JP3508367B2 - Method of manufacturing polyester products - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a polyester product having excellent impact resilience and shape stability.

[0002]

2. Description of the Related Art Conventionally, synthetic fibers such as nylon and polyester have been widely used in the field of clothing or industrial fields because of their high performance. Fiber sheets made of nylon or polyester can be used for clothing interlinings, bras,
It is often used as a three-dimensional product such as chest and shoulder pads. In addition, recently, the morphological stabilization of a shirt made of a blended yarn of polyester and cotton is often performed.

However, nylon is remarkably inferior in dimensional stability in dry and wet conditions, that is, it expands when it absorbs moisture and contracts when it dries, and it is a difficult material to use in fields where dimensional stability is important. Therefore, in recent years, most of the clothing fibers have been replaced with polyester.

On the other hand, polyester has good dimensional stability when dry and wet, but has a drawback that it has a weak impact resilience and is liable to be set upon repeated bending. Therefore, even though the polymer cost is lower than that of nylon 6 or nylon 66, it is rarely used for toothbrushes, artificial grass, carpets and the like.

Further, in Japanese Patent Application Laid-Open No. 2-289101, an interlining using a composite fiber exhibiting a spiral crimp,
-130434 discloses an interlining made of a knitted fabric using loop fluff forming yarn, and JP-A-3-152203 discloses an adhesive interlining using crimpable yarn.

However, conventional polyester fibers are poor in resilience, and when good resilience is required in applications such as interlining, they are used in combination with animal hair such as horse hair or human hair having high resilience. It was necessary to devise such as. In addition, the higher the repulsive interlining, the more difficult it is to adapt to the shape of the clothes, and therefore there is a drawback that a high level of sewing technology is required.

[0007]

Under the present circumstances, it is difficult to obtain a conventional polyester fiber having good impact resilience and dimensional stability, or a fiber product having excellent shape retention in addition to it. This was especially true for products having a three-dimensional shape.

[0008] Taking the interlining of clothes as an example, the interlining is sewn by stacking a number of flatly manufactured fiber sheets on the curved surface of the interlining in order to beautifully express the shape retention and body lines of the clothes. Although it has a curved three-dimensional shape, the sewing process is complicated, and the fiber remembers the original shape, and the one that is forced to deform returns to the original shape with time. However, it was difficult to obtain a durable shape, and this caused the product to lose its shape and greatly deteriorated its quality. In addition, the characteristics of the interlining may be the same as the conventional thread characteristics in the longitudinal direction, but a curved surface convex in the outward direction is required in the lateral direction.

On the other hand, recently, cross-linking or modification of cellulose has been often carried out to improve the morphological stability of shirts, but the chemicals for shape stabilizing treatment remain (especially formalin is not suitable for those that come into contact with the skin). ), There is a problem that the strength is lowered or the shape stabilizing effect is small.

It is an object of the present invention to solve the above-mentioned drawbacks, to provide a method for producing a polyester product which has good impact resilience and dimensional stability and has excellent shape retention.

[0011]

The method for producing a polyester product of the present invention, which achieves the above-mentioned object, has the following constitution.

[0012] In the load-elongation curve for measuring the tensile strength and elongation of the polyester fiber or film, the yield stress point and
A polyester fiber, a film having a constant stress elongation region that is elongated at a stress lower than the stress of the yield stress point, and having an elongation from the yield stress point to the end point of the constant stress elongation region of less than 100%. It is a method for producing a polyester product, which comprises subjecting a product containing the same to heat treatment at 90 ° C. or higher under wet heat and / or dry heat.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION In the case of a fiber, the method for producing a polyester product of the present invention is a requirement of the present invention based on a fiber melt-spun under a specific condition (hereinafter, a fiber in a first specific region). By subjecting it to a specific heat treatment, a polyester product (hereinafter, a polyester product in the second specific region) having both good impact resilience and dimensional stability, which is the object of the present invention, and excellent shape retention and shape retention is obtained. It is what we can offer.

The present invention shifts a fiber or film from the primary specific area to the secondary specific area by subjecting it to a specific heat treatment, so that although it is a polyester product, it has high elasticity such as nylon and repeatability. The present invention relates to a method for producing a polyester product which has excellent bending resistance against bending and also has dimensional stability in dry and wet which is an original advantage. That is, the polyester fiber and the polyester film according to the present invention can be utilized very effectively in industry as having the unprecedented epoch-making effect of having the advantages of nylon and polyester at the same time and the practical physical properties.

