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
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
  • D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
• • 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

Definitions

• Synthetic fibers particularly polyester fibers, have excellent mechanical properties and dimensional stability and are therefore used in a wide range of applications, from clothing applications to non-clothing applications such as materials and medical use.
• Patent Literature 1 discloses that by applying a high-temperature heat treatment using steam or a water-soluble non-swelling medium before dyeing, the fiber structure is changed and a loss tangent (tan ⁇ ) determined by dynamic viscoelasticity measurement is controlled, which increases dyeing sites, improves the dye exhaustion ability, and improves dye utilization efficiency.
• Patent Literature 2 discloses that by focusing on the control of a tan ⁇ peak temperature determined by dynamic viscoelasticity measurement and copolymerizing an aliphatic dicarboxylic acid to produce a modified polyester fiber, dyeability of the polyester fiber at a normal pressure is improved, and the polyester fiber has a high shrinkage property even after a high-temperature treatment, which overcomes high temperature and high pressure conditions required for dyeing a general polyester fiber.
• the synthetic fiber according to the present invention can produce a deep color in the dyeing step because of excellent dye exhaustion ability, has a fast dyeing speed, and can produce a fiber structure that maintains a soft texture even after dyeing.
• the synthetic fiber in the present invention refers to a fiber produced by chemical synthesis, such as a polyester fiber, a polyamide fiber, and an acrylic fiber.
• the synthetic fiber in the present invention is preferably a polyester fiber, which can easily introduce a copolymerization component in a production process and can be dyed with a disperse dye in an amorphous portion.
• the polyester fiber preferred in the present invention includes terephthalic acid and ethylene glycol as main components, and may include a copolymerization component.
• the copolymerization component may be used alone or in combination of two or more thereof.
• the loss tangent peak temperature in the present invention refers to a value determined as a loss tangent peak temperature when the loss tangent (dimensionless quantity) is measured using a dynamic viscoelasticity measuring device, under conditions of clamping the synthetic fiber at a distance between chucks of 30 mm, applying a tension of 0.15 g/dtex, and increasing the temperature from 30°C to 200°C at a temperature increase rate of 3°C/min and a frequency of 110 Hz.
• the dynamic viscoelasticity measuring device include "RHEOVIBRON DOV-II-EP" manufactured by ORIENTEC CO., LTD.
• the loss tangent peak temperature is higher than 150°C, in the dyeing step, the micro Brownian motion of the amorphous portion is small, the dyeability of the amorphous portion with a disperse dye is low and thus the dye exhaustion ability is low, making it difficult to obtain a deep color and resulting in insufficient dyeing.
• the loss tangent peak temperature is 150°C or lower, in the dyeing step, the dye exhaustion ability is excellent to thereby make it possible to produce a deep color and have an excellent color development property.
• the loss tangent peak value can be measured by the above method using a dynamic viscoelasticity measuring device.
• the loss tangent area from 30°C to 130°C is more preferably 4.2°C or more, still more preferably 4.5°C or more, and is more preferably 7.0°C or less.
• the synthetic fiber according to the present invention needs to have a dry heat shrinkage of 5% or more and less than 15%.
• the dry heat shrinkage is 5% or more, in case of dyeing with a disperse dye, there are sufficient amorphous portions into which the dye can be introduced, and the color development property is excellent.
• the dry heat shrinkage is less than 15%, in a heat treatment, the synthetic fiber does not shrink excessively and does not harden or deteriorate in texture.
• an absolute value of a difference between an average pixel value of a circle that is concentric with a center of an inscribed circle and that has an area of 10% of an area of the fiber cross section and an average pixel value of an outer peripheral portion that has an area of 10% of the area of the fiber cross section is preferably 15 or less, which is sufficient to determine whether a dye has penetrated the fiber cross section.
• the L* value represents lightness in the L*a*b* color space, and is measured using a spectrophotometer with a D65 light source, a viewing angle of 10°, and optical conditions of SCE (specular component exclude method).
• the dye penetrates the fiber, and unlike the case where only the surface of the fiber is dyed, the dye is evenly absorbed into the amorphous portion of the entire fiber, and therefore, the dye exhaustion ability is improved to make it possible to produce a deep color, and the color development property is excellent, which is preferable.
• the absolute value of the difference is more preferably 10 or less, and when the dye has uniformly penetrated the fiber, the absolute value of the difference is 0, so that there is no particular lower limit value.
• the synthetic fiber according to the present invention is not particularly limited with respect to the form of the fiber, and may be in any form such as a monofilament, a multifilament, or a staple, and in order to take advantage of the property of an excellent dye exhaustion ability, the synthetic fiber is preferably in the form of a multifilament or a staple.
• a single fiber fineness and the number of filaments of the synthetic fiber according to the present invention are suitably selected appropriately depending on applications and required properties, and assuming a practical range, the fineness as a multifilament is preferably 10 dtex to 3000 dtex.
• the synthetic fiber preferably has a fineness of 10 dtex or more since it is less likely to break yarn and has good process passability, and it generates less fluff during use and has excellent durability.
• the synthetic fiber preferably has a fineness of 3000 dtex or less since flexibility of the fiber and the fiber structure is not impaired.
• the elongation (%) is calculated by performing a tensile test under conditions of an environment with a temperature of 20°C and a humidity of 65% RH, an initial sample length of 20 cm, and a tensile speed of 20 cm/min, dividing a stress (cN) at a point showing the maximum load by the fineness (dtex) to calculate a strength (cN/dtex), and using an elongation (L1) at the point showing the maximum load and the initial sample length (L0) according to the following equation.
• Elongation % L 1 ⁇ L 0 / L 0 ⁇ 100
• the elongation of the synthetic fiber according to the present invention may be adjusted according to the required elongation for use. It is particularly preferable that the elongation be adjusted to 30% to 50% when used for clothing applications, and 20% to 40% when used for non-clothing applications.
• the synthetic fiber according to the present invention can be processed into false twisted yarns or twisted yarns in the same manner as general fibers, and can also be woven and knitted in the same manner as general fibers.
• the synthetic fiber according to the present invention can be produced by known methods such as a melt spinning method, a drawing method, and a false twisting method.
• the moisture content in a raw material is preferably 0.3 wt% or less since no foaming occurs due to moisture during the melt spinning, and the spinning can be stably performed. It is also preferred since, depending on the type of the raw material, a decrease in mechanical properties and deterioration in color tone due to hydrolysis can be prevented.
• the moisture content in the raw material is more preferably 0.1 wt% or less.
• chips having different compositions are optionally dried and then mixed in a chip state so as to obtain a final fiber composition, and then the mixed chips are fed to a melt spinning machine, melted, and measured by using a measuring pump. Thereafter, the resultant is introduced into a heated spinning pack in a spinning block, sea-island components of the molten polymer are kneaded and filtered in the spinning pack, and then the product is discharged from a spinneret to form a fiber thread.
• chips having different compositions are optionally dried, and then the chips are fed separately, melted and measured by using a measuring pump.
• the resultant is introduced into a heated spinning pack in a spinning block, the molten polymer is kneaded so as to have a final fiber composition and filtered in the spinning pack, and then the product is discharged from a spinneret to form a fiber thread.
• the fiber thread discharged from the spinneret is cooled and solidified by using a cooling device, taken off by a first godet roller, passes through a second godet roller, and wound by a winder to form a wound yarn.
• a cooling device taken off by a first godet roller, passes through a second godet roller, and wound by a winder to form a wound yarn.
• an oil supplying device may be used to supply oil to the fiber thread
• an entanglement device may be used to entangle the fiber thread.
• a spinning temperature in the melt spinning can be appropriately selected depending on melting points and heat resistance of the components in the fiber, and is preferably 240°C to 300°C.
• the spinning temperature is preferably 240°C or higher since an elongational viscosity of the fiber thread discharged from the spinneret is sufficiently reduced to enable stable discharge, a spinning tension is not excessively high, and yarn breakage is prevented.
• the spinning temperature is preferably 300°C or lower since thermal decomposition during spinning can be prevented, and a decrease in mechanical properties and coloring of the synthetic fiber to be obtained can be prevented.
• the spinning speed is preferably 1000 m/min to 3000 m/min for a low-speed roller and 2500 m/min to 6000 m/min for a high-speed roller.
• the low-speed roller and the high-speed roller preferably have the spinning speed within the above ranges since the running thread is stabilized, yarn breakage can be prevented, and the spinning can be stably performed.
• the synthetic fiber In order to make the synthetic fiber have a loss tangent peak temperature of 100°C or higher and 150°C or lower, a loss tangent peak value of 0.15 or more, and a dry heat shrinkage of 5% or more and less than 15%, it is preferable to perform drawing or false twisting by using a one-step method or a two-step method, and the drawing during the process may be either a one-stage drawing method or a multi-stage drawing method having two or more stages.
• a heating method in the drawing or the false twisting is not particularly limited as long as the device can directly or indirectly heat the running thread.
• a drawing ratio in the case of performing drawing can be appropriately selected depending on the elongation of the fiber before drawing and the strength and the elongation of the fiber after drawing, and is preferably 1.02 times to 5.0 times.
• the drawing ratio is 1.02 times or more, the drawing can improve the mechanical properties of the fiber, such as the strength and the elongation, which is preferable.
• the drawing ratio is preferably 5.0 times or less, yarn breakage during drawing is prevented and the drawing can be performed stably, which is preferable.
• a drawing ratio that results in an elongation after drawing of about 40% is preferred.
• a drawing speed in the case of performing drawing can be appropriately selected depending on whether the drawing method is a one-step method or a two-step method.
• the speed of the high-speed roller at the above spinning speed corresponds to the drawing speed.
• the drawing speed is preferably 100 m/min to 1000 m/min.
• the drawing speed is preferably 100 m/min or more, the running thread is stable and yarn breakage can be prevented, which is preferable.
• the drawing speed is 1000 m/min or less, yarn breakage during drawing is prevented and the drawing can be performed stably, which is preferable.
• the elongation of the undrawn yarn or drawn yarn used can be appropriately selected depending on the applications and the required properties, and is preferably in a range of 30% to 300%.
• the elongation is 30% or more, the fluff of the false twisted yarn made of the synthetic fiber and yarn breakage during the false twisting can be prevented, and when the elongation is 300% or less, the false twisting can be performed stably.
• Examples of a device used for the false twisting include those shown below, but are not limited thereto.
• a false twisting device including a 1DR (1 draw roller), a 1HT (1 heater), a cooling plate, a false twister, 2DR (2 draw roller), 3DR (3 draw roller), 4DR (4 draw roller), and a winder is used.
• a processing ratio between the 1DR and the 2DR can be selected depending on the elongation of the fiber used in the processing and the elongation of the false twisted yarn made of the synthetic fiber, and is preferably in a range of 1.1 times to 3.0 times.
• the heater may be of either contact or non-contact type.
• a 1HT temperature can be appropriately selected depending on the glass transition temperatures and melting points of the components of the synthetic fiber, and the strength, the elongation, the dry heat shrinkage, and a crimp recovery rate of the fiber after the false twisting.
• the upper limit of the 1HT temperature may be any temperature at which the undrawn yarn or drawn yarn used does not fuse in the heater.
• the false twister is preferably of a friction false twist type, and examples thereof include a friction disk type and a belt nip type. Preferably, it is of a friction disk type.
• the ratios between the 2DR and the 3DR and between the 3DR and the 4DR can be appropriately set depending on the false twisted yarn made of the synthetic fiber, and are generally preferably 0.9 to 1.0.
• entanglement may be imparted by an entanglement nozzle or additional oil may be applied by using an oil supplying guide between the 2DR and the 3DR, between the 3DR and the 4DR, or between the 4DR and the winder.
• a false twisting device including a 1DR, a 1HT, a cooling plate, a false twister, 2DR, 3DR, 2HT (2 heater), 4DR, and a winder is used.
• a processing ratio between the 1DR and the 2DR can be selected depending on the elongation of the fiber used in the processing and the elongation of the false twisted yarn made of the synthetic fiber, and is preferably in a range of 1.1 times to 3.0 times.
• the 1HT temperature can be appropriately selected depending on the glass transition temperatures and melting points of the components of the synthetic fiber, and the strength, the elongation, the dry heat shrinkage, and the crimp recovery rate of the fiber after the false twisting.
• the upper limit of the 1HT temperature may be any temperature at which the undrawn yarn or drawn yarn used does not fuse in the heater.
• the false twister is preferably of a friction false twist type, and examples thereof include a friction disk type and a belt nip type. Preferably, it is of a friction disk type.
• entanglement may be imparted by an entanglement nozzle between the 2DR and the 3DR.
• a processing ratio between the 3DR and the 4DR can be selected depending on the elongation of the fiber used in the processing and the elongation of the false twisted yarn made of the synthetic fiber, and is preferably in a range of 0.8 times to 1.1 times.
• a 2HT temperature can be appropriately selected depending on the glass transition temperatures and melting points of the components of the synthetic fiber, and the strength, the elongation, the dry heat shrinkage, and the crimp recovery rate of the fiber after the false twisting.
• the upper limit of the 2HT temperature may be any temperature at which the undrawn yarn or drawn yarn used does not fuse in the heater. Additional oil may be applied by using an oil supplying guide between the 4DR and the winder.
• a chip-like polymer sample was prepared by reducing the moisture content to 200 ppm or less using a vacuum dryer, and the measurement was performed using a Capilograph 1B manufactured by Toyo Seiki Seisaku-sho, Ltd. The time from when the sample was charged into a heating furnace to when the measurement was started was 5 minutes, and the melt viscosity was measured at a measurement temperature of 290°C while changing a strain rate stepwise in a nitrogen atmosphere. Note that, in Examples and Comparative Examples, a melt viscosity of 1216 s -1 was recorded.
• Fineness dtex weight g of 100 m of fiber ⁇ 100
• the strength and the elongation were calculated in accordance with 8.5.1 in JIS L1013:2010 (Testing methods for man-made filament yarns) using the fiber obtained in each of Examples and Comparative Examples as a sample.
• a tensile test was performed using a TENSILON UTM-III-100 manufactured by ORIENTEC CO., LTD. under conditions of an initial sample length of 20 cm and a tensile speed of 20 cm/min under an environment with a temperature of 20°C and a humidity of 65% RH.
• the fiber obtained in each of Examples and Comparative Examples was used as a sample, and was subjected to DSC measurement using a differential scanning calorimeter (DSC) Model Q2000 manufactured by TA Instruments Japan Inc., with the temperature being increased from 30°C to 280°C at a temperature increase rate of 16°C/min, and the melting point (Tm) and the heat amount of fusion ( ⁇ Hm) were calculated from a melting peak observed during the temperature increase process. The measurement was performed three times for one sample, and an average value thereof was defined as the heat amount of fusion. Note that, when a plurality of melting peaks were observed, Tm and ⁇ Hm were read in order from the melting peak top on the lowest temperature side and recorded separately.
• DSC differential scanning calorimeter
• the cylindrical knitted fabric after finish setting prepared in the above G was evaluated on the following four criteria by a panel of five inspectors with five years or more of experience in determining quality, and the average of the results given by the five inspectors was regarded as the texture evaluation result of the fabric. Ratings S, A and B represent pass, while the rating C represents failed.
• Friction tester type II Gakushin type
• JIS L0849:2013 Test methods for color fastness to rubbing
• the cylindrical knitted fabric after finish setting prepared in the above G was used as a sample, a Gakushin type friction tester RT-200 manufactured by DAIEI KAGAKU SEIKI MFG. co., ltd. was used to rub the sample with white cotton cloth (cotton No. 3-1) specified in JIS L0803:2011, and then a degree of staining of the white cotton cloth was graded using the staining gray scale specified in JIS L0805:2005 to evaluate the friction fastness (staining).
• the evaluation on the crimp recovery rate (CR) was performed in accordance with 6 (sample collection and preparation) and 8.12 (crimp recovery rate) in JIS L1013 (2010).
• the false twisted yarn was wound into a hank having a hank length of 40 cm and having 10 turns while applying a load of 0.176 mN ⁇ fineness (dtex) ⁇ 10, and then this hank was subjected to an initial load of 0.176 mN ⁇ 20 ⁇ fineness (dtex) ⁇ 10, subjected to a hot water treatment in 90°C hot water for 20 minutes, dehydrated through filter paper, and then naturally dried for 12 hours or longer.
• Crimp recovery rate (CR) (%) ⁇ (hank length a - hank length b)/hank length a ⁇ ⁇ 100
• Polyethylene terephthalate (melt viscosity: 112 Pa s) obtained by copolymerization of 7.0 mol% of isophthalic acid and 4.0 mol% of 2,2-bis[4-(2-hydroxyethoxy)phenyl]propane was used as a chip A
• polyethylene terephthalate (melt viscosity: 120 Pa ⁇ s) was used as a chip B
• the chip A and the chip B were mixed in advance in a chip form at a blending ratio of 25 wt% of chip A and 75 wt% of chip B respectively such that the final composition was 1.8 mol% of isophthalic acid and 1.0 mol% of 2,2-bis[4-(2-hydroxyethoxy)phenyl]propane regarding a copolymerization amount.
• the mixed chips were supplied to an extruder-type melt spinning machine, melt-mixed, and discharged from a spinneret (discharge hole diameter: 0.23 mm, discharge hole length: 0.30 mm, number of holes: 36, round holes) at a spinning temperature of 290°C and a discharge rate of 42.0 g/min to obtain a spun thread.
• a spinneret discharge hole diameter: 0.23 mm, discharge hole length: 0.30 mm, number of holes: 36, round holes
• the spun thread was cooled with cooling air at a temperature of 20°C and a speed of 25 m/min, supplied with oil from an oil supplying device, bundled, taken off by a first godet roller rotating at 2500 m/min, passed through a second godet roller rotating at the same speed as the first godet roller, and wound by a winder to obtain an undrawn yarn having 168 dtex-36f.
• the obtained undrawn yarn was drawn between a first hot roller set to 90°C and a second hot roller set to 130°C at a drawing ratio of 2.0 times, and then subjected to heat setting to obtain a drawn yarn having 84 dtex-36f.
• the evaluation results of the fiber properties and the fabric properties of the obtained drawn yarn are shown in Table 1.
• the obtained drawn yarn had a dry heat shrinkage of 10.4% and had an excellent texture even when finish setting was performed after dyeing.
• the loss tangent peak value was large, the loss tangent area was large, and the dyeing speed was so fast that the yarn was sufficiently dyed after 5 minutes of dyeing.
• a difference in pixel value after dyeing between the inner and outer layers was 3.1, and the dyeing was achieved up to the center, indicating that the dye had been sufficiently exhausted and that the color development property was excellent.
• Drawn yarns were prepared in the same manner as in Example 1, except that proportions of the copolymerization components in the polyethylene terephthalate composition were changed as shown in Table 1 (adjusted by the blending ratio of the chip A and the chip B).
• Drawn yarns were prepared in the same manner as in Example 1, except that the temperature of the second hot roller during the drawing was changed as shown in Table 1.
• the evaluation results of the fiber properties and the fabric properties of the obtained drawn yarn are shown in Table 2. Due to the core-sheath structure, the dyeing was not sufficiently performed unless the dyeing time was 30 minutes, and the difference in pixel value after dyeing between the inner and outer layers was large, but the loss tangent peak value was large and the loss tangent area was large, so that the color development property was good after dyeing for 30 minutes.
• the undrawn yarn obtained in Example 1 was subjected to false twisting using a false twisting device including a 1DR, a 1HT, a cooling plate, a false twister, 2DR, 3DR, 2HT, 4DR, and a winder, to obtain a false twisted yarn made of a synthetic fiber.
• a false twisting device including a 1DR, a 1HT, a cooling plate, a false twister, 2DR, 3DR, 2HT, 4DR, and a winder, to obtain a false twisted yarn made of a synthetic fiber.
• the conditions in the false twisting are as follows.
• 1DR speed 150 m/min, processing ratio between 1DR and 2DR: 2.0 times, 1HT (hot plate type contact heater, length: 2500 mm): 140°C, cooling plate length: 1050 mm, friction disk type friction false twister, ratio between 2DR and 3DR: 1.0 time, 2HT (hot plate type contact heater, length: 2000 mm): 120°C, ratio between 3DR and 4DR: 0.92 times, ratio between 4DR and winder: 0.98 times.
• 1HT hot plate type contact heater, length: 2500 mm
• cooling plate length 1050 mm
• friction disk type friction false twister ratio between 2DR and 3DR: 1.0 time
• 2HT hot plate type contact heater, length: 2000 mm
• ratio between 3DR and 4DR 0.92 times
• ratio between 4DR and winder 0.98 times.
• the evaluation results of the fiber properties and the fabric properties of the obtained false twisted yarn are shown in Table 5.
• the obtained false twisted yarn had a dry heat shrinkage of 13.5% and had an excellent texture even when finish setting was performed after dyeing.
• the loss tangent peak value was large, the loss tangent area was large, and the dyeing speed was so fast that the yarn was sufficiently dyed after 5 minutes of dyeing.
• the difference in pixel value after dyeing between the inner and outer layers was 2.4, and the dyeing was achieved up to the center, indicating that the dye had been sufficiently exhausted and that the color development property was excellent.
• False twisted yarns were prepared in the same manner as in Example 18, except that the 1HT temperature and the 2HT temperature during the false twisting were changed as shown in Table 5.
• Example 20 The evaluation results of the fiber properties and the fabric properties of the obtained false twisted yarns are shown in Table 5.
• Example 20 since the 2HT temperature was higher than the 1HT temperature, the heat setting proceeded more, and both the dry heat shrinkage and the crimp recovery rate were small.
• the synthetic fiber according to the present invention provides, in the dyeing step, a synthetic fiber that has an excellent dye exhaustion ability in a dyeing step to thereby make it possible to produce a deep color, that has a fast dyeing speed, that has an excellent texture, and that can be suitably used as a fiber structure.

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• Artificial Filaments (AREA)

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• 2023
  • 2023-08-23 JP JP2023552573A patent/JPWO2024043287A1/ja active Pending
  • 2023-08-23 WO PCT/JP2023/030391 patent/WO2024043287A1/ja not_active Ceased
  • 2023-08-23 EP EP23857395.0A patent/EP4579010A1/en active Pending
  • 2023-08-23 CN CN202380061965.9A patent/CN120035697A/zh active Pending
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