JP6697972B2 - Sea-island type composite fiber - Google Patents
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本発明は、ポリプロピレン樹脂と熱可塑性樹脂を用いた染色性、耐熱性に優れる海島型複合繊維に関する。 The present invention relates to a sea-island type composite fiber which is excellent in dyeability and heat resistance using a polypropylene resin and a thermoplastic resin.
ポリオレフィン繊維は軽量性や撥水性等に優れているため、産業用途に幅広く用いられている。その中でもポリプロピレン繊維が多く用いられているが、ポリプロピレン繊維は染料により染色されにくいため、衣料用途に適用することは困難であった。
染色性を改善するために、特許文献１では、芯成分に分散染料で染色することが可能なポリエステル樹脂、鞘成分にポリプロピレン樹脂を配置したポリプロピレン複合繊維が提案されている。このような構成とすることにより繊維を濃色に染色できるうえ、耐光・耐塩素堅牢度も良好なポリプロピレン繊維が得られることが記載されている。
一方、ポリオレフィン樹脂と、ポリエステル樹脂やポリアミド樹脂等の熱可塑性樹脂とからなる繊維は、相溶性が低いため、樹脂の接合面で剥離し易く、製糸安定性や染色性の悪化が生じ、取り扱いが難しいという問題があった。
そこで、特許文献２では、芯成分にポリプロピレン樹脂、鞘成分にポリエステル樹脂を配置し、ポリプロピレン樹脂のメルトフローレート（ＭＦＲ）が２８ｇ／ｍｉｎを超えて６０ｇ／ｍｉｎ未満の芯鞘型複合繊維とすることで、糸切れがなく安定して紡糸でき、染色性も良好な芯鞘型複合繊維が得られることが記載されている。また、この文献には、比較的低温の温水浴中で湿熱延伸するなど、穏やかな延伸条件により芯成分と鞘成分の剥離を起こさないようにすることが記載されている。
Polyolefin fibers are widely used in industrial applications because of their light weight and excellent water repellency. Among them, polypropylene fibers are often used, but since polypropylene fibers are difficult to be dyed with a dye, it is difficult to apply them to clothing.
In order to improve the dyeability, Patent Document 1 proposes a polypropylene composite fiber in which a polyester resin capable of being dyed with a disperse dye in a core component and a polypropylene resin in a sheath component are arranged. It is described that with such a constitution, the fibers can be dyed in a dark color and, at the same time, polypropylene fibers having good light resistance and chlorine fastness can be obtained.
On the other hand, a fiber made of a polyolefin resin and a thermoplastic resin such as a polyester resin or a polyamide resin has a low compatibility, so that it is easily peeled off at the joint surface of the resin, resulting in deterioration of yarn-forming stability and dyeability, and handling There was a problem that it was difficult.
Therefore, in Patent Document 2, a polypropylene resin is disposed as a core component and a polyester resin is disposed as a sheath component to obtain a core-sheath type composite fiber having a melt flow rate (MFR) of polypropylene resin of more than 28 g/min and less than 60 g/min. It is described that a core-sheath type conjugate fiber which can be stably spun without yarn breakage and has good dyeability can be obtained. Further, this document describes that peeling of the core component and the sheath component does not occur under mild stretching conditions such as wet heat stretching in a relatively low temperature hot water bath.
しかしながら、特許文献１記載の繊維は、染色できるものの、芯鞘剥離が生じ易いため、製糸安定性に問題があり、色斑が生じ易いものとなる。また、製織、製編された生地は、通常、プレセットやファイナルセット等の乾熱処理を行う。ポリプロピレン樹脂を用いた繊維は、ポリエステル樹脂やポリアミド樹脂を用いた繊維と比べて融点が低く、乾熱処理の際、融着が生じる。このため、ポリエステル繊維やナイロン繊維等との併用が困難であった。
また、特許文献２は、低温での湿熱処理を行うなどの穏やかな延伸条件とすることによって、繊維の芯鞘剥離を生じにくくすることが記載されているものの、具体的には不織布や紡績糸に用いており、長繊維での使用は記載されていない。
したがって、本発明は、ポリプロピレン樹脂と可染性の熱可塑性樹脂とからなる複合繊維において、特別な延伸方法をとらなくとも、耐剥離性、製糸安定性及び耐熱性が良好で染色斑の少ない、長繊維として使用できるポリオレフィン複合繊維を得ることを目的としたものである。
However, although the fiber described in Patent Document 1 can be dyed, core-sheath peeling easily occurs, so that there is a problem in yarn-forming stability, and color spots easily occur. The woven or knitted fabric is usually subjected to dry heat treatment such as presetting and final setting. Fibers made of polypropylene resin have a lower melting point than fibers made of polyester resin or polyamide resin, and fusion occurs during dry heat treatment. Therefore, it has been difficult to use the polyester fiber and the nylon fiber together.
In addition, although Patent Document 2 describes that the core-sheath separation of the fiber is less likely to occur by setting a mild stretching condition such as performing a wet heat treatment at a low temperature, specifically, a nonwoven fabric or spun yarn is described. The use in long fibers is not described.
Therefore, the present invention, in a composite fiber composed of a polypropylene resin and a dyeable thermoplastic resin, peel resistance, yarn-forming stability and heat resistance are good and there are few stains even without using a special drawing method. The purpose is to obtain a polyolefin composite fiber that can be used as long fibers.
すなわち、本発明の要旨は、海部と２つ以上の島部とからなり、海部と島部との接合面が繊維長さ方向に連続した海島構造を有し、以下の（ａ）〜（ｅ）を満たす海島型複合繊
維にある。
（ａ）島成分がポリプロピレンを主成分とするポリプロピレン樹脂
（ｂ）海成分が染色可能な熱可塑性樹脂
（ｃ）繊維横断面における海部の面積比率が３０％以上、７０％以下
（ｄ）繊維横断面における海部の最小厚みが１μｍ以上
（ｅ）重量平均粒子径が０．８μｍ以上、１．８μｍ以下の酸化チタンが、島成分のポリプロピレンに対し５質量％以上含有する
また、その中でも、染色可能な熱可塑性樹脂はポリエステル樹脂またはポリアミド樹脂であることが好ましい。また、前記繊維が１７０℃の乾熱雰囲気下で乾熱処理後に融着・
溶断のないことが好ましい。さらに、前記繊維の単糸繊度が１ｄｔｅｘ以上であることが好ましい。また、前記繊維は島部の個数が４０個以下であることが好ましく、５０ｃｍ上部から５００Ｗのレフランプを３０分間照射した際に基準とした繊維の編地との温度差が−２℃以上であることが好ましい。
That is, the gist of the present invention is to have a sea-island structure composed of a sea part and two or more island parts, and the joint surface between the sea part and the island part is continuous in the fiber length direction, and has the following (a) to ( e ) ) In the sea-island type composite fiber.
(A) Polypropylene resin whose island component is polypropylene as a main component (b) Thermoplastic resin which can be dyed by sea component (c) Area ratio of sea part in fiber cross section is 30% or more and 70% or less (d) Fiber crossing The minimum thickness of the sea area on the surface is 1 μm or more
(E) Titanium oxide having a weight average particle size of 0.8 μm or more and 1.8 μm or less is contained in an amount of 5% by mass or more with respect to the polypropylene of the island component . Among them, the dyeable thermoplastic resin is a polyester resin or a polyamide. It is preferably a resin. In addition, the fibers are fused/bonded after dry heat treatment in a dry heat atmosphere of 170°C.
It is preferable that there is no fusing. Furthermore, it is preferable that the single yarn fineness of the fibers is 1 dtex or more. Further, the number of islands of the fiber is preferably 40 or less, and the temperature difference from the knitted fabric of the fiber is −2° C. or more when irradiated with a 500 W reflex lamp from 50 cm above for 30 minutes. Preferably.
本発明の海島型複合繊維によれば、特別な延伸方法をとらなくても、耐剥離性、製糸安定性、耐熱性、遮熱性及び染色性が良好で、長繊維として使用できるポリオレフィン複合繊維を提供できる。また本発明の海島型複合繊維は、ポリエステル繊維やポリアミド繊維等の熱可塑性樹脂繊維と併用できる。 According to the sea-island type composite fiber of the present invention, peeling resistance, yarn-forming stability, heat resistance, heat- shielding property and dyeability are excellent without using a special drawing method, and a polyolefin composite fiber that can be used as a long fiber is obtained. Can be provided. Further, the sea-island type composite fiber of the present invention can be used in combination with a thermoplastic resin fiber such as polyester fiber or polyamide fiber.
本発明において、海島型複合繊維とは、海成分からなる海部と島成分からなる島部とから構成される海島型複合繊維のことをいう。 In the present invention, the sea-island type composite fiber means a sea-island type composite fiber composed of a sea part composed of a sea component and an island part composed of an island component.
本発明の海島型複合繊維は、海成分が染色可能な熱可塑性樹脂、島成分がポリプロピレン樹脂から構成される。 The sea-island type composite fiber of the present invention is composed of a thermoplastic resin capable of dyeing the sea component and a polypropylene resin as the island component.
本発明の海島型複合繊維において、海成分のポリプロピレン樹脂とは、ポリプロピレン（ＰＰ）が主成分である樹脂をいう。プロピレン単独重合体であっても、他の成分を繰り返し単位として含む共重合体であってもよい。共重合体としては、プロピレンに、例えば、エチレン、ブテン−１、ヘキセン−１等を１種以上共重合したものが挙げられる。 In the sea-island type composite fiber of the present invention, the polypropylene resin as a sea component means a resin whose main component is polypropylene (PP). It may be a propylene homopolymer or a copolymer containing other components as repeating units. Examples of the copolymer include those obtained by copolymerizing propylene with at least one of ethylene, butene-1, hexene-1 and the like.
本発明において、樹脂の融点とは、示差走査熱量計（ＤＳＣ）を用いて、窒素雰囲気下、１０℃／ｍｉｎで３００℃まで昇温した時の吸熱ピークのピークトップが示す値のことをいう。 In the present invention, the melting point of the resin means the value indicated by the peak top of the endothermic peak when the temperature is raised to 300° C. at 10° C./min in a nitrogen atmosphere using a differential scanning calorimeter (DSC). .
上記ポリプロピレンの融点は１４５℃以上、２５０℃以下が好ましい。融点が１４５℃より低いと、十分な耐熱性が得られない傾向がある。融点が２５０℃より高いと、溶融紡糸において、海成分の熱可塑性樹脂との複合が困難となる傾向があり、海島型複合繊維を得難い傾向がある。すなわち、上記の範囲であると、ポリエステル樹脂やポリアミド樹脂等の熱可塑性樹脂からなる繊維を混用して繊維構造物とした際、通常実施する、プレセットやファイナルセット等の後加工における乾熱処理（例えば、１２０〜１９０℃の乾熱処理）や染色処理（例えば、１００〜１３５℃の湿熱処理）を行うのに、十分良好な耐熱性を備えるものを得られ易い。より好ましいポリプロピレンの融点は、１６０℃以上、２３５℃以下である。 The melting point of the polypropylene is preferably 145° C. or higher and 250° C. or lower. When the melting point is lower than 145°C, sufficient heat resistance tends to be unobtainable. When the melting point is higher than 250° C., it tends to be difficult to combine with a thermoplastic resin as a sea component in melt spinning, and it tends to be difficult to obtain a sea-island type composite fiber. That is, in the above range, when fibers made of a thermoplastic resin such as a polyester resin or a polyamide resin are mixed to form a fiber structure, a dry heat treatment is usually carried out in a post-processing such as a preset or final set ( For example, it is easy to obtain one having sufficiently good heat resistance for performing a dry heat treatment at 120 to 190° C.) or a dyeing treatment (for example, a wet heat treatment at 100 to 135° C.). A more preferable melting point of polypropylene is 160° C. or higher and 235° C. or lower.
上記ポリプロピレンの２３０℃、荷重２．１６ｋｇにおけるメルトフレート（ＭＦＲ）は、９ｇ／１０ｍｉｎ以上、３０ｇ／１０ｍｉｎ以下が好ましい。すなわち、ＭＦＲが９ｇ／１０ｍｉｎ以上であれば、島部同士の融合による凝集塊が生じ難い傾向があるため、海部と島部の剥離が生じ難くなる。この結果、紡糸工程や延撚工程での製糸安定性は良好となり、染色した後に白化現象等の染色斑も生じ難い傾向がある。また繊維の機械的強度を良好に保つ点からは、ＭＦＲが３０ｇ／１０ｍｉｎ以下であることが好ましい。よって、ＭＦＲが上記の範囲内であると、島部同士の融合が生じ難く、海部と島部の剥離がなく、機械的強度の良好な繊維を得られ易い。なかでも、ＭＦＲは９ｇ／１０ｍｉｎ以上が好ましく、２０ｇ／１０ｍｉｎ以下が好ましい。より好ましくは９ｇ／１０ｍｉｎ以上、１５ｇ／１０ｍｉｎ以下である。 The melt fret (MFR) of the polypropylene at 230° C. and a load of 2.16 kg is preferably 9 g/10 min or more and 30 g/10 min or less. That is, when the MFR is 9 g/10 min or more, there is a tendency that aggregates due to the fusion of the islands are less likely to occur, and thus the sea and islands are less likely to be separated. As a result, the spinning stability in the spinning process and the twisting process becomes good, and dyeing unevenness such as whitening after dyeing tends not to occur easily. From the viewpoint of maintaining good mechanical strength of the fiber, it is preferable that the MFR is 30 g/10 min or less. Therefore, when the MFR is within the above range, the fusion of the island portions is unlikely to occur, the sea portion and the island portion are not separated, and the fiber having good mechanical strength is easily obtained. Among them, the MFR is preferably 9 g/10 min or more and 20 g/10 min or less. More preferably, it is 9 g/10 min or more and 15 g/10 min or less.
本発明の海島型複合繊維において、海成分は、染色可能な熱可塑性樹脂であれば特に限定されることはない。具体例として、例えば、ポリエステル樹脂、ポリアミド樹脂、ポリビニルアルコール樹脂が挙げられる。これらの中でも、耐熱性や機械的特性の観点からポリエステル樹脂、ポリアミド樹脂が好ましい。 In the sea-island type composite fiber of the present invention, the sea component is not particularly limited as long as it is a dyeable thermoplastic resin. Specific examples include polyester resin, polyamide resin, and polyvinyl alcohol resin. Among these, polyester resins and polyamide resins are preferable from the viewpoint of heat resistance and mechanical properties.
上記熱可塑性樹脂は、融点は１８０℃以上、２８０℃以下が好ましい。
本発明において島部は、海部の海成分に覆われており、通常のプレセットやファイナルセット等の後加工における乾熱処理でも問題のない良好な耐熱性を備えている。海成分の融点が低すぎると、乾熱処理により、海部の融解が生じ、風合いが硬くなる傾向がある。また高過ぎると、海成分との複合紡糸が難しくなる傾向がある。よって、耐熱性、安定した製糸性や海部と島部との剥離を抑制し易い点から、上記の範囲が好ましい。より好ましい上記熱可塑性樹脂の融点は、２１０℃以上、２７０℃以下であり、さらに好ましくは２２０℃以上、２６５℃以下である。
The melting point of the thermoplastic resin is preferably 180° C. or higher and 280° C. or lower.
In the present invention, the island portion is covered with the sea component of the sea portion, and has good heat resistance that causes no problem even in dry heat treatment in post-processing such as usual presetting and final setting. When the melting point of the sea component is too low, the dry heat treatment tends to cause melting of the sea part, resulting in a hard texture. On the other hand, if it is too high, the composite spinning with the sea component tends to be difficult. Therefore, the above range is preferable from the viewpoint of heat resistance, stable spinnability, and easy prevention of peeling between the sea part and the island part. The more preferable melting point of the thermoplastic resin is 210° C. or higher and 270° C. or lower, and further preferably 220° C. or higher and 265° C. or lower.
上記海成分、または島成分は、本発明の効果を損なわない範囲内で、添加物を添加することにより改質が行われたものであっても良い。添加物としては相溶化剤、熱安定化剤、酸化防止剤、蛍光増白剤、赤外線遮蔽剤、赤外線吸収剤等が挙げられる。また、添加物は単独で用いても良いし併用しても良い。
上記赤外線吸収剤としては、例えば、アンチモンドープ酸化スズ（ＡＴＯ）やスズドープ酸化インジウム（ＩＴＯ）等が挙げられる。アンチモンドープ酸化スズの場合、ポリプロピレンに対し、１質量％以上含有することが好ましく、より好ましくは、２質量％以上である。
上記赤外線遮蔽剤としては、例えば、六ホウ化ランタン（ＬａＢ６）、セシウム酸化タングステン（ＣＷＯ）、大粒子径酸化チタン（大粒径ＴｉＯ２）等が挙げられる。大粒子径酸化チタンの場合、重量平均粒子径が０．８〜１．８μｍの酸化チタンを、ポリプロピレンに対し、５質量％以上含有することが好ましい。より好ましくは、８質量％以上である。
The sea component or the island component may be modified by adding an additive within a range that does not impair the effects of the present invention. Examples of the additive include a compatibilizer, a heat stabilizer, an antioxidant, a fluorescent brightening agent, an infrared shielding agent, an infrared absorbing agent and the like. The additives may be used alone or in combination.
Examples of the infrared absorber include antimony-doped tin oxide (ATO) and tin-doped indium oxide (ITO). In the case of antimony-doped tin oxide, the content is preferably 1% by mass or more, and more preferably 2% by mass or more, based on polypropylene.
Examples of the infrared shielding agent include lanthanum hexaboride (LaB 6 ), cesium tungsten oxide (CWO), and large particle size titanium oxide (large particle size TiO 2 ). In the case of large particle size titanium oxide, it is preferable to contain titanium oxide having a weight average particle size of 0.8 to 1.8 μm in an amount of 5% by mass or more based on polypropylene. More preferably, it is 8% by mass or more.
上記ポリエステル樹脂としては、ジカルボン酸類またはそのエステル形成誘導体とジオールまたはそのエステル形成誘導体を原料として重縮合反応によって製造される線状飽和ポリエステルであればよく、ポリエチレンテレフタレート（ＰＥＴ）、ポリトリメチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート、ポリ乳酸等が挙げられるが、これらに限定されるものではない。特に、ポリエチレンテレフタレートを主体とするものが好ましく、またホモポリエステルであってもコポリエステルであってもよい。共重合成分としてはアジピン酸、セバシン酸、フタル酸、イソフタル酸、ナフタレン−２，６−ジカルボン酸、ジフェニルジカルボン酸、５−ナトリウムスルホイソフタル酸、ジフェニルスルホンジカルボン酸、ｐ−オキシエトキシ安息香酸等のジカルボン酸類またはそのエステル形成誘導体成分、またはポリエチレングリコール、ポリテトラメチレングリコール、ポリヘキサンメチレングリコールなどのポリアルキレングリコール成分を含んでいるものが好ましい。ポリアルキレングリコールには、ジエチレングリコール、プロピレングリコール、ネオペンチルグリコール、ポリオキシアルキレングリコール、ｐ−キシレングリコール、１，４−シクロヘキサンジメタノール等のジオールまたはそのエステル形成誘導体成分を含んでいてもよい。これらの共重合成分は互いに１種ずつ用いてもよいし、２種以上用いることもできる。 The polyester resin may be a linear saturated polyester produced by a polycondensation reaction using a dicarboxylic acid or its ester-forming derivative and a diol or its ester-forming derivative as raw materials, and polyethylene terephthalate (PET), polytrimethylene terephthalate, Examples thereof include, but are not limited to, polybutylene terephthalate, polyethylene naphthalate, and polylactic acid. Particularly, those mainly composed of polyethylene terephthalate are preferable, and homopolyester or copolyester may be used. Examples of the copolymerization component include adipic acid, sebacic acid, phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, diphenyldicarboxylic acid, 5-sodium sulfoisophthalic acid, diphenylsulfonedicarboxylic acid and p-oxyethoxybenzoic acid. Those containing a dicarboxylic acid or its ester-forming derivative component or a polyalkylene glycol component such as polyethylene glycol, polytetramethylene glycol or polyhexanemethylene glycol are preferable. The polyalkylene glycol may contain a diol such as diethylene glycol, propylene glycol, neopentyl glycol, polyoxyalkylene glycol, p-xylene glycol, 1,4-cyclohexanedimethanol, or an ester-forming derivative component thereof. These copolymerization components may be used each alone or in combination of two or more.
上記ポリアミド樹脂としては、ポリアミド６、ポリアミド１０、ポリアミド１２、ポリアミド６６などの単独の重合体または共重合体が挙げられ、これらに限定されるものではない。 Examples of the polyamide resin include homopolymers or copolymers of polyamide 6, polyamide 10, polyamide 12, polyamide 66 and the like, but are not limited to these.
本発明の海島型複合繊維の断面形状について、以下説明する。 The cross-sectional shape of the sea-island type composite fiber of the present invention will be described below.
本発明の海島型複合繊維は、１つ以上の海部と、２つ以上の島部とを、長さ方向に連続して形成された海島構造を有する複合繊維である。また海部と島部との接合面は、繊維長さ方向に途切れずに連続してなる海島構造を有することが好ましい。 The sea-island type composite fiber of the present invention is a composite fiber having a sea-island structure formed by continuously forming one or more sea parts and two or more island parts in the longitudinal direction. Further, it is preferable that the joint surface between the sea part and the island part has a sea-island structure which is continuous without interruption in the fiber length direction.
本発明の海島型複合繊維は、繊維表面に海成分が露出している。すなわち、繊維横断面（繊維長さ方向に垂直な繊維断面）においては、外周に海部が露出している。 The sea-island type composite fiber of the present invention has a sea component exposed on the fiber surface. That is, in the fiber cross section (fiber cross section perpendicular to the fiber length direction), the sea part is exposed on the outer periphery.
図１は、本発明の海島型複合繊維の繊維横断面の断面形状の一例を示す図である。この例では、丸断面の繊維の海部ａに、丸断面の１９個の島部ｂが繊維中央に寄り合う形で配置されている。また、海部の最小厚みは１μｍ以上で構成される。ここで、海部の最小厚みとは、繊維外周と島部外周との最短距離であり、繊維外周の法線（繊維外周の一点を通り、この点における接線に垂直な直線）をひいたときに最も近い島部の外周までの距離を示す。例えば、図１の海島型複合繊維において、繊維外周上の点ｐから法線をひき、島部ｂの外周との交点をｑとする。繊維横断面中で、この点ｐと点ｑを結ぶ線分ｐ−ｑの最も短い長さＸが海部の最小厚みとなる。
海部の最小厚みが１μｍ未満の場合、延伸工程、製織編工程、染色工程において、海成分と島成分との剥離が生じ易くなる。このため、製糸安定性の悪化、白化現象等の染色斑が生じ易い。また、乾熱処理による、島部の融解が生じ、風合いが硬くなり易い。
FIG. 1 is a view showing an example of the cross-sectional shape of the fiber cross section of the sea-island type composite fiber of the present invention. In this example, 19 island portions b having a circular cross section are arranged in the sea portion a of the fiber having a circular cross section so as to be close to the center of the fiber. Further, the minimum thickness of the sea part is 1 μm or more. Here, the minimum thickness of the sea part is the shortest distance between the fiber outer circumference and the island outer circumference, and when a normal line of the fiber outer circumference (a straight line passing through a point on the fiber outer circumference and perpendicular to a tangent line at this point) is drawn. Indicates the distance to the outer circumference of the nearest island. For example, in the sea-island type composite fiber of FIG. 1, a normal line is drawn from the point p on the outer circumference of the fiber, and the intersection point with the outer circumference of the island portion b is q. In the fiber cross section, the shortest length X of the line segment pq connecting the point p and the point q is the minimum thickness of the sea part.
When the minimum thickness of the sea part is less than 1 μm, peeling between the sea component and the island component is likely to occur in the stretching process, the weaving/knitting process, and the dyeing process. Therefore, the stability of yarn production is deteriorated and stains such as a whitening phenomenon are likely to occur. Further, the dry heat treatment causes melting of the island portion, and the texture tends to be hard.
本発明の海島型複合繊維の繊維横断面において、島部の個数を４０個以下にすることが好ましい。島部の個数が４０個以下であれば、適度な強度を備えた海部と島部の剥離が生じ難い海島型複合繊維が安定的に得られ易くなる。一方、島部の個数が４０個を超える場合は繊維中の島部の密集度が大きくなり、紡糸過程で互いの島部同士が融合し凝集塊が発生し易くなり、海部と島部の剥離が生じ易くなる傾向がある。また、より安定した繊維横断面の形成を確保する点から、配置される島部の個数は２０個以下がより好ましい。島部をこのような個数とすることにより島部同士の凝集を抑制することがさらに容易になる。加えて、海部と島部の接合面積を大きくしつつ剥離を防ぐ点から、配置される島部の個数は３個以上が好ましく、より好ましくは１０個以上である。 In the fiber cross section of the sea-island type composite fiber of the present invention, the number of islands is preferably 40 or less. When the number of islands is 40 or less, it becomes easy to stably obtain sea-island type composite fibers having appropriate strength and in which separation between the sea and islands is unlikely to occur. On the other hand, if the number of islands exceeds 40, the density of the islands in the fiber will be high, and the islands will fuse together during the spinning process and aggregates will tend to form, resulting in separation of the sea and islands. Tends to be easier. Further, from the viewpoint of ensuring a more stable formation of the fiber cross section, the number of islands arranged is more preferably 20 or less. By setting the number of islands to such a number, it becomes easier to suppress aggregation between islands. In addition, the number of islands to be arranged is preferably 3 or more, more preferably 10 or more, from the viewpoint of preventing the peeling while increasing the joint area between the sea and the islands.
本発明の海島型複合繊維の繊維横断面において、繊維横断面全体に対する海部の面積比率が３０％以上で構成される。すなわち、繊維横断面において、海部の面積比率が３０％未満であると、島部と島部の間の海部の厚さが薄くなり、島部同士が融合し、海部と島部の剥離が生じ易くなる。また、染色後に淡色となる傾向があるため、好ましくは面積比率が３５％以上であり、より好ましくは、４０％以上である。 In the fiber cross section of the sea-island composite fiber of the present invention, the area ratio of the sea part to the entire fiber cross section is 30% or more. That is, in the fiber cross section, when the area ratio of the sea part is less than 30%, the thickness of the sea part between the island parts becomes thin, the island parts are fused, and the sea part and the island part are separated from each other. It will be easier. In addition, the area ratio is preferably 35% or more, and more preferably 40% or more, because it tends to become a light color after dyeing.
本発明の海島型複合繊維の繊維横断面において、繊維横断面全体に対する島部の面積比率は、７０％以下が好ましい。島部の面積比率は、軽量性、染色性とのバランスを考慮して、適宜設定するとよい。 In the fiber cross section of the sea-island type composite fiber of the present invention, the area ratio of the island portion to the entire fiber cross section is preferably 70% or less. The area ratio of the island portion may be appropriately set in consideration of the balance between lightness and dyeability.
本発明の海島型複合繊維の繊維横断面において、島部は、島部同士が融合しない範囲で、中心部に配置することが好ましい。例えば、繊維横断面において、繊維半径をｒとした場合、繊維中心点から［半径ｒ×０．９０］以下の範囲に島部を配置することが好ましく、より好ましくは［半径ｒ×０．８５］以下の範囲に島部を配置することである。これにより、海部の最小厚みを１μｍ以上にでき易く、製糸安定性の悪化、白化現象等の染色斑を抑制し易い傾向がある。 In the fiber cross section of the sea-island type composite fiber of the present invention, it is preferable that the island portion is arranged at the center portion within a range where the island portions do not fuse with each other. For example, in the fiber cross section, when the fiber radius is r, it is preferable to arrange the island portion within a range of [radius r×0.90] or less from the fiber center point, and more preferably [radius r×0.85]. ] It is to arrange the island portion in the following range. As a result, the minimum thickness of the sea part can be easily made to be 1 μm or more, and there is a tendency that deterioration of yarn-forming stability and dyeing spots such as whitening phenomenon are easily suppressed.
本発明の海島型複合繊維において、総繊度は、製糸安定性の点から、４０ｄｔｅｘ以上、２００ｄｔｅｘ以下が好ましい。より好ましくは４０ｄｔｅｘ以上、１５０ｄｔｅｘ以下、さらに好ましくは４０ｄｔｅｘ以上、１００ｄｔｅｘ以下である。 In the sea-island type composite fiber of the present invention, the total fineness is preferably 40 dtex or more and 200 dtex or less from the viewpoint of yarn-forming stability. It is more preferably 40 dtex or more and 150 dtex or less, and further preferably 40 dtex or more and 100 dtex or less.
また、本発明の海島型複合繊維において、単糸繊度は１ｄｔｅｘ以上で構成されることが好ましい。単糸繊度が１ｄｔｅｘ未満では海部の最小厚みを１μｍ以上に維持することが難しい傾向があり、製糸安定性の悪化、白化現象等の染色斑が起こり易くなる。また、布帛にした時の風合いの点から、単糸繊度は５ｄｔｅｘ以下が好ましい。５ｄｔｅｘを超えると布帛にした時に風合いが硬いものとなり易い。より好ましくは４ｄｔｅｘ以下、さらに好ましくは３ｄｔｅｘ以下である。 In the sea-island composite fiber of the present invention, it is preferable that the single yarn fineness is 1 dtex or more. When the single yarn fineness is less than 1 dtex, it tends to be difficult to maintain the minimum thickness of the sea portion at 1 μm or more, and the yarn production stability is deteriorated and dyeing spots such as a whitening phenomenon are likely to occur. Further, from the viewpoint of the texture when made into a cloth, the single yarn fineness is preferably 5 dtex or less. If it exceeds 5 dtex, the texture tends to be hard when made into a fabric. It is more preferably 4 dtex or less, and further preferably 3 dtex or less.
本発明の海島複合繊維において、強度は、後加工の点から、２．０ｃＮ／ｄｔｅｘ以上、５．５ｃＮ／ｄｔｅｘ以下が好ましい。さらに好ましくは２．５ｃＮ／ｄｔｅｘ以上、５．０ｃＮ／ｄｔｅｘ以下である。 In the sea-island composite fiber of the present invention, the strength is preferably 2.0 cN/dtex or more and 5.5 cN/dtex or less from the viewpoint of post-processing. More preferably, it is 2.5 cN/dtex or more and 5.0 cN/dtex or less.
本発明の海島複合繊維において、伸度は、後加工の点から、２０％以上、４５％以下が好ましい。さらに好ましくは２５％以上、４０％以下である。 In the sea-island composite fiber of the present invention, the elongation is preferably 20% or more and 45% or less from the viewpoint of post-processing. More preferably, it is 25% or more and 40% or less.
本発明の海島型複合繊維の密度について説明する。島成分のポリプロピレンは密度が０．９１ｇ／ｃｍ３程度と軽量性に優れている。一方、本発明において、海成分は、染色可能な熱可塑性樹脂からなる。そのため、本発明の海島型複合繊維の密度は、繊維横断面における島部の面積比率に応じて変化する。軽量性の点から密度の小さいポリプロピレン樹脂からなる島成分の面積比率が大きい程良いが、染色性の点からポリプロピレンより密度の大きい熱可塑性樹脂からなる島成分の面積比率が大きい方が好ましい。これらのバランスを考慮すると、繊維横断面における海部の面積比率の下限は３０％であり、好ましくは３５％、より好ましくは４０％である。海部の面積比率の上限は７０％であり、好ましくは６５％、より好ましくは６０％である。このような範囲であれば軽量性と染色性の両方に優れた海島型複合繊維を得ることが容易となる。 The density of the sea-island type composite fiber of the present invention will be described. The polypropylene as an island component has a density of about 0.91 g/cm 3 and is excellent in lightness. On the other hand, in the present invention, the sea component is made of a dyeable thermoplastic resin. Therefore, the density of the sea-island type composite fiber of the present invention changes according to the area ratio of the island portion in the fiber cross section. From the viewpoint of lightness, the larger the area ratio of the island component made of a polypropylene resin having a lower density, the better, but from the viewpoint of dyeability, the larger the area ratio of the island component made of a thermoplastic resin having a higher density than polypropylene is preferable. Considