Classifications

• • 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
  • D01D5/08—Melt spinning methods
  • D01D5/098—Melt spinning methods with simultaneous stretching
• • 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
  • D01D5/34—Core-skin 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
  • D01F8/16—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
• • 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
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
• • 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
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
  • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
  • D03D15/47—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads multicomponent, e.g. blended yarns or threads
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
  • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
  • D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/06—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/02—Moisture-responsive characteristics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/02—Moisture-responsive characteristics
  • D10B2401/022—Moisture-responsive characteristics hydrophylic
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/06—Load-responsive characteristics

Definitions

• the present invention relates to a hygroscopic core-sheath composite yarn and fabric.
• Synthetic fibers made of thermoplastic resins including polyamide and polyester are widely used for clothing and industrial applications because of being high in strength, chemical resistance, heat resistance, and the like.
• polyamide fiber in addition to its unique characteristics including softness, high tensile strength, coloring property in dyeing processes, and high heat resistance, polyamide fiber is so high in hygroscopicity that it is widely used for applications such as inner wear and sports wear.
• polyamide fibers are not sufficiently hygroscopic as compared with natural fibers such as cotton and have some problems such as undesired stuffiness and stickiness, leading to inferior comfortability to natural fibers.
• Patent document 1 proposes a method of improving hygroscopic performance by blending polyvinylpyrrolidone, used as a hydrophilic polymer, with polyamide, followed by spinning.
• Patent document 2 discloses a core-sheath composite fiber composed mainly of a core component and a sheath component in such a manner that the core component is not exposed in the fiber surface.
• the core component is a polyether block amide copolymer containing 6-nylon as a hard segment whereas the sheath component is a 6-nylon fiber, wherein the area ratio between the core component and the sheath component in the cross section of the fiber is 3/1 to 1/5.
• Patent document 3 discloses a sheath-core type composite fiber containing a thermoplastic resin as the core component and a fiber-forming polyamide resin as the sheath component, wherein the main constituent of the thermoplastic resin in the core component is a polyether ester amide, the core component accounting for 5% to 50% by weight of the total weight of the composite fiber.
• the document describes a highly hygroscopic core-sheath type composite fiber with the above feature containing polyether ester amide as the core component and polyamide as the sheath component.
• Patent document 4 describes a composite fiber having moisture absorbing and releasing properties characterized by containing polyamide or polyester as the sheath component and a thermoplastic water absorbing resin made of crosslinked polyethylene oxide as the core component.
• JP-A-H09 41204 describes a core - sheath filament comprising polyetheresteramide as core and polyamide as sheath.
• the filament has a moisture absorption - release coefficient ⁇ MR of 2.5% or more.
• JP-A-H09 41221 describes a similar core/sheath filament having a moisture absorption - release coefficient ⁇ MR of 1.5% or more.
• JP-A-H07 278964 discloses a hygroscopic sheath-core conjugate fiber having a polyetheresteramide core.
• the core-sheath composite fibers described in Patent documents 2 to 4 tend to suffer from thermal degradation of the core component and hardening of the fibers as they undergo frequent washing and drying in household type machines, causing the fabrics to suffer from hardening of the texture, a decrease in durability, or deterioration in moisture absorbing and releasing performance.
• the present invention adopts the following constitution to solve the problems described above:
• the present invention can provide a core-sheath composite yarn that is high in hygroscopic performance, higher in comfortability than natural fibers, and able to maintain a soft texture, high durability, and moisture absorbing and releasing performance after undergoing repeated washing and drying.
• the core-sheath composite yarn according to the present invention includes polyamide as the sheath component and a polyether ester amide copolymer as the core component.
• the polyether ester amide copolymer is a block copolymer having an ether bond, an ester bond, and an amide bond in one molecular chain. More specifically, the block copolymer polymer which can be produced by subjecting one, two, or more selected from the group consisting of lactams, aminocarboxylic acids, and salts of diamine and dicarboxylic acid, referred to polyamide component (A), and a polyether ester component (B) formed of a dicarboxylic acid and a poly(alkylene oxide) glycol to condensation polymerization reaction.
• Substances suitable as the polyamide component (A) include lactams such as ⁇ -caprolactam, dodecanolactam, and undecanolactam; ⁇ -aminocarboxylic acids such as aminocaproic acid, 11-aminoundecanoic acid, and 12-aminododecanoic acid; and nylon salts of diamine-dicarboxylic acids that serve as precursors of nylon 66, nylon 610, nylon 612, etc., of which ⁇ -caprolactam is preferred as polyamide-forming component.
• lactams such as ⁇ -caprolactam, dodecanolactam, and undecanolactam
• ⁇ -aminocarboxylic acids such as aminocaproic acid, 11-aminoundecanoic acid, and 12-aminododecanoic acid
• nylon salts of diamine-dicarboxylic acids that serve as precursors of nylon 66, nylon 610, nylon 612, etc., of which
• the polyether ester component (B) is formed of a dicarboxylic acid containing 4 to 20 carbon atoms and a poly(alkylene oxide) glycol.
• the dicarboxylic acid containing 4 to 20 carbon atoms include aliphatic dicarboxylic acids such as succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, sebacic acid, and dodecanoic acid; aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, and 2,6-naphthalene dicarboxylic acid; and alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, which may be used singly or as a mixture of two or more thereof.
• Preferable dicarboxylic acids include adipic acid, sebacic acid, dodecanoic acid, terephthalic acid, and isophthalic acid.
• Examples of the poly(alkylene oxide) glycol include polyethylene glycol, poly(1,2- or 1,3-propylene oxide) glycol, poly(tetramethylene oxide) glycol, and poly(hexamethylene oxide) glycol, of which polyethylene glycol is preferable because of having high hygroscopic performance.
• the poly(alkylene oxide) glycol prefferably has a number average molecular weight of 300 to 3,000, more preferably 500 to 2,000.
• a molecular weight of 300 or more is preferable because scattering out of the system during condensation polymerization reaction can be prevented to ensure the formation of a fiber with stable hygroscopic performance.
• a molecular weight of 3,000 or less is preferable because the poly(alkylene oxide) glycol can be dispersed uniformly in the polymer to ensure high hygroscopic performance.
• component percentage of the polyether ester component (B) it preferably accounts for 20% to 80% by mole of the total quantity of the polyether ester amide copolymer. A percentage of 20% or more is preferable because high hygroscopic performance can be realized. On the other hand, a percentage of 80% or less is preferable to ensure high dyed color fastness and little hygroscopic performance deterioration by washing.
• the component percentages of the polyamide and poly(alkylene oxide) glycol are preferably 20%/80% to 80%/20% by mole.
• a poly(alkylene oxide) glycol content of 20% or more is preferable because high hygroscopic performance can be realized.
• a poly(alkylene oxide) glycol preferably content of 80% or less is preferable to ensure high dyed color fastness and little hygroscopic performance deterioration by washing.
• polyamide used as the sheath component examples include nylon 6, nylon 66, nylon 46, nylon 9, nylon 610, nylon 11, nylon 12, and nylon 612; and copolymer polyamides containing, as a copolymer component, a compound having a functional group that can form an amide with the former, such as laurolactam, sebacic acid, terephthalic acid, isophthalic acid, and 5-sodium sulfoisophthalic acid.
• nylon 6, nylon 11, nylon 12, nylon 610, and nylon 612 are preferable from the viewpoint of yarn-making performance because they are small in the difference in melting point from the polyether ester amide copolymer, serving to depress the thermal degradation of the polyether ester amide copolymer during melting spinning.
• nylon 6 is particularly preferable because of high dyeability.
• the core-sheath composite yarn according to the present invention prefferably has a strength retention rate of 50% or more and 100% or less after undergoing dry heat treatment at 150°C for 1 hour. If it is less than 50%, the raw threads will become hard and brittle and a fabric test piece will decrease in durability and suffer breakage etc. when subjected to repeated drying test in a household washing and drying machine (hereinafter referred to as tumble drying). It is preferably 60% or more and 100% or less. If it is in this range, it will be possible to produce clothing that can maintain durability after repeated tumble drying.
• the core-sheath composite yarn according to the present invention prefferably has a tensile strength of 2.5 cN/dtex or more. It is more preferably 3.0 cN/dtex or more. If it is in this range, it will be possible to produce clothing that are high enough in strength to serve for practical clothing uses such as innerwear and sports apparel applications.
• the core-sheath composite yarn according to the present invention It is essential for the core-sheath composite yarn according to the present invention to have a function to maintain controlled humidity in clothing to ensure high comfortability when they are worn.
• the degree of humidity control is examined based on ⁇ MR, which denotes the difference between the hygroscopicity at 30°C and 90% RH, which represent a typical temperature and humidity conditions in clothing resulting from a light to medium degree of work or a light to medium degree of exercise and that at 20°C and 65% RH, which represent a typical outdoor air temperature and humidity conditions.
• ⁇ MR denotes the difference between the hygroscopicity at 30°C and 90% RH, which represent a typical temperature and humidity conditions in clothing resulting from a light to medium degree of work or a light to medium degree of exercise and that at 20°C and 65% RH, which represent a typical outdoor air temperature and humidity conditions.
• a larger ⁇ MR value ensures a higher hygroscopic performance and higher comfort
• the core-sheath composite yarn according to the present invention prefferably has a ⁇ MR value of 5.0% or more. It is more preferably 7.0% or more and still more preferably 10.0% or more. If it is in this range, it will be possible to produce clothing that have reduced stuffiness and stickiness when worn and have high comfortability.
• the core-sheath composite yarn according to the present invention prefferably has a ⁇ MR retention rate of 70% or more and 100% or less after undergoing dry heat treatment at 150°C for 1 hour. If it is in this range, it will be possible to produce clothing that can maintain moisture absorbing and releasing performance as well as high comfortability after undergoing repeated tumble drying.
• a polyether ester amide copolymer to be used in the core for the present invention contains both a hindered phenolic stabilizer, which is an antioxidant to capture radicals, and a hindered amine based stabilizer (hereinafter referred to as HALS type stabilizer) to make it possible to provide a core-sheath composite yarn characterized by depressed thermal degradation of the polyether ester amide copolymer even after undergoing repeated tumble drying to ensure a high durability and moisture absorbing and releasing performance as well as a soft texture.
• HALS type stabilizer hindered amine based stabilizer
• the polyether ester amide copolymer used in the core contains poly(alkylene oxide) glycol, and when the poly(alkylene oxide) glycol is heated, radicals will be generated from the molecule and attack adjacent atoms to further generate radicals to cause chain reaction, and the reaction heat will work to increase the temperature up to as high as 200°C. As the molecular weight of the poly(alkylene oxide) glycol decreases, the molecular chain will be heated more easily to generate more radicals and generate more reaction heat.
• the polyether ester amide copolymer used for the present invention contains a poly(alkylene oxide) glycol having a relatively low number average molecular weight of 300 to 3,000 and accordingly, the polyether ester amide copolymer tends to undergo thermal degradation easily through the above mechanism, thus leading very easily to raw threads that are hard and brittle and have an inferior hygroscopic performance.
• a hindered phenolic stabilizer which is an antioxidant to capture radicals
• the addition of a hindered phenolic stabilizer alone will lead to progress of thermal degradation of the polyether ester amide copolymer due to the heat history in the spinning step (high temperature heating for melting the polymer and thermal setting after stretching) and the heat history in high-order processing steps (dyeing, thermal setting, etc. of fabric), resulting in a large decrease in the effective component quantity of the antioxidant working to capture radicals remaining at the stages of fabrics and clothing.
• the polyether ester amide copolymer will suffer from further thermal degradation and the raw threads will become harder and more brittle and deteriorate in hygroscopic performance.
• the texture will become harder due to repeated washing and drying, leading to deterioration in durability and moisture absorbing and releasing performance.
• HALS hindered amine light stabilizer
• thermal degradation of the hindered phenolic stabilizer will be depressed to allow a soft texture, high durability, and moisture absorbing and releasing performance to be maintained after repeated tumble drying.
• the quantity of the hindered phenolic stabilizer to be added when producing the core-sheath composite yarn according to the present invention preferably accounts for 1.0 wt% or more and 5.0 wt% or less relative to the weight of the polyether ester amide copolymer in the core. It more preferably accounts for 2 wt% or more and 4 wt% or less. If it is 1.0 wt% or more, it will be possible to produce raw threads that will not become hard or brittle or deteriorate in hygroscopic performance after undergoing repeated tumble drying. If it is 5.0 wt% or less, the yarn-making performance will be high and yellowing of the raw threads will be reduced.
• the quantity of the residual hindered phenolic stabilizer in the core-sheath composite yarn is preferably 70% or more of the quantity of the hindered phenolic stabilizer (relative to the core-sheath composite yarn) added in the production process. It is more preferably 80% or more. If it is in this range, it will be possible to produce raw threads that will not become hard or brittle or deteriorate in hygroscopic performance after undergoing repeated tumble drying.
• the quantity of the HALS type stabilizer to be added when producing the core-sheath composite yarn according to the present invention preferably accounts for 1.0 wt% or more and 5.0 wt% or less relative to the weight of the polyether ester amide copolymer in the core. It more preferably accounts for 1.5 wt% or more and 4.0 wt% or less. If it is 1.0 wt% or more, it will be possible to depress the thermal degradation of the hindered phenolic stabilizer used in combination. If it is 5.0 wt% or less, the yarn-making performance will be high and yellowing of raw threads will be reduced.
• the 5% weight loss temperature during thermogravimetric analysis is preferably 300°C or more. If it is 300°C or more, the stabilizer itself will suffer little degradation that may be caused by the heat history in the spinning step or the heat history in high-order processing steps to allow a significant effective component quantity of the antioxidant to be left to capture radicals remaining in fabric and clothing products so that the polyether ester amide copolymer will suffer little thermal degradation after undergoing repeated tumble drying and serve to maintain a soft texture and high durability and moisture absorbing and releasing performance, and therefore it is preferable.
• IR101010 pentaerythritoltetrakis [3-(3,5-di-tert-
• HALS type stabilizer used for the present invention examples include, for example, a polycondensate of dibutylamine-1,3,5-triazine, N,N-bis(2,2,6,6-tetramethyl-4-piperidyl-1,6-hexamethylene diamine, and N-(2,2,6,6-tetramethyl-4-piperidyl)butyl amine (CHIMASSORB2020FDL), 4,7,N,N'-tetrakis [4,6-bis[butyl(1,2,2,6,6-pentamethyl-4-piperidinyl)amino]-1,3,5-triazine-2-yl]-4,7-diazadecan e-1,10-diamine (CHIMASSORB119), poly[ ⁇ 6-(1,1,3.3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl) ((2,2,6,6-tetramethyl-4-piperidyl)imino) hex
• the polyamide sheath component for the present invention may contain, in the form of a copolymer or a mixture, various additives such as, for example, delustering agent, flame retardant, ultraviolet absorber, infrared ray absorbent, crystal nucleating agent, fluorescent whitening agent, antistatic agent, hygroscopic polymer, and carbon, as required in such a manner that the total additive content is in the range of 0.001% to 10 wt% of the total fiber quantity.
• various additives such as, for example, delustering agent, flame retardant, ultraviolet absorber, infrared ray absorbent, crystal nucleating agent, fluorescent whitening agent, antistatic agent, hygroscopic polymer, and carbon, as required in such a manner that the total additive content is in the range of 0.001% to 10 wt% of the total fiber quantity.
• the core-sheath composite yarn according to the present invention prefferably has an elongation percentage of 35% or more. It is more preferably 40% to 80%. If it is in this range, a high process passability will be ensured for high-order steps such as weaving, knitting, and false-twisting.
• multifilaments produced therefrom preferably have a total fineness of 5 decitex or more and 235 decitex or less and contain 2 or more and 144 or less filaments.
• the cross section may preferably be circular, triangle, flattened, Y-shaped, start-like, eccentric, or pasted type.
• the core-sheath composite yarn according to the present invention can be produced by a generally known method such as melt-spinning and composite spinning, and typical methods are described below.
• polyamide the sheath component
• a polyether ester amide copolymer the core
• a gear pump a gear pump
• they are combined by a common method into a composite flow having a core-sheath structure and discharged from a spinneret to produce threads, which are then cooled to room temperature by applying cooling air from a cooling apparatus such as chimney, bundled while supplying oil from an oil feeding apparatus, interlaced by a first fluid interlacing nozzle apparatus, and transported on a take-up roller and a stretching roller where the yarn is stretched according to the ratio of circumferential speeds of the take-up roller and the stretching roller. Subsequently, the yarn is heat-set by the heat of the stretching roller and wound up by a winder (winding-up apparatus).
• the spinning temperature it is preferable for the spinning temperature to be 240°C or more and 270°C or less.
• a spinning temperature of 240°C or more is preferable because the polyamide and polyether ester amide copolymer will have a melt viscosity suitable for melt-spinning.
• a temperature of 270°C or less is preferable because the hindered phenolic stabilizer and the HALS type stabilizer can be performed effectively without undergoing thermal decomposition, thus serving to depress the thermal decomposition of the polyether ester amide copolymer.
• the core-sheath composite yarn according to the present invention it is necessary for the core to account for 20 wt% to 80 wt% of the entire composite yarn. It is more preferably 30 wt% to 70 wt%. If it is in this range, it will be possible to stretch the polyamide in the sheath to an appropriate degree. It will be also possible to achieve a desired dyed color fastness and hygroscopic performance. If it is less than 20 wt%, a sufficient hygroscopic performance may not be achieved.
• the sheath of the present invention is preferably formed of polyamide chips having a sulfuric acid relative viscosity of 2.3 or more and 3.3 or less. If it is in this range, it will be possible to stretch the polyamide in the sheath to an appropriate degree.
• the polymer chips of the polyether ester amide copolymer used in the core preferably has an orthochlorophenol relative viscosity of 1.2 or more and 2.0 or less.
• An orthochlorophenol relative viscosity of 1.2 or more is preferable because an optimum stress will be applied to the sheath during spinning and accordingly, the crystallization of the polyamide in the sheath will be accelerated to ensure high strength.
• Good methods for blending a hindered phenolic stabilizer or a HALS type stabilizer with a polyether ester amide copolymer include the dry blending method in which a hindered phenolic stabilizer or a HALS type stabilizer is attached to chips of a polyether ester amide copolymer and the master chip method in which master chips of a polyether ester amide copolymer mixed with a high concentration of a hindered phenolic stabilizer or HALS type stabilizer are prepared first in a twin screw extruder or a single screw extruder, followed by blending the master chips and polyether ester amide copolymer chips in the spinning step.
• Use of the master chips is preferable because a high concentration of a hindered phenolic stabilizer or HALS type stabilizer can be dispersed uniformly in the polymer.
• the spinning conditions are preferably set up so that the speed of the threads taken up on the take-up roller (spinning speed) multiplied by the draw ratio, which is the ratio in circumferential speed between the take-up roller and the stretching roller, is 3,300 or more and 4,500 or less in the stretching step. It is more preferably 3,300 or more and 4,000 or less.
• This value represents the total quantity of stretching that the polymer undergoes as it is discharged from the spinneret, accelerated from the spinneret discharging linear speed to the circumferential speed of the take-up roller, and pulled further from the circumferential speed of the take-up roller to the circumferential speed of the stretching roller.
• a value of 3,300 or more is preferable because it ensures accelerated crystallization of the polyamide in the sheath, leading to an improved raw thread strength and heat resistance.
• a value of 4,500 or less is preferable because it ensures moderate crystallization of the polyamide in the sheath, leading to a lower degree of thread breakage and fuzzing in the yarn-making step.
• the thermal setting temperature on the stretching roller is preferably 110°C or more and 160°C or less.
• a temperature of 110°C or more is preferable because it ensures accelerated crystallization of the nylon in the sheath, leading to improvement in strength and depression of tight winding by the drum.
• a temperature of 160°C or less is preferable because it ensures depression of the thermal decomposition of the hindered phenolic stabilizer.
• the spinning oil solution fed by the oil feeding apparatus is preferably a non-aqueous oil solution.
• the polyether ester amide copolymer in the core is a highly hygroscopic polymer with a ⁇ MR value of 10% or more, and accordingly, the use of a non-aqueous oil solution is preferable because it allows gradual absorption of moisture from air, thus preventing significant swelling to ensure stable winding-up.
• the core-sheath composite yarn according to the present invention shows high hygroscopic performance and accordingly, it is preferred for production of clothing.
• the intended fabric may be in the form of woven fabric, knitted fabric, nonwoven fabric, etc., as required to meet particular purposes. As described above, a larger ⁇ MR value ensures a higher hygroscopic performance and higher comfortability when the fabric is worn.
• clothing with high comfortability can be produced by controlling the mixing rate of the core-sheath composite yarn according to the present invention so as to adjust the ⁇ MR value to 5.0% or more. Examples of such clothing include innerwear, sportswear, and other various clothing products.
• a fiber specimen was set on a sizing reel with a circumference of 1.125 m and rotated 200 times to prepare a loop like hank, and then the hank was dried in a hot air drier (105 ⁇ 2°C for 60 minutes) and weighed in a balance, followed by multiplying the weight by an official moisture regain to calculate the fineness.
• the official moisture regain of the core-sheath composite yarn was assumed to be 4.5%.
• a fiber specimen was subjected to measurement using TENSILON (registered trademark) UCT-100 manufactured by Orientec Co., Ltd. under the constant stretching rate conditions specified in JIS L1013 (Chemical fiber filament test method, 2010).
• the elongation percentage was determined from the elongation at the maximum strength point on the tensile strength vs. elongation curve. The strength is calculated by dividing the maximum strength by the fineness. For strength and elongation percentage, ten measurements were taken and their average was adopted.
• a fiber specimen was set on a sizing reel with a circumference of 1.125 m and rotated 200 times to prepare a loop like hank, and then the hank was heat-treated in a hot air drier (150 ⁇ 2°C for 60 minutes), followed by calculating the strength of the dry-heat-treated specimen as described in paragraph (4).
• the strength retention rate of a heat-treated specimen was calculated by the equation given blow: strength after dry heat treatment / strength before dry heat treatment ⁇ 100 .
• thermogravimetric analyzer (TGA7, manufactured by Perkin Elmer) was used for the measurement. In a nitrogen atmosphere, a 10 mg specimen was heated from 30°C to 400°C at a heating rate of 10°C/min, followed by calculating the temperature at the point of 5% weight reduction.
• Pre-treatment was performed without using a specimen to provide a blank test solution.
• a cylindrical knitted fabric sample was produced using a cylindrical knitting machine while adjusting the density to 50. If the fiber is low in the corrected weight based fineness, yarn doubling is performed appropriately so that the fiber fed to the cylindrical knitting machine would have a total fineness of 50 to 100 decitex. If the total fineness is more than 100 decitex, a single yarn was fed to the cylindrical knitting machine and the density was adjusted to 50 as in the above case.
• the cylindrical knitted fabric sample was heat-treated (150 ⁇ 2°C for 60 minutes) in a hot air drier and then its moisture absorbing and releasing properties were measured, followed by making calculations.
• the ⁇ MR retention rate of a dry-heat-treated specimen was calculated by the equation given below: ⁇ MR after dry heat treatment / ⁇ MR before dry heat treatment ⁇ 100 .
• the cylindrical knitted fabric sample was dried at a temperature of 80°C for 1 hour in a type-A1 tumble drying machine as specified in JIS L1930 (2014, household washing test method) Appendix G. This procedure was repeated 10 times.
• the texture of the tumble-dried cylindrical knitted fabric sample was evaluated according to the four stage criterion given below. A specimen rated as A or higher was assumed to be acceptable.
• master chips prepared by adding a hindered phenolic stabilizer (IR1010, manufactured by BASF, 5% weight loss temperature 351°C) and a HALS type stabilizer (CHIMASSORB2020FDL, manufactured by BASF, 5% weight loss temperature 404°C) to high concentrations to the polyether ester amide copolymer and chips of the polyether ester amide copolymer were blended in a twin screw extruder so that the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) would account for 2.0 wt%/2.0 wt%, respectively, of the core.
• IR1010 hindered phenolic stabilizer
• CHIMASSORB2020FDL manufactured by BASF, 5% weight loss temperature 404°C
• the polyether ester amide copolymer adopted as core component and the nylon 6 adopted as sheath component were melted at a spinning temperature of 260°C and spun through a spinneret designed for concentric circular core-sheath composite yarn at a core/sheath ratio (wt%) of 30/70.
• the rotating speed of the gear pump was controlled so as to produce a core-sheath composite yarn having a total fineness of 56 dtex and the threads were cooled and solidified in a thread cooling apparatus, fed with oil from a non-aqueous oil solution feeding apparatus, interlaced in a first fluid interlacing nozzle apparatus, stretched by a take-up roller (first roller) having a circumferential speed of 2,405 m/min and a stretching roller (second roller) having a circumferential speed of 3,608 m/min, thermally set by the stretching roller at 150°C, and wound up at a speed of 3,500 m/min to provide a 56-decitex, 24-filament core-sheath composite yarn.
• Physical properties of the resulting fiber are shown in Table 1.
• the proportion of the residual hindered phenolic stabilizer was 88%, and the strength retention rate after dry heat treatment and the ⁇ MR retention rate after dry heat treatment were 65% and 75%, respectively.
• the raw threads in the resulting core-sheath composite yarn hardly became hard or brittle and maintained a soft texture and a high durability and moisture absorbing and releasing performance.
• Example 1 Except for adjusting the spinning temperature to 270°C, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 1.
• the proportion of the residual hindered phenolic stabilizer was 75%, and the strength retention rate after dry heat treatment and the ⁇ MR retention rate after dry heat treatment were 60% and 72%, respectively.
• Example 1 Except for adjusting the spinning temperature to 240°C, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 1.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 93%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 70% and 77%, respectively.
• Example 1 Except for adjusting the stretching roller temperature to 120°C, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 1.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 90%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 67% and 77%, respectively.
• Example 1 Except for performing the spinning at a core/sheath ratio of 50/50 (parts by weight), the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 1.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 85%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 63% and 72%, respectively.
• Example 1 Example 2
• Example 3 Example 4
• Example 5 Core component polymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer relative viscosity 1.69 1.69 1.69 1.69 Sheath component polymer nylon 6 nylon 6 nylon 6 nylon 6 relative viscosity 2.71 2.71 2.71 2.71 2.71 Core-sheath ratio core/sheath 30/70 30/70 30/70 30/70 50/50 Hindered phenolic stabilizer type IR1010 IR10 IR10 IR10 IR10 IR10 content (wt%) 2.00 2.00 2.00 2.00 2.00 2.00 5% weight loss temperature (°C) 351 351 351 351 351 HALS type stabilizer type CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020
• Example 2 Except for performing the spinning step at a core/sheath ratio of 70/30 (parts by weight), the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 2.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 83%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 60% and 70%, respectively.
• Example 2 Except for adjusting the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) to 3.0 wt% and 2.0 wt%, respectively, relative to the weight of the core, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 2.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 86%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 70% and 78%, respectively.
• Example 2 Except for adjusting the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) to 3.0 wt% and 3 wt%, respectively, relative to the weight of the core, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 2.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 90%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 75% and 80%, respectively.
• Example 2 Except for adjusting the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) to 4 wt% and 4 wt%, respectively, relative to the weight of the core, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 2.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 93%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 80% and 85%, respectively.
• Example 2 Except for adjusting the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) to 1 wt% and 1 wt%, respectively, relative to the weight of the core, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 2.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a high 75%, and the strength retention rate after heat treatment and the ⁇ MR retention rate after heat treatment were high 55% and 70%, respectively.
• Example 6 Example 7
• Example 8 Example 9
• Example 10 Core component polymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer polyether ester amide copolymer relative viscosity 1.69 1.69 1.69 1.69 Sheath component polymer nylon 6 nylon 6 nylon 6 nylon 6 relative viscosity 2.71 2.71 2.71 2.71 2.71 Core-sheath ratio core/sheath 70/30 30/70 30/70 30/70 30/70 30/70 Hindered phenolic stabilizer type IR1010 IR10 IR10 IR10 IR1010 content (wt%) 2.00 3.00 3.00 4.00 1.00 5% weight loss temperature (°C) 351 351 351 351 351 HALS type stabilizer type CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020FDL CHIMASSROB 2020F
• Example 3 Except for omitting the addition of a hindered phenolic stabilizer and a HALS type stabilizer and adjusting the strength retention rate after dry heat treatment to 30%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• the resulting core-sheath composite yarn had a ⁇ MR retention rate after dry heat treatment of 50%. After undergoing repeated tumble drying, the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• Example 3 Except for omitting the addition of a HALS type stabilizer (CHIMASSORB2020FDL) and adjusting the strength retention rate after dry heat treatment to 40%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• HALS type stabilizer CHIMASSORB2020FDL
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a low 40%, and the ⁇ MR retention rate after heat treatment was 55%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• the hygroscopic performance deteriorated as a result of thermal degradation of the polyethylene glycol component contained in the polyether ester amide copolymer.
• Example 3 Except for omitting the addition of a hindered phenolic stabilizer (IR1010) and adjusting the strength retention rate after dry heat treatment to 33%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• IR1010 hindered phenolic stabilizer
• the resulting core-sheath composite yarn had a ⁇ MR retention rate after heat treatment of 52%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• the hygroscopic performance deteriorated as a result of thermal degradation of the polyethylene glycol component contained in the polyether ester amide copolymer.
• Example 3 Except for adjusting the hindered phenolic stabilizer (IR1010) and HALS type stabilizer (CHIMASSORB2020FDL) to 0.5 wt% and 0.5 wt%, respectively, relative to the weight of the core and adjusting the strength retention rate after dry heat treatment to 45%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• the proportion of the residual hindered phenolic stabilizer in the resulting core-sheath composite yarn was a low 60%, and the ⁇ MR retention rate after heat treatment was 65%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• the hygroscopic performance deteriorated as a result of thermal degradation of the polyethylene glycol component contained in the polyether ester amide copolymer.
• Example 3 Except for using a hindered phenolic stabilizer with a 5% weight loss temperature of 223°C (IR1135, manufactured by BASF) and adjusting the strength retention rate after dry heat treatment to 40%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• the proportion of the residual hindered phenolic stabilizer was 50% and the ⁇ MR retention rate after dry heat treatment was 60%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• the hygroscopic performance deteriorated as a result of thermal degradation of the polyethylene glycol component contained in the polyether ester amide copolymer.
• Example 2 Except for using a HALS type stabilizer with a 5% weight loss temperature of 275°C (Adeka Stab LA-81, manufactured by Adeka Corporation) and adjusting the strength retention rate after dry heat treatment to 45%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn. Physical properties of the resulting fiber are shown in Table 3.
• the proportion of the residual hindered phenolic stabilizer was 63% and the ⁇ MR retention rate after dry heat treatment was 65%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability.
• the hygroscopic performance deteriorated as a result of thermal degradation of the polyethylene glycol component contained in the polyether ester amide copolymer.
• Example 1 Except for replacing the hindered phenolic stabilizer with a phosphorus-based antioxidant (Adeka Stab PEP-36, manufactured by Adeka Corporation, 5% weight loss temperature 316°C) and adjusting the strength retention rate after dry heat treatment to 45%, the same procedure as in Example 1 was carried out to provide a 56-decitex, 24-filament core-sheath composite yarn.
• a phosphorus-based antioxidant Alka Stab PEP-36, manufactured by Adeka Corporation, 5% weight loss temperature 316°C
• the resulting fiber had a fineness of 56 decitex, an elongation percentage of 50%, a strength of 3.0 cN/dtex, a ⁇ MR value of 6.7%, and a ⁇ MR retention rate after dry heat treatment of 60%.
• the raw threads in the resulting core-sheath composite yarn were found to be hard or brittle and have a stiff texture and an inferior durability and hygroscopicity retention property. Thus, the phosphorus-based antioxidant did not work effectively.
• the present invention can provide a core-sheath composite yarn that is high in hygroscopic performance, higher in comfortability than natural fibers, and able to maintain a soft texture, high durability, and moisture absorbing and releasing performance after undergoing repeated washing and drying.

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