongement de frisure après traitement à l'eau bouillante : 3 à 30 %, et
    non circularité (D1/D2) 1,2 à 7.
  12. Fil frisé selon l'une quelconque des revendications précédentes, dans lequel au moins un type d'agent de nucléation cristallin choisi parmi le talc, un dérivé de sorbitol, un sel métallique d'ester d'acide phosphorique, un composé basique inorganique de l'aluminium et un sel de composé de mélamine est présent en une quantité de 0,01 à 2 % en poids par rapport à la résine de polyester aliphatique (A).
  13. Procédé de production d'un fil frisé selon l'une quelconque des revendications 1 à 12, dans lequel, lors du malaxage d'une résine de polyester aliphatique (A) et d'une résine de polyamide thermoplastique (B) en un rapport de mélange (rapport en poids) de 5/95 à 55/45, une combinaison de leur rapport de viscosité à l'état fondu (ηb/ηa) située dans la plage allant de 0,1 à 2 est sélectionnée, et après pastillage ou en continuité avec le malaxage, le mélange est filé à l'état fondu à une température de filage, si l'on considère que le point de fusion de la résine de polyamide thermoplastique (B) est Tmb, de Tmb+3°C à Tmb+40°C, de façon à former un multifilament à une vitesse de décharge linéaire dans le trou de filage de la filière de 0,02 à 0,4 m/s et, par établissement d'un point de départ de refroidissement pratiquement verticalement 0,01 à 0,15 m sous la surface de filière, il est refroidi pratiquement à angle droit par un gaz à une vitesse de 0,3 à 1 m/s et à une température de 15 à 25°C, après quoi ledit multifilament est recouvert d'un agent de finissage pour le filage, étiré en 1 à 3 étapes tout en étant chauffé avec des cylindres chauds à 50-130°C de façon que l'allongement à la rupture du multifilament soit de 15 à 65 %, en outre thermodurci par établissement d'une température du cylindre final, après l'étirage, en considérant que le point de fusion de la résine de polyester aliphatique (A) est Tma, de Tma-30 à Tma+30°C, et introduit dans une machine de garnissage à jet d'air et soumis à un traitement de frisage par établissement d'une température de buse de ladite machine supérieure de 5 à 100°C à celle du cylindre final après l'étirage, de manière à former ainsi un fil frisé dans trois dimensions, qui est repris en étant mis au contact d'un tambour de refroidissement et enroulé à une vitesse inférieure de 10 à 30 % à celle du cylindre final après l'étirage (où ηa : viscosité à l'état fondu de la résine de polyester aliphatique (A), ηb : viscosité à l'état fondu de la résine de polyamide thermoplastique (B)).
  14. Procédé de production d'un fil frisé selon la revendication 13, dans lequel le composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif est ajouté à la résine de polyester aliphatique (A) et/ou à la résine de polyamide thermoplastique (B) en tant qu'agent de compatibilité, et fondu et malaxé.
  15. Procédé de production d'un fil frisé selon la revendication 13, dans lequel le composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif est ajouté en une quantité de 0,005 à 5 % en poids par rapport à la quantité totale de la résine de polyester aliphatique (A), de la résine de polyamide thermoplastique (B) et du composé (C) contenant par molécule deux ou plus de deux groupes réactifs contenant de l'hydrogène actif.
  16. Procédé de production d'un fil frisé selon la revendication 13, dans lequel au moins un type d'agent de nucléation cristallin choisi parmi le talc, un dérivé de sorbitol, un sel métallique d'un ester d'acide phosphorique, un composé basique inorganique de l'aluminium, un sel d'un composé de mélamine, est ajouté à la résine de polyester aliphatique (A) et/ou à la résine de polyamide thermoplastique (B) et malaxé à l'état fondu.
  17. Procédé de production d'un fil frisé selon la revendication 16, dans lequel au moins un type d'agent de nucléation cristallin choisi parmi le talc, un dérivé de sorbitol, un sel métallique d'un ester d'acide phosphorique, un composé basique inorganique de l'aluminium, un sel d'un composé de mélamine, est ajouté en une quantité de 0,01 à 2 % en poids par rapport à la résine de polyester aliphatique (A).
  18. Fil frisé constitué par un composant de coeur comprenant l'alliage polymère de la résine de polyester aliphatique (A) et de la résine de polyamide thermoplastique (B) ayant une structure en îlots dans la mer, tel que défini dans la revendication 1, et un composant de gaine comprenant la résine de polyamide thermoplastique (B), dans lequel les propriétés physiques (4) à (6) suivantes sont satisfaites :
    (4) résistance : 1,5 à 3 cN/dtex,
    (5) épaisseur d'une fibre unique : 5 à 40 dtex, et
    (6) retrait dans l'eau bouillante : 6 % ou moins.
  19. Fil frisé selon la revendication 18, dans lequel la capacité thermique totale du pic de fusion d'une courbe calorimétrique différentielle mesurée pour le fil frisé à une vitesse de montée en température de 16°C/min est de 50 J/g ou plus.
  20. Fil frisé selon la revendication 18 ou 19, dans lequel le rapport gaine/coeur (rapport en poids) est de 10/90 à 65/35.
  21. Fil frisé selon l'une quelconque des revendications 18 à 20, dans lequel la non-circularité (D3/D4) d'une fibre isolée du fil frisé est de 1,3 à 4.
  22. Fil frisé selon l'une quelconque des revendications 18 à 21, dans lequel le pourcentage d'allongement de frisure après traitement à l'eau bouillante du fil frisé est de 5 à 35 %.
  23. Fil frisé selon l'une quelconque des revendications 18 à 22, dans lequel le pourcentage d'allongement de frisure après traitement à l'eau bouillante sous une charge de 2 mg/dtex (pourcentage d'allongement sous charge) est de 2 à 30 %.
  24. Fil frisé selon l'une quelconque des revendications 18 à 23, dans lequel le rapport de mélange (rapport en poids) de la résine de polyester aliphatique (A) et de la résine de polyamide thermoplastique (B) du composant de coeur est de 95/5 à 20/80.
  25. Procédé de production pour produire un fil frisé selon l'une quelconque des revendications 18 à 24, caractérisé en ce que, par utilisation d'une machine de traitement de filage/étirage/frisage direct, un composant de coeur comprenant un alliage polymère obtenu par malaxage à l'état fondu d'une résine de polyester aliphatique (A) et d'une résine de polyamide thermoplastique (B) en tant que composant de coeur au moyen d'une machine d'extrusion/ malaxage double vis et/ou d'une machine d'extrusion/ malaxage simple vis, à une température de malaxage située dans la plage allant du point de fusion de la résine de polyamide thermoplastique (B), (Tmb), à Tmb+40°C, à une vitesse de cisaillement de 200 à 20 000 s-1, et pendant un temps de séjour de 0,5 à 30 minutes, et un composant de gaine comprenant une résine de polyamide thermoplastique (B), sont joints dans une filière et déchargés.
  26. Structure fibreuse contenant un fil frisé décrit dans la revendication 1 au moins en tant que partie de celle-ci.
  27. Structure fibreuse selon la revendication 26, laquelle structure fibreuse est un tapis.
  28. Structure fibreuse selon la revendication 27, qui est un tapis pour intérieur d'automobile.
EP06821902A 2005-10-19 2006-10-18 Fil frise, procede de fabrication correspondant et structure de fibre Not-in-force EP1939336B1 (fr)

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JP2005304036 2005-10-19
JP2005371658 2005-12-26
JP2005371657A JP4872339B2 (ja) 2005-12-26 2005-12-26 芯鞘型複合繊維、捲縮糸、およびそれらを用いてなる繊維構造体
JP2006054234 2006-03-01
PCT/JP2006/320700 WO2007046397A1 (fr) 2005-10-19 2006-10-18 Fil frise, procede de fabrication correspondant et structure de fibre

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EP1939336A4 (fr) 2009-12-02
US20090068463A1 (en) 2009-03-12
CA2625343A1 (fr) 2007-04-26
EP1939336A1 (fr) 2008-07-02
KR20080059232A (ko) 2008-06-26

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