EP4212655A1 - Sea-island-type composite fiber, and fiber product including sea-island-type composite fiber - Google Patents

Sea-island-type composite fiber, and fiber product including sea-island-type composite fiber Download PDF

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Publication number
EP4212655A1
EP4212655A1 EP21864348.4A EP21864348A EP4212655A1 EP 4212655 A1 EP4212655 A1 EP 4212655A1 EP 21864348 A EP21864348 A EP 21864348A EP 4212655 A1 EP4212655 A1 EP 4212655A1
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EP
European Patent Office
Prior art keywords
fiber
island
sea
island parts
outermost periphery
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.)
Pending
Application number
EP21864348.4A
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German (de)
English (en)
French (fr)
Inventor
Kirita Sato
Masashi Nagao
Masato Masuda
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Toray Industries Inc
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Toray Industries Inc
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Publication of EP4212655A1 publication Critical patent/EP4212655A1/en
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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
    • D01F8/14—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
    • 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
    • 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
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D10B2331/042—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET] aromatic polyesters, e.g. vectran
    • 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

Definitions

  • the present invention relates to a polyester fiber having hygroscopicity.
  • Polyester fibers typified by polyethylene terephthalate are widely used in clothing applications and industrial applications because of their characteristics, such as having excellent mechanical properties, chemical resistance, and heat resistance, having characteristic texture with tension and stiffness, hardly absorbing moisture and having small change in properties with wet, and having excellent dimensional stability.
  • polyester fibers do not have hygroscopicity, and they have a problem of getting sweaty or sticky particularly in a high-temperature and high-humidity environment in summer.
  • Patent Document 1 proposes a sea-island composite fiber having hygroscopicity in which polyethylene terephthalate is used as a sea part and a polyether block amide copolymer is used as an island part.
  • Patent Document 2 proposes a sea-island composite fiber in which hygroscopicity is imparted to a fiber by using a polymer having hygroscopicity in an island part, and the thickness of a sea part present in an outermost layer in a transverse section of the fiber is controlled to reduce breaking of the sea part in a hot water treatment.
  • the thickness of the sea part and the number of the island parts are defined regarding the arrangement of the island parts in a transverse section of the fiber, but when the single fiber fineness is reduced to obtain a soft texture required for clothing applications, stress generated with volume swelling of the polymer having hygroscopicity in a hot water treatment cannot disperse, and breaking such as cracks may occur in the fiber surface. In this case, the quality of a woven or knitted fabric or the like may degrade because of generation of dyeing unevenness, fuzz, and the like.
  • the fiber surface may break when the fibers or a textile made of the fibers are worn, which has been a problem in applying the fibers to clothing that is repeatedly washed, such as an inner, clothing that is repeatedly abraded, such as sports clothing, and the like.
  • an object of the present invention is to solve the above problems, in which breaking of the fiber surface is dramatically reduced by dispersing the stress generated with volume swelling of the fiber at the time of moisture absorption. Further, an object of the present invention is to provide a polyester fiber that is free from dyeing unevenness, fuzz, and the like when formed into a woven or knitted fabric, has excellent quality, and does not decrease its hygroscopicity because of a hot water treatment or the like.
  • the present invention has the following configuration.
  • the present invention in which stress generated with volume swelling of the fiber at the time of moisture absorption can be dispersed and breaking of the fiber surface is reduced, is free from dyeing unevenness, fuzz, and the like when it is formed in a woven or knitted fabric, with which a polyester fiber excellent in quality can be obtained.
  • the fiber since the hygroscopicity does not degrade, the fiber has excellent hygroscopicity, and it can be suitably used particularly in clothing applications.
  • the polyester fiber of the present invention includes an aromatic polyester as a main component. Having an aromatic polyester as the main component allows the polyester fiber to have excellent mechanical properties and heat resistance, and thus the polyester fiber has a favorable tactile sensation such as tension, stiffness, and dry feeling. Further, since the polyester fiber of the present invention has excellent hygroscopicity with a moisture absorption/release parameter ⁇ MR of 2.0% or more, the polyester fiber can obtain a fiber structure body excellent in wearing comfort as a cooling material.
  • the fiber having hygroscopicity incorporates water molecules through physical adsorption of water molecules to the fiber and/or formation of an interaction between a functional group in a molecular structure of a component constituting the fiber and water molecules.
  • water molecules are incorporated into the fiber, and thus the fiber is swollen in volume.
  • aromatic polyesters which have rigid aromatic rings in their polymer structures, are hardly deformed, and stress generated with volume swelling due to moisture absorption cannot disperse, which may cause cracks and the like in the fiber surface.
  • the centroids of the components disposed on the outermost periphery among the components disposed inside the fiber in a transverse section of the fiber form a regular polygon with line segments connecting the centroids as vertexes.
  • the sectional form of the fiber having components disposed inside the fiber in a transverse section of the fiber is preferably a sea-island composite fiber composed of two or more polymers, and the components disposed inside the fiber is island parts.
  • the figure obtained by connecting the centroids of the components disposed on the outermost periphery among the components disposed inside the fiber in a transverse section of the fiber that is, the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery in a transverse section of the fiber with line segments, is drawn by selecting the centroids such that the line segments do not intersect with each other except for the centroids as shown in Fig. 1(a) when the centroids of the island parts are connected with the line segments.
  • the line segments intersect each other at a part other than the centroids of the island parts.
  • a figure drawn at this time is not included in the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments in the present invention.
  • FIG. 1(c) with respect to an island part 2f, other island parts (2a, 2b, 2c, 2d, 2e) are disposed between the island part 2f and the fiber surface.
  • the island part 2f is not included in the island part disposed on the outermost periphery in a transverse section of the fiber.
  • n line segments is an n-sided polygon, and the length of each line segment is A1, A2, A3 ⁇ An.
  • the average value of the lengths of these line segments is Lx, the ratio (A1/Lx, A2/Lx, A3/Lx ...
  • An/Lx) of the length of each line segment to the average value Lx is obtained by rounding off the ratio to the second decimal place, and the ratio is 0.97 to 1.03, it means that the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery in a transverse section of the fiber with line segments is a regular n-sided polygon.
  • the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery in a transverse section of the fiber with line segments is a regular polygon having the centroids as vertexes, vectors of stress generated when the fiber swells in volume because of moisture absorption are diametrically opposite between adjacent island parts, and the stress is canceled between the island parts, which can reduce stress to propagate to the sea part on the fiber surface side. Because the stress to propagate to the sea part on the fiber surface side is reduced, the fiber surface hardly breaks, and generation of dyeing unevenness and fuzz can be reduced.
  • the island components disposed on the outermost periphery are disposed in a regular polygon to greatly improve the problem in the conventional composite fiber having a hygroscopic component, and the number of island parts disposed on the outermost periphery in a transverse section of the fiber is preferably an odd number.
  • the number of island parts disposed on the outermost periphery in a transverse section of the fiber is more preferably an odd number of 9 or less, still more preferably an odd number of 5 or less, and the minimum number of the island parts is 3.
  • the total number of the island parts in a transverse section of the fiber is preferably 15 or less. Setting the total number of the island parts in such a range can reduce concentration of stress generated with volume swelling due to moisture absorption in a linear shape, can disperse the stress, and can reduce breaking of the fiber surface. Thus, the fiber can reduce generation of dyeing unevenness and fuzz caused by breaking of the fiber surface and obtain excellent quality when the fiber is formed into a woven or knitted fabric.
  • the total number of the island parts in a transverse section of the fiber is more preferably 10 or less, still more preferably 6 or less, and the minimum number of the island parts is 3.
  • a ratio C/L of the radius of curvature C ( ⁇ m) of a side on the fiber surface side of the outer periphery of an island part disposed on the outermost periphery in a transverse section of the fiber to the radius L ( ⁇ m) of a circumscribed circle including the island parts disposed on the outermost periphery in a transverse section pf the fiber is preferably 0.50 to 0.90.
  • the circumscribed circle including the island parts disposed on the outermost periphery in a transverse section of the fiber is the circle 4 in Fig. 2(b)
  • L is a radius of the circle 4.
  • the radius of curvature C of a side on the fiber surface side of the outer periphery of an island part disposed on the outermost periphery in a transverse section of the fiber is the radius of the circle 5 in Fig. 2(c) obtained by the method described in Examples.
  • C/L indicates the sharpness of the curve of the side on the fiber surface side of the outer periphery of the island part disposed on the outermost periphery in a transverse section of the fiber with respect to the fiber surface.
  • C/L is 0.50 or more, stress generated with volume swelling at the time of moisture absorption is uniformly applied and dispersed in the sea part, and the fiber surface hardly breaks.
  • C/L is more preferably 0.55 or more, still more preferably 0.60 or more.
  • C/L is 0.90 or less
  • the curve of the side part on the fiber surface side of the outer periphery of the island part disposed on the outermost periphery in a transverse section of the fiber does not become large, and no corners are formed.
  • stress generated with volume swelling at the time of moisture absorption does not concentrate on these parts, and the fiber surface hardly breaks.
  • C/L is more preferably 0.85 or less, still more preferably 0.80 or less.
  • the fact that C/L is 1.0 indicates that the bending of the fiber surface is equivalent to the curve of the side on the fiber surface side of the outer periphery of the island part disposed on the outer periphery.
  • a specific example of a transverse section of the fiber in this case includes a core-sheath composite fiber having one island part.
  • the ratio L/R of the radius L ( ⁇ m) of the circumscribed circle including all the island parts disposed on the outermost periphery in a transverse section of the fiber to the fiber radius R ( ⁇ m) is preferably 0.50 to 0.90.
  • L/R indicates the thickness of the sea part between the fiber surface and the island parts disposed on the outermost periphery in a transverse section of the fiber.
  • L/R is more preferably 0.80 or less, still more preferably 0.60 or less.
  • a ratio S/L of the minimum distance S ( ⁇ m) between island parts in a transverse section of the fiber to the radius L ( ⁇ m) of the circumscribed circle including all the island parts disposed on the outermost periphery in the transverse section of the fiber is preferably 0.05 to 0.50.
  • the minimum distance between island parts in a transverse section of the fiber is the line segment 7 in Fig. 2(d) obtained by the method described in Examples.
  • the minimum distance between the island parts in a transverse section of the fiber is the thickness of the sea parts sandwiched between two adjacent island parts.
  • S/L is 0.05 or more, stress generated with volume swelling at the time of moisture absorption is relaxed in the sea part between the island parts, propagation of stress to the sea part is reduced, and breaking of the fiber surface can be reduced.
  • S/L is more preferably 0.10 or more, still more preferably 0.15 or more.
  • S/L is 0.50 or less, since the distance between island parts is not long, a stress relaxation effect by the sea part between the island parts is exhibited, propagation of stress to the sea part on the fiber surface side can be reduced, and breaking of the fiber surface can be reduced. Based on this idea, S/L is more preferably 0.40 or less, still more preferably 0.30 or less.
  • the minimum thickness of the sea part is preferably 0.3 um or more.
  • the minimum thickness of the sea part is the smallest distance among the distances between the intersection of a straight line and the outer periphery of any island part and the intersection of the straight line and any fiber surface, the straight line being drawn from the centroid of the island part in a transverse section of the fiber toward the fiber surface by the method described in Examples.
  • the minimum thickness is the length of the line segment 6 in Fig. 2(c) .
  • breaking of the sea part due to stress generated with volume swelling at the time of moisture absorption can be reduced, generation of dyeing unevenness and fuzz due to breaking of the fiber surface caused by breaking of the sea part can be reduced, and the fiber has excellent quality when formed into a woven or knitted fabric.
  • the minimum thickness is more preferably 1.0 um or more, still more preferably 2.5 um or more.
  • the composite ratio of the sea part/island part of the polyester fiber of the present invention is preferably 50/50 to 90/10 in terms of weight ratio.
  • the proportion of the sea part is 50 wt% or more, the aromatic polyester of the sea part provides excellent mechanical properties and heat resistance, tension, stiffness, and dry feeling, and a fiber structure body excellent in wearing comfort can be obtained.
  • breaking of the sea part due to stress generated with volume swelling at the time of moisture absorption can be reduced, and generation of dyeing unevenness and fuzz due to breaking of the fiber surface caused by breaking of the sea part is reduced, and the fiber has excellent quality when formed into a woven or knitted fabric.
  • the proportion of the sea part is more preferably 60 wt% or more, still more preferably 70 wt% or more.
  • the proportion of the sea part of the polyester fiber is 90 wt% or less, that is, the proportion of the island part is 10 wt% or more, the rigidity with the thickness of the aromatic polyester disposed in the sea part can be reduced, and stress generated with volume swelling at the time of moisture absorption can be reduced.
  • the proportion of the sea part is more preferably 85 wt% or less, still more preferably 80 wt% or less.
  • the polyester fiber of the present invention has a moisture absorption/release parameter ⁇ MR, which is an index of hygroscopicity, of 2.0% or more.
  • ⁇ MR is a difference in the moisture absorption rate of a fiber at a high temperature and a high humidity represented by 30°C ⁇ 90% RH and at a temperature and a humidity in a standard state represented by 20°C ⁇ 65% RH, and the higher ⁇ MR is, the higher the hygroscopicity of the fiber is.
  • ⁇ MR is 2.0% or more, stuffy feeling in clothes is small, and wearing comfort is exhibited.
  • the range of ⁇ MR is more preferably 2.5% or more, still more preferably 3.0% or more, and particularly preferably 4.0% or more.
  • polyester fiber of the present invention satisfies the above-described range of ⁇ MR before and after a hot water treatment such as dyeing.
  • the aromatic polyester as the main component of the polyester fiber of the present invention is a polymer composed of a combination of an aromatic dicarboxylic acid and an aliphatic diol, an aliphatic dicarboxylic acid and an aromatic diol, and an aromatic dicarboxylic acid and an aromatic diol.
  • an aromatic polyester composed of a combination of an aromatic dicarboxylic acid and an aliphatic diol.
  • aromatic dicarboxylic acid examples include, but are not limited to, terephthalic acid, isophthalic acid, phthalic acid, 5-sodium sulfoisophthalic acid, 5-lithium sulfoisophthalic acid, 5-(tetraalkyl) phosphonium sulfoisophthalic acid, 4,4'-diphenyl dicarboxylic acid, and 2,6-naphthalene dicarboxylic acid.
  • aliphatic diol examples include, but are not limited to, ethylene glycol, 1,3-propanediol, 1,4-butanediol, hexanediol, cyclohexanediol, diethylene glycol, hexamethylene glycol, and neopentyl glycol.
  • the method for producing the aromatic polyester in the present invention is not limited, and the aromatic polyester may be produced by synthesizing monomers by a general polycondensation reaction, an addition polymerization reaction, or the like when raw materials at the time of production are comprehensively used as the monomers.
  • the monomers are not limited, and examples thereof include petroleum-derived monomers, biomass-derived monomers, and mixtures of the petroleum-derived monomers and the biomass-derived monomers.
  • the aromatic polyester in the present invention may be copolymerized or mixed with a second and third components in addition to the main component without departing from the object of the present invention.
  • the copolymerization amount is 10 mol% or less as the monomer amount of the copolymerization component with respect to the total monomer amount.
  • the main component of the sea part is an aromatic polyester as described above.
  • aromatic polyesters typically do not have a functional group or the like that forms a strong interaction with water molecules in the polymer structure.
  • adding a hygroscopic compound, disposing a polymer having high hygroscopicity hereinafter, it may be referred to as hygroscopic polymer
  • hygroscopic polymer a polymer having high hygroscopicity
  • treating polymer molecules on the fiber surface with ozone or the like to generate a hygroscopic functional group, and the like are given.
  • it is preferable to dispose a hygroscopic polymer in the island parts with consideration of obtaining a polyester fiber having excellent hygroscopicity.
  • Examples of the hygroscopic polymer suitably disposed in the island parts of the polyester fiber of the present invention include polyether esters, polyether amides, polyether ester amides, polyamides, thermoplastic cellulose derivatives, and polyvinylpyrrolidone.
  • polyether esters, polyether amides, and polyether ester amides containing a polyether as a copolymerization component are excellent in stability in melt molding, have high hygroscopicity which is intended, and are more preferably used for the polyester fiber of the present invention.
  • polyether esters having excellent affinity with the aromatic polyester in the sea part and excellent heat resistance of the hygroscopic polymer, have an effect of improving the mechanical properties of the resulting sea-island composite fiber, and they are particularly preferably used in the present invention.
  • a polyether ester composed of polybutylene terephthalate having excellent crystallinity and a polyether is more preferable since elution of the hygroscopic polymer into hot water can be reduced.
  • the hygroscopic polymer as described above has high affinity with water and is easily eluted when brought into contact with water or hot water in a dyeing treatment.
  • breaking of the fiber surface occurs because of stress generated with volume swelling at the time of moisture absorption, the hygroscopic polymer in the island parts may come into contact with hot water and elute off the fiber, leading to degradation of the hygroscopicity of the fiber.
  • the hygroscopic polymer is disposed in the island parts, the effect of reducing breaking of the fiber surface because of the composite sectional shape of the polyester fiber of the present invention is remarkably exhibited, and a polyester fiber having excellent hygroscopicity is obtained.
  • the second and third components may be copolymerized or mixed in addition to the main component without departing from the object of the present invention, and the copolymerization amount is 10 mol% or less as the monomer amount of the copolymerization component with respect to the total monomer amount.
  • sectional shape of the polyester fiber of the present invention not only a round section but also a wide variety of sectional shapes, such as a flat shape, a Y shape, a T shape, a hollow shape, a cross-in-square shape, and a shape like a hash tag, may be employed.
  • the polyester fiber of the present invention may be in any form, such as a long fiber (filament) or a short fiber (staple).
  • a long fiber a monofilament composed of one single yarn or a multifilament composed of a plurality of single yarns may be used.
  • a short fiber the cut length and the number of crimps are not limited.
  • the total fineness of the polyester fiber of the present invention may be appropriately set according to the application, but it is preferably 8 dtex or more and 150 dtex or less in the case of a long fiber for clothing in practice.
  • the strength is preferably 1.5 cN/dtex or more for clothing, but the polyester fiber with a strength of 1.5 cN/dtex or less can also be used without any problems by taking measures such as using the fiber together with other fibers in producing a fabric.
  • the elongation may be appropriately set according to the application, but it is preferably 25% or more and 60% or less from the viewpoint of processability in processing into a fabric.
  • the polyester fiber of the present invention preferably has a single fiber fineness of 6.0 dtex or less. Having a single fiber fineness in such a range can reduce rigidity with the thickness of the aromatic polyester disposed in the sea part, and in addition, a fiber structure body having excellent mechanical properties and heat resistance, tension, stiffness, and dry feeling, and excellent wearing comfort can be obtained. In addition, breaking of the sea part due to stress generated with volume swelling at the time of moisture absorption can be reduced, and generation of dyeing unevenness and fuzz due to breaking of the fiber surface caused by breaking of the sea part is reduced, and the fiber has excellent quality when formed into a woven or knitted fabric.
  • the single fiber fineness is more preferably 4.0 dtex or less, still more preferably 2.0 dtex or less.
  • polyester fiber of the present invention may be obtained by known methods of melt spinning and composite spinning, and examples thereof are as follows.
  • the spinning method and the composite method are not limited to those exemplified herein.
  • the polyester fiber of the present invention composed of two or more polymers may be produced by a melt spinning method for the purpose of producing a long fiber, a solution spinning method such as a wet method or a dry-wet method, a melt blowing method and a spunbonding method suitable for obtaining a sheet-shaped fiber structure, or the like, and the melt spinning method is suitable from the viewpoint of enhancing productivity.
  • the melt spinning method it is preferable to use a composite spinneret described later.
  • the spinning temperature at that time is set to a temperature at which a polymer having a high-melting point or a high-viscosity polymer among polymer types to be used exhibits fluidity.
  • the temperature at which the polymer exhibits fluidity varies depending on the molecular weight, but when the temperature is set between the melting point of the polymer and the melting point + 60°C, the fiber can be stably produced.
  • a production method by a melt spinning method includes, for example, separately melting a polymer in the sea part and a polymer in the island part, measuring and transporting them by using a gear pump, forming a composite flow to have a specific composite structure as it is by an ordinary method, and discharging the composite flow from a spinneret, cooling a thread to room temperature by blowing cooling air with a thread cooling device such as a chimney, converging the thread with a supply of oil from an oil supply device, entangling the thread with a fluid entangling nozzle device, and passing the thread through a take-up roller and a stretching roller, and then stretching the thread according to a ratio of peripheral speeds of the take-up roller and the stretching roller.
  • the method includes thermally setting the thread with a stretching roller and winding the thread with a winder (winding device).
  • a winder winding device.
  • the circumferential speeds of the take-up roller and the stretching roller are set to the same speed, and the thread is wound with a winder at the same speed to once form an unstretched yarn, and the yarn is stretched in a separate step.
  • polyester fiber of the present invention when the melt viscosity ratio of two or more polymers used in the sea part and the island part is less than 5.0, a composite polymer flow can be stably formed, and a fiber having a good composite section can be obtained, which is preferable.
  • a composite spinneret described in Japanese Patent Laid-open Publication No. 2011-208313 is preferably used as the composite spinneret used in production of the polyester fiber of the present invention.
  • the composite spinneret shown in Fig. 3 of the present application is incorporated into a spinning pack in a state where mainly three types of members, that is, a measuring plate 8, a distribution plate 9, and a discharge plate 10 are stacked in this order from the top, and the spinneret is used for spinning.
  • Fig. 3 is an example in which two polymers of A polymer and B polymer are used.
  • the measuring plate 8 has a role of measuring the amount of the polymer per discharge hole and per distribution hole and flowing the polymer into the distribution plate 9.
  • the distribution plate 9 has a role of controlling the composite section and the sectional shape in the single fiber section, and the discharge plate 10 has a role of compressing and discharging the composite polymer flow formed with the distribution plate 9.
  • a member having a channel may be used in accordance with the spinning machine and the spinning pack.
  • the measuring plate 8 in accordance with the existing channel member, the existing spinning pack and members of the spinning pack can be used as they are, and there is no need to exclusively use a spinning machine for the spinneret.
  • a plurality of channel plates may be stacked between the channel and the measuring plate 8 or between the measuring plate 8 and the distribution plate 9. With this configuration, a flow path can be provided through which the polymer is efficiently transferred and introduced into the distribution plate 9 in the spinneret sectional direction and the single-fiber sectional direction.
  • the composite polymer flow discharged from the discharge plate 10 is cooled and solidified according to the above production method, then an oil agent is applied to the composite polymer flow, and the composite polymer flow is taken up by a roller having a specified peripheral speed, whereby a fiber having a desired composite section is obtained.
  • the polyester fiber of the present invention can be subjected to post-processing such as false twisting or twisting, and it can be handled for weaving and knitting in the same manner as in common fibers.
  • the polyester fiber of the present invention and/or its post-processed yarn may be formed into a fiber structure such as a woven fabric, a knitted fabric, a pile fabric, a nonwoven fabric, a spun yarn, or batting according to a known method.
  • the fiber structure composed of the polyester fiber of the present invention and/or its post-processed yarn may be any woven or knitted structure.
  • a plain weave, a twill weave, a satin weave, or a weave changed from these weaves; or warp knitting, weft knitting, circular knitting, lace stitching, knitting or stitching changed from these knitting or stitching or the like can be suitably employed.
  • the polyester fiber of the present invention may be combined with other fibers by union weaving or union knitting in the formation of the fiber structure, or it may be combined with other fibers to form a combined filament yarn and then the combined filament yarn may be formed into a fiber structure.
  • the fiber structure body composed of the polyester fiber of the present invention and/or its post-processed yarn is excellent in hygroscopicity, and therefore it can be suitably used in applications requiring comfort and quality.
  • the applications include, but are not limited to, general clothing applications, sports apparel applications, bedding applications, interior applications, and materials applications.
  • a polymer sample having a moisture content set to 300 ppm or less with a vacuum dryer was put into a heating furnace set at the same temperature as the spinning temperature, melted under a nitrogen atmosphere, and extruded from a capillary at the tip of the heating furnace while changing the strain rate stepwise, then the viscosity was measured with Capilograph manufactured by Toyo Seiki Seisaku-sho, Ltd. The measurement was started after the sample was put into the heating furnace and left for 5 minutes, and the value at a shear rate of 1216 sec -1 was taken as the melt viscosity of the polymer.
  • DSC differential scanning calorimeter
  • a hank was made by winding the sample yarn 200 times using a wrap reel with a frame circumference of 1.125 m, the hank was dried with a hot-air dryer (105 ⁇ 2°C ⁇ 60 minutes), then the hank was weighed with a balance, and the total fineness was calculated from a value obtained by multiplying the weight by official moisture regain. The measurement was performed four times, and the average was defined as the total fineness.
  • the tensile strength was defined as the value obtained by dividing the maximum strength by the total fineness.
  • a hank was made by winding the fiber sample 20 times using a warp reel with a frame circumference of 1.125 m, and an initial length L 0 of the sample was determined under a load of 0.09 cN/dtex. Next, the sample was treated in boiling water under no load for 30 minutes, and then air-dried. Subsequently, a length L 1 of the sample after the treatment under a load of 0.09 cN/dtex was obtained, then calculated with Formula (1).
  • Boiling water shrinkage percentage % L 0 ⁇ L 1 / L 0 ⁇ 100
  • a tubular knitting was produced by adjusting the fiber sample to have a density of 50 using a circular knitting machine NCR-BL (pot diameter 3 inch and half (8.9 cm), 27 gauge) manufactured by EIKO INDUSTRIAL CO., LTD.
  • NCR-BL pot diameter 3 inch and half (8.9 cm), 27 gauge
  • the fiber was appropriately combined so that the total fineness of the fiber to be fed to the tubular knitting machine was 80 to 160 dtex, and when the total fineness was more than 80 dtex, one yarn was fed to the tubular knitting machine, and the tubular knitting was produced by adjusting the fiber sample to have the density of 50 as described above.
  • the obtained tubular knitting was charged into an aqueous solution containing sodium carbonate at 1 g/L and a surfactant SUNMORL BK-80 manufactured by NICCA CHEMICAL, CO., LTD, treated for 20 minutes with the aqueous solution whose temperature was raised to 80°C, and then dried in a hot air dryer at 60°C for 60 minutes.
  • the tubular knitting after drying was subjected to a hot water treatment under the conditions of a bath ratio of 1 : 100, a treatment temperature of 130°C, and a treatment time of 60 minutes, and then dried in a hot air dryer at 60°C for 60 minutes to obtain a tubular knitting after the hot water treatment.
  • ⁇ MR was calculated according to the description of item F.
  • the fiber sample was embedded in an embedding agent such as an epoxy resin, and an image was taken at a magnification at which 10 or more single fibers can be observed with a scanning electron microscope (SEM) manufactured by HITACHI, Ltd. in a fiber transverse section in a direction perpendicular to the fiber axis.
  • SEM scanning electron microscope
  • the obtained image was analyzed using computer software WinROOF manufactured by MITANI CORPORATION to determine the radius of curvature C of a side on the fiber surface side of the outer periphery of the island part disposed on the outermost periphery in the fiber transverse section.
  • a straight line was drawn from the centroid G of the island part toward any fiber surface, the length of the line segment BF including the intersection B of the outer periphery of the island part and the straight line and the intersection F of the fiber surface and the straight line was measured to the second decimal place, and the intersection B at which the length of the line segment BF has the minimum value was obtained.
  • This operation was performed on all the island parts included in one single fiber, and this operation was further performed on three single fibers randomly extracted, and the average value of the obtained radiuses was obtained and rounded off to the second decimal place. This value was defined as the radius of curvature C ( ⁇ m).
  • a tubular knitting produced by the method described in the item G and subjected to the hot water treatment was vapor-deposited with a platinum-palladium alloy and observed at a magnification of 1,000 using scanning electron microscope (SEM) S-4000 manufactured by HITACHI, Ltd., and micrographs of 10 fields were randomly taken.
  • SEM scanning electron microscope
  • a tubular knitting was produced by the method described in the item G, and the obtained tubular knitting was charged into an aqueous solution containing sodium carbonate at 1 g/L and a surfactant SUNMORL BK-80 manufactured by NICCA CHEMICAL, CO., LTD, treated for 20 minutes with the aqueous solution whose temperature was raised to 80°C, and then dried in a hot air dryer at 60°C for 60 minutes. Next, the tubular knitting was subjected to dry heat setting at 160°C for 2 minutes. The tubular knitting after the dry heat setting was charged into a dyeing solution in which 1.3 wt% of Kayalon Polyester Blue UT-YA manufactured by NIPPON KAYAKU, Co., Ltd.
  • the L value was measured three times per sample using a spectrophotometer CM-3700d manufactured by Minolta Co., Ltd. with a D65 light source and a viewing angle of 10° under an optical condition of SCE (specular component excluded), and the average value thereof was rounded off to the first decimal place to obtain the L value of the sample.
  • This operation was performed on 10 samples randomly extracted, and the variation rate was obtained from the average value and standard deviation of the L values of 10 samples. When the variation rate of the L value of the 10 samples was 5.0% or less, it was determined that there was no dyeing unevenness.
  • the fiber sample was run at 600 m/min and measured for 10,000 m, and the fuzz number displayed on the apparatus was counted.
  • a warping reed (made of stainless steel, with an interval of 1 mm between reeds) was provided before the measurement point, and the fiber was passed therethrough. This measurement was repeated 10 times, the average value at 10,000 m was taken as the fuzz number, and when the fuzz number was 10/10,000 m or less, it was regarded as pass.
  • a tubular knitting produced by the method described in the item G and subjected to the hot water treatment was held at a temperature of 20°C and a relative humidity of 65% for 24 hours, and then the mass thereof was measured and taken as w a .
  • 0.3 ml of water was dripped to the center of the sample, and the mass was measured. This mass was defined as w 0min .
  • the moment when water was dripped to the sample was defined as 0 minutes, the mass of the sample was measured at intervals of 5 minutes, and the mass was defined as w nmin .
  • n minutes represents a freely-selected time at which the mass of the sample was measured, having 5 minutes of intervals, such as 5 minutes, 10 minutes, and 15 minutes.
  • the moisture residual ratio WR at the free-selected time was calculated from Formula (5).
  • WR w 0 min ⁇ w nmin / w 0 min ⁇ w a ⁇ 100
  • the time at which the moisture residual ratio WR calculated from Formula (5) was less than 30% was 60 minutes or less, it was determined that the sample has water-absorbing and quick-drying properties.
  • Polyethylene terephthalate (melt viscosity: 120 Pa ⁇ s, melting point: 254°C) was used as the sea part, and polybutylene terephthalate (melt viscosity: 50 Pa ⁇ s, melting point: 217°C) copolymerized with 50 wt% of polyethylene glycol having a number average molecular weight of 8,300 g/mol (PEG6000S manufactured by Sanyo Chemical Industries, Ltd.) was used as the island part.
  • the polymers for the sea part and the island part were separately melted at a spinning temperature of 285°C, and then weighed such that the sea-island ratio was 80 : 20 in terms of weight ratio.
  • the polymers were allowed to flow into a spinning pack incorporating the composite spinneret shown in Fig. 3 , and the inflow polymers were discharged from discharge holes (hole diameter: 0.30 mm, number of holes: 36 holes) to have a sea-island composite form in which the number of island parts disposed on the outermost periphery was 3, and the total number of island parts was 3.
  • the discharged composite polymer flow was cooled and solidified with a cooling device, supplied with a water-containing oil agent from an oil supply device, and then wound up at a peripheral speed of a take-up roller as a first roller of 2,000 m/min, a peripheral speed of a stretching roller as a second roller of 2,000 m/min, and a winding speed of a winder of 2,000 m/min to obtain a polyester fiber of unstretched yarn of 200 dtex and 36 filaments.
  • the obtained unstretched yarn was stretched at a first roller temperature of 90°C, a second roller temperature of 130°C, and a stretch ratio represented by a ratio between peripheral speeds of the first roller and the second roller of 2.38 times to obtain a stretched yarn of polyester fiber of 84 dtex and 36 filaments.
  • a stretch ratio represented by a ratio between peripheral speeds of the first roller and the second roller of 2.38 times to obtain a stretched yarn of polyester fiber of 84 dtex and 36 filaments.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 1, except that the sea part was changed to polyethylene terephthalate (melt viscosity: 170 Pa ⁇ s, melting point: 244°C) copolymerized with 1.5 mol% of 5-sulfoisophthalic acid sodium salt and 1.0 wt% of polyethylene glycol having a number average molecular weight of 1,000 g/mol (PEG1000 manufactured by Sanyo Chemical Industries, Ltd.).
  • a stretched yarn of polyester fiber of 84 dtex and 72 filaments was obtained under the same conditions as in Example 2 except that the number of discharge holes was 72, a polyester fiber of unstretched yarn of 155 dtex and 72 filaments was obtained, and the obtained unstretched yarn was stretched at a stretch ratio of 1.84 times.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 0.99, 0.99, and 1.02, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 1.
  • a stretched yarn of polyester fiber of 84 dtex and 14 filaments was obtained under the same conditions as in Example 2 except that the number of discharge holes was 14, a polyester fiber of unstretched yarn of 258 dtex and 14 filaments was obtained, and the obtained unstretched yarn was stretched at a stretch ratio of 3.07 times.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 0.97, 1.00, and 1.03, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 1.
  • a stretched yarn of polyester fiber of 84 dtex and 72 filaments was obtained under the same conditions as in Example 3 except that the sea-island ratio was 50 : 50 in terms of weight ratio.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.00, 0.99, and 1.01, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 1.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 1 except that the sea part was changed to polyethylene terephthalate (melt viscosity: 40 Pa ⁇ s, melting point: 254°C).
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 0.98, 1.03, and 0.99, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 1.
  • a stretched yarn of polyester fiber of 84 dtex and 72 filaments was obtained under the same conditions as in Example 3 except that the sea part was changed to polyethylene terephthalate (melt viscosity: 40 Pa ⁇ s, melting point: 254°C), and the sea-island ratio was 50 : 50 in terms of weight ratio.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.03, 1.01, and 0.97, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 1.
  • a stretched yarn of polyester fiber of 66 dtex and 96 filaments was obtained under the same conditions as in Example 3 except that a polyester fiber of unstretched yarn of 115 dtex and 96 filaments was obtained with discharge holes having a hole diameter of 0.23 mm and the number of holes of 96, and the obtained unstretched yarn was stretched at a stretch ratio of 1.72.
  • a stretched yarn of polyester fiber of 56 dtex and 144 filaments was obtained under the same conditions as in Example 3 except that a polyester fiber of unstretched yarn of 88 dtex and 144 filaments was obtained with discharge holes having a hole diameter of 0.20 mm and the number of holes of 144, and the obtained unstretched yarn was stretched at a stretch ratio of 1.57.
  • Polyethylene terephthalate (melt viscosity: 68 Pa ⁇ s, melting point: 251°C) copolymerized with 16 wt% of polyethylene glycol having a number average molecular weight of 8,300 g/mol (PEG6000S manufactured by Sanyo Chemical Industries, Ltd.) was used as the sea part, and polyethylene terephthalate (melt viscosity: 120 Pa ⁇ s, melting point: 254°C) was used as the island part.
  • the polymers for the sea part and the island part were separately melted at a spinning temperature of 285°C, and then weighed such that the sea-island ratio was 90 : 10 in terms of weight ratio.
  • the polymers were allowed to flow into a spinning pack incorporating the composite spinneret shown in Fig. 3 , and the inflow polymers were discharged from discharge holes (hole diameter: 0.30 mm, number of holes: 36 holes) to have a sea-island composite form in which the number of island parts disposed on the outermost periphery was 3, and the total number of island parts was 3.
  • the discharged composite polymer flow was cooled and solidified with a cooling device, supplied with a water-containing oil agent from an oil supply device, and then wound up at a peripheral speed of a take-up roller as a first roller of 2,000 m/min, a peripheral speed of a stretching roller as a second roller of 2,000 m/min, and a winding speed of a winder of 2,000 m/min to obtain a polyester fiber of unstretched yarn of 215 dtex and 36 filaments.
  • the obtained unstretched yarn was stretched at a first roller temperature of 90°C, a second roller temperature of 130°C, and a stretch ratio represented by a ratio between peripheral speeds of the first roller and the second roller of 2.48 times to obtain a stretched yarn of polyester fiber of 84 dtex and 36 filaments.
  • a stretch ratio represented by a ratio between peripheral speeds of the first roller and the second roller of 2.48 times to obtain a stretched yarn of polyester fiber of 84 dtex and 36 filaments.
  • Polyethylene terephthalate (melt viscosity: 170 Pa ⁇ s, melting point: 244°C) copolymerized with 1.5 mol% of 5-sulfoisophthalic acid sodium salt and 1.0 wt% of polyethylene glycol having a number average molecular weight of 1,000 g/mol (PEG1000 manufactured by Sanyo Chemical Industries, Ltd.) was used as the sea part.
  • the master chip was chip-blended with polycaprolactam (sulfuric acid relative viscosity: 2.71, melting point: 220°C) containing no additives to prepare a polycaprolactam blended polymer having a polyvinylpyrrolidone additive rate of 5.0 wt%, and this blended polymer (melt viscosity: 130 Pa ⁇ s, melting point: 220°C) was used as the island part.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 1 except that the polymers were combined as the sea part and the island part, and the sea-island ratio was 50 : 50 in terms of weight ratio.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 2 except that the island part was changed to "PEBAX MH1657" (melt viscosity: 45 Pa ⁇ s, melting point: 203°C) manufactured by Arkema Inc.
  • PEBAX MH1657 melt viscosity: 45 Pa ⁇ s, melting point: 203°C
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.01, 1.01, and 0.98, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 2.
  • a stretched yarn of polyester fiber of 84 dtex and 72 filaments was obtained under the same conditions as in Example 3 except that the polymers were allowed to flow into a spinning pack incorporating the composite spinneret shown in Fig. 3 , and the inflow polymers were discharged from discharge holes (hole diameter: 0.30 mm, number of holes: 72 holes) to have a sea-island composite form in which the number of island parts disposed on the outermost periphery was 5, and the total number of island parts was 6.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 2 except that the polymers were allowed to flow into a spinning pack incorporating the composite spinneret shown in Fig. 3 , and the inflow polymers were discharged from discharge holes (hole diameter: 0.30 mm, number of holes: 36 holes) to have a sea-island composite form in which the number of island parts disposed on the outermost periphery was 9, and the total number of island parts was 12.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 2 except that the sea-island ratio was 65 : 35 in terms of weight ratio.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.01, 0.98, and 1.01, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the evaluation results of the obtained polyester fiber are shown in Table 2.
  • Example 1 Example 2
  • Example 3 Example 4 Sea part Polymer type PET SIPA-PET SIPA-PET SIPA-PET Melt viscosity (Pa ⁇ s) 120 170 170 170 Island part Polymer type PBT-PEG PBT-PEG PBT-PEG PBT-PEG Melt viscosity (Pa ⁇ s) 50 50 50 50 Spinning conditions Melt viscosity ratio between sea part and island part 2.4 3.4 3.4 3.4 Sea-island composite ratio 80/20 80/20 80/20 80/20 Stretch ratio 2.38 2.38 1.84 3.07 Transverse section of fiber Figure formed by centroids of outermost peripheral island parts Regular triangle Regular triangle Regular triangle Regular triangle Number of outermost peripheral island parts 3 3 3 3 3 Total number of island parts 3 3 3 3
  • Polyethylene terephthalate (melt viscosity: 120 Pa.s, melting point: 254°C) was used as the sea part, and polybutylene terephthalate (melt viscosity: 50 Pa ⁇ s, melting point: 217°C) copolymerized with 50 wt% of polyethylene glycol having a number average molecular weight of 8,300 g/mol (PEG6000S manufactured by Sanyo Chemical Industries, Ltd.) was used as the island part.
  • the polymers for the sea part and the island part were separately melted at a spinning temperature of 285°C, and then weighed such that the sea-island ratio was 80 : 20 in terms of weight ratio.
  • the polymers were allowed to flow into a spinning pack incorporating the composite spinneret shown in Fig. 3 , and the inflow polymers were discharged from discharge holes (hole diameter: 0.30 mm, number of holes: 36 holes) to have a core-sheath composite form in which the number of island parts disposed on the outermost periphery was 1, and the total number of islands was 1.
  • the discharged composite polymer flow was cooled and solidified with a cooling device, supplied with a water-containing oil agent from an oil supply device, and then wound up at a peripheral speed of a take-up roller as a first roller of 2,000 m/min, a peripheral speed of a stretching roller as a second roller of 2,000 m/min, and a winding speed of a winder of 2,000 m/min to obtain a polyester fiber of unstretched yarn of 200 dtex and 36 filaments.
  • the obtained unstretched yarn was stretched at a first roller temperature of 90°C, a second roller temperature of 130°C, and a stretch ratio represented by a ratio between peripheral speeds of the first roller and the second roller of 2.38 times to obtain a stretched yarn of polyester fiber of 84 dtex and 36 filaments. Since the total number of island parts was 1 in a transverse section the fiber of the obtained polyester fiber, no figure was obtained by connecting the centroids of island parts disposed on the outermost periphery with line segments, and thus the obtained polyester fiber had breaking of the sea part at the time of moisture absorption, and dyeing unevenness and fuzz were generated when the polyester fiber was formed into a fabric. In addition, the polymer of the island part was eluted from the broken part of the sea part, and the moisture absorption and release properties after the hot water treatment were also poor. The evaluation results of the obtained polyester fiber are shown in Table 3.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 1 except that the sea part was changed to polyethylene terephthalate (melt viscosity: 500 Pa ⁇ s, melting point: 254°C).
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.10, 1.04, and 0.86, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was not a regular triangle.
  • the obtained polyester fiber had breaking of the sea part at the time of moisture absorption, and dyeing unevenness and fuzz were generated when the polyester fiber was formed into a fabric.
  • the polymer of the island part was eluted from the broken part of the sea part, and the moisture absorption and release properties after the hot water treatment were also poor.
  • the evaluation results of the obtained polyester fiber are shown in Table 3.
  • a stretched yarn of polyester fiber of 84 dtex and 36 filaments was obtained under the same conditions as in Example 1 except that the sea-island ratio was 40 : 60 in terms of weight ratio.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 1.09, 0.96, and 0.95, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was not a regular triangle.
  • the obtained polyester fiber had breaking of the sea part at the time of moisture absorption, and dyeing unevenness and fuzz were generated when the polyester fiber was formed into a fabric.
  • the amount of polyethylene terephthalate in the sea part was small, the water-absorbing and quick-drying properties were poor.
  • the evaluation results of the obtained polyester fiber are shown in Table 3.
  • a stretched yarn of polyester fiber of 84 dtex and 10 filaments was obtained under the same conditions as in Example 2 except that the number of discharge holes was 10, a polyester fiber of unstretched yarn of 270 dtex and 10 filaments was obtained, and the obtained unstretched yarn was stretched at a stretch ratio of 3.21 times.
  • the ratios of the length of each line segment to the average value of the lengths of the line segments were 0.98, 1.02, and 1.00, and the figure obtained by connecting the centroids of the island parts disposed on the outermost periphery with line segments was a regular triangle.
  • the polyester fiber of the present invention in which stress generated with volume swelling of the fiber at the time of moisture absorption can be dispersed and breaking of the fiber surface is reduced, has excellent quality when formed into a woven or knitted fabric without having dyeing unevenness, fuzz, and the like.
  • the fiber since the hygroscopicity does not degrade, the fiber has excellent hygroscopicity, and it can be suitably used particularly in clothing applications.

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EP21864348.4A 2020-09-07 2021-09-01 Sea-island-type composite fiber, and fiber product including sea-island-type composite fiber Pending EP4212655A1 (en)

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