The present invention will be described in more detail below.

According to one aspect of the present invention, a yield stress point and a constant stress elongation region that is stretched at a stress lower than the stress at the yield stress point in a load elongation curve in which the tensile strength and elongation of polyester fiber or film are measured. A polyester fiber or film having an elongation from the yield stress point to the end point of the constant stress elongation region of less than 100% and having a heat treatment of 90 ° C. or higher in wet heat and / or dry heat. By applying it, it is possible to provide a product having both good impact resilience and dimensional stability and excellent shape retention.

The load extension curve referred to here is JI.
S-L1013 7.5 (tensile strength and elongation) is measured according to the test method. The measurement of FIGS. 1 to 5 was performed under the following conditions.

Test length (distance between chucks): 5 cm Initial load (fiber): 0.1 g / d (For film, the weight per test length was converted to denier.) Pulling speed: 100 mm / min Chart speed: 100 mm / min Temperature: 20 ℃ ± 2 Humidity: 65% RH ± 5 Testing machine: Autograph (Shimadzu Corporation) Data reduction: Vertical axis stress, horizontal axis elongation (first quadrant) Also, the yield stress point is the stress on the vertical axis. In a load extension curve having elongation on the horizontal axis, as shown in FIG. 1, it means a peak (A) where the curve goes down beyond the initial rising. On the other hand, the end of the constant stress extension region means a portion (B) where the region showing the stress lower than the yield point beyond the yield point is finished and the sharp rise again occurs.

The heat treatment of the present invention is preferably carried out in an atmosphere in which crystallization of polyester occurs. In the case of polyethylene terephthalate, it is preferably treated in an atmosphere of 90 ° C or higher, particularly preferably 120 ° C or higher. Therefore, the temperature range of the treatment is preferably 90 to 230 ° C, and 1
20-230 degreeC is more preferable, and 140-230 degreeC is still more preferable. Further, the heating means may be either dry heat and / or wet heat, but if subtracted, wet heat with good thermal efficiency is preferable.

The state of the polyester product in the primary specific region to which the heat treatment of the present invention is applied is performed in a relaxed state, a restrained state without substantial stretching, or a state of being fixed in an arbitrary shape. Of course, it goes without saying that there are changes such as contraction and extension.

In the present invention of this aspect, the melt-spun polyester fiber (hereinafter, referred to as a fiber in the primary specific region), which has an elongation at the end of the constant stress elongation region of less than 100%, has a tensile strength of the fiber. In the load elongation curve obtained by measuring the elongation, as shown in FIG. 1, there is a maximum yield stress point (A) in the initial stage of elongation, and then elongation is performed at a stress lower than the yield stress point (A). A region having a load extension curve reaching the end point (B) of the constant stress extension region and having an elongation at the end of the constant stress extension region of less than 100%, preferably less than 80%. Is. In other words, the load extension curve is present below the straight line connecting A and B, and a shaded area as shown in FIG. 1 is formed between the straight line AB and the load extension curve. Therefore, it does not have a maximum yield stress point (A) like the conventional polyester drawn yarn (98 denier-24 filament) as shown in FIG. 2, or is stretched at a stress lower than the yield stress point (A). Region-free or conventional polyester undrawn yarn (275 denier-96 filaments) shown in FIG.
As described above, fibers having an elongation of 100% or more at the end of the constant stress elongation region are excluded.

Polyester is used as the method for obtaining fibers having primary specific regions. Aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate or copolymers containing them as a main component are preferably used. The take-up speed in melt spinning is 2000 m / min to 4
000 m / min is preferable, and 2500-3500 m / min is more preferable. For example, a polyethylene terephthalate fiber having a take-up speed of 1500 m / min is substantially called an undrawn yarn, and when subjected to a heat treatment without drawing, it becomes extremely brittle and loses industrial utility value. In addition, the polyethylene terephthalate fiber having a take-up speed of 5000 m / min does not have the above-mentioned yield stress point and end point of the constant stress extension region, cannot be shifted to the secondary specific region by heat treatment, and has impact resilience and shape retention property. The expression is remarkably inferior. However, even fibers which have been spun at a speed lower than 2000 m / min and which have been stretched at a low ratio (including stretching by twisting) include those having the characteristics of the load elongation curve described above.

As the polyester fiber, polyethylene terephthalate, polybutylene terephthalate or its copolyester as a main component, polystyrene polymer as another component, or polyethylene terephthalate, polybutylene terephthalate or its copolyester with boric acid or a boron compound. When using a composite fiber made of a polyester polymer to which is added,
Even when the take-up speed is higher than 4000 m / min, the spinning stress is mainly applied to the other components, so that the orientation of the polyester as the main component can be suppressed, and the polyester fibers in the primary specific region can be obtained. . Collection speed is 400
It is possible even in the range of 0 m / min to 8000 m / min.

For example, even if the composite spinning in which polystyrene is the core component and polyethylene terephthalate is the sheath is carried out at a take-up speed of 4500 m / min, the take-up speed of 2000 m / min.
Fibers close to the so-called POY obtained at 4000 m / min are obtained. When polyethylene terephthalate alone is spun, the fibers become crystallized at a rate of more than 4500 m / min. However, when the polystyrene component is used as described above, the polystyrene component receives the spinning stress, so that a fiber close to POY is obtained. Conceivable.

With such a composite fiber, 4000 m
The method for producing the polyester product of the present invention can be carried out by using the fibers collected at a rate of from 1 / min to 8000 m / min.
In this case, a polyester polymer obtained by adding boric acid, a boron compound or the like to polyethylene terephthalate, polybutylene terephthalate or a copolyester thereof to thicken the polymer can be used as the polymer used for the core component. It should be noted that the core component and the sheath component referred to herein may have opposite configurations, but the one in which the main component is the sheath component is
From the viewpoints of dyeability, frosting, formation of fibrous material, etc., the characteristics of the main component can be exhibited more, which is preferable.

The thickness of the polyester fiber used in the present invention is not particularly limited, but it is generally preferable to use it as a yarn having a single fiber fineness of 0.01 to 200 denier and a total fineness of 20 to 1000 denier.

From the viewpoint of obtaining high strength, high elasticity and shrink resistance, the intrinsic viscosity (orthochlorophenol, 30 ° C.) of the polyester is preferably 0.55 to 1.00. From the viewpoint of facilitating dyeing, it is preferable that the polyester is a copolymer of polyethylene terephthalate and polyalkylene glycol, and is disperse dyeable at 110 ° C. or lower. In the case of a polyester fiber using this polyester, it can be mixed with a natural fiber for dyeing. Furthermore, from the viewpoint of deep color and clear dyeing, the polyester is preferably a cationic dye-dyeable polyester in which 5-sodium sulfoisophthalic acid is copolymerized. In addition, when the molten polyester is drawn at a drawing speed of 2000 to 4000 m / min and the polyester fibrous material in the primary specific region is subjected to the heat treatment, if a heated roll before winding is used, the heat treatment is simultaneously performed in the spinning step. Since productivity can be improved, productivity can be improved. The heat treatment may be performed using heated air, for example, air entanglement may be performed. Furthermore, it is also possible to heat the heat treatment after forming the polyester fibrous material into a knit, and then heat the knit to unwind the knit.

The polyester product of the present invention can be used as a mixture with other fibers. For example, polyester fiber having no specific structure, polyamide fiber, polyacrylic fiber, aramid fiber, polyurethane fiber, animal hair,
Mixing with at least one kind of fiber among silk, cotton, rayon and hemp is a preferable mode.

The polyester product referred to in the present invention means fibers such as monofilaments, multifilament yarns, spun yarns, long and short composite yarns, fibrous substances such as braids, fiber materials such as fibers for fiber reinforced plastics, and woven fabrics. , Knitted fabrics, non-woven fabrics, nets, ribbons, sheets, and other sheet-like products. The shape is not particularly limited, and includes any object shape, including sheet, bag, and clothes.

The form of the fiber / yarn is not particularly limited, and includes forms such as twisted yarn, false twisted yarn, entangled yarn, loop yarn, and mixed fiber yarn.

In the case of the polyester fiber, what is called a conventionally known composite fiber in which other components such as nylon and polyolefin are composited, for example, split type, chrysanthemum type,
Fibers such as sea-island type fibers are also applicable and may be preferable depending on the application. Further, the film includes a slit-shaped film, a ribbon-shaped film, and a tape-shaped film whose thickness is smaller than its width and length.

The nets are not particularly limited, and include fishing nets such as frogs and knots, double frogs and knots, insect nets, laundry nets, duvet cover nets, curtains, and hat nets. By applying the present invention to these, it is effective for holding various three-dimensional shapes, and these can be made extremely easy to use.

In particular, the present invention exerts a remarkable effect in retaining a three-dimensional shape such as an interlining material, a brassiere, a pad of the chest and shoulders, and a collar core, and is preferably applied. In this case, usually
These are set in the target mold and then exposed to the atmosphere of heat treatment.

The interlining material for clothes is made into an interlining material called a construction core, or after being sewn as clothes, it is subjected to heat treatment to impart the shape-retaining property which is the effect of the present invention. be able to. Conventionally, the interlining has a three-dimensional curved shape by sewing many fiber sheets in order to beautifully express the shape of the clothes and the lines of the body,
When the present invention is applied, the three-dimensional curved surface shape can be maintained without using a conventional multi-layer structure, so that it is possible to achieve weight reduction and cooling.

Although it does not matter about the structure or organization of the interlining,
Coarse knitted fabrics such as mesh knitting and open stitch knitting are preferably applied to further enhance the effects of the present invention. In addition, various three-dimensional objects such as brassieres and pads for chest and shoulders are not particularly limited.

Even in napped fabrics such as carpets, artificial lawns, and moquettes, or brush-molded products such as toothbrushes and cleaning brushes, remarkable shape-retaining property and durable bending property can be obtained, and napped products that are not easily worn can be obtained.

Further, it is more effective and preferable to subject the fibrous structure obtained in the present invention to various finishing processes such as dyeing, water repellent treatment, laminating and coating.

As an example of the present invention, a load elongation curve (190 denier-24 filaments) of a fiber heat-treated under a restrained condition is shown in FIG.

In FIG. 4, the end point of the constant stress extension region is virtually eliminated, but the polyester fiber or polyester film in the secondary specific region has the constant stress extension region. However, in that case, the difference in elongation between the yield stress point and the end point of the constant stress elongation region is preferably 20% or less. A more preferred embodiment is that the difference in elongation is substantially 0%.

[0040]

【Example】

Example 1, Comparative Example 2, Comparative Example 3 Polyethylene terephthalate (IV = 0.68) was melt-spun at a spinning temperature of 285 ° C. and a take-up speed of 3100 m / min to obtain a raw yarn of 185 denier and 24 filaments.
The load elongation curve of this raw yarn is as shown in FIG. 5, and shows a curve having a yield stress point A and beyond which it is elongated at a low stress and reaches a constant stress elongation region end point B. The strength of the raw yarn was 2.3 g / d and the elongation was 170%. A tubular knitted product was produced by using a tubular knitting machine using the raw yarn, fixed and fixed on the outer periphery of a rectangular form frame, and subjected to dry heat treatment at 180 ° C. for 60 seconds to produce a form-shaped polyester product (Example 1).

As Comparative Example 1, the above-mentioned raw yarn was further added to 150
What was drawn 1.4 times through a heating roll at ℃ was used. As Comparative Example 2, nylon was used as the raw material and the take-up speed was 3
The same treatment as in Example 1 was performed using 200 denier, 24 filaments, strength 3.2 g / d, and elongation 175% melt-spun at 000 m / min.

As a result, in Example 1, the one having the same shape as the rectangular mold and having the preferable resilience was obtained. Moreover, the shape of the rectangular parallelepiped was not broken even after washing with water and dry washing five times, the dimensional stability was good, and the resilience was not deteriorated. No settling was observed even after 20 buckling tests. On the other hand, both Comparative Example 1 and Comparative Example 2 were in a state of being cluttered and could not have a rectangular shape.

Examples 2, 3, 4, Comparative Example 3, Comparative Example 4 Using the raw yarn of Example 1, a 4-course double atlas having a surface design of 1/1 by an 18-gauge, 4-blade Russell knitting machine,
A four-course double-atlas mesh knitted fabric with a back structure of 1/3 was knitted. Using this knitted fabric, a front body interlining of clothes (Example 2), a brassiere (Example 3), and a breast pad of a swimsuit (Example 4) were produced, and each was fixed to a three-dimensional shape mold and 180 Dry heat treatment was performed at 30 ° C. for 30 seconds to produce polyester products of each mold shape.

As Comparative Example 3, a drawn yarn obtained by further stretching the melt-spun raw yarn by 1.4 times using a heating roll of 150 ° C. was used, and as Comparative Example 4, nylon was drawn at a drawing speed of 3000 m / min. 200 denier melt-spun, 24
Using filaments, a strength of 3.2 g / d and an elongation of 175%, the same molds as in Example 2, Example 3 and Example 4 were used and the same treatment was performed.

As a result, all of the polyester products of the present invention were extremely good in shape retention and had favorable resilience. The clothes of Example 2 had a three-dimensional shape capable of expressing a beautiful curved surface along the body line. Further, such clothes are lighter in weight, more breathable and more comfortable than conventional ones. Also, 5
The shape did not collapse even after repeated washing with water and dry washing, and no reduction in resilience was observed. Also in Examples 3 and 4, the three-dimensional shape retaining property was good, and no problem occurred in terms of dimensional change even when sweat or water was contained.

On the other hand, in Comparative Examples 2 and 3, the shape retention was not sufficient and the desired shape could not be obtained.

[0047]

【The invention's effect】

(1) It is possible to provide a polyester product having both good impact resilience and dimensional stability and excellent shape retention.

(2) In particular, it is easy to obtain a polyester product having a three-dimensional shape, and its shape durability is good.

(3) Since no chemicals are used as compared with the conventional shape-retained processed products, no toxic chemicals remain and the strength does not decrease.

(4) In napped fabrics and brushes, the napped hair has good bending resistance and is difficult to set.

[Brief description of drawings]

FIG. 1 shows an example of a load elongation curve of polyester fiber in a primary specific region.

FIG. 2 shows a load elongation curve of a conventional polyester drawn yarn.

FIG. 3 shows a load elongation curve of a conventional polyester undrawn yarn.

FIG. 4 shows an example of a load elongation curve of polyester fibers constituting the polyester product obtained by the present invention.

5 shows a load elongation curve of the raw yarn in Example 1. FIG.

[Explanation of symbols]

A: Yield stress point B: End point of constant stress extension region

Claims (11)

(57) [Claims] 1. A yield stress point in a load elongation curve obtained by measuring the tensile strength and elongation of a polyester fiber or film, and
A polyester fiber, a film having a constant stress elongation region that is elongated at a stress lower than the stress of the yield stress point, and having an elongation from the yield stress point to the end point of the constant stress elongation region of less than 100%. A method for producing a polyester product, which comprises subjecting a product containing the same to heat treatment at 90 ° C. or higher under wet heat and / or dry heat. 2. The method for producing a polyester product according to claim 1, wherein the heat treatment is carried out at a temperature or for a time sufficient to substantially eliminate the region stretched at a stress lower than the yield stress. 3. The polyester fiber or film according to claim 1, wherein the polyester fiber or film before heat treatment is a polyester fibrous material obtained by drawing molten polyester at a drawing speed of 2000 to 4000 m / min. Product manufacturing method. 4. The method for producing a polyester product according to claim 1, wherein the heat treatment is performed using a heated roll. 5. The method for producing a polyester product according to claim 1, wherein the heat treatment is performed using heated air. 6. The method for producing a polyester product according to claim 1, wherein the heat treatment is performed after forming the polyester fibrous material into a knitted fabric, and then the knitted fabric is unwound. 7. The polyester product according to claim 1, wherein the main component is polyethylene terephthalate, polybutylene terephthalate or a copolyester thereof, and the other component is a polystyrene polymer.
Alternatively, there is provided a method for producing a polyester product, which is a composite fiber comprising a polyester polymer obtained by adding boric acid or a boron compound to polyethylene terephthalate, polybutylene terephthalate or a copolyester thereof. 8. The composite fiber according to claim 7, wherein the composite fiber is 40
A method for producing a polyester product, which is a fiber taken out at 00 m / min to 8000 m / min. 9. The intrinsic viscosity of polyester according to any one of claims 1 to 8 (orthochlorophenol, 30 ° C.).
Is 0.55-1.00, The manufacturing method of the polyester product characterized by the above-mentioned. 10. The polyester according to claim 1, wherein the polyester is a copolymer of polyethylene terephthalate and polyalkylene glycol.
A method for producing a polyester product, which is dyeable with a disperse dye at a temperature of not higher than 0 ° C. 11. A method for producing a polyester product according to any one of claims 1 to 9, wherein the polyester is a cationic dye-dyeable polyester in which 5-sodium sulfoisophthalic acid is copolymerized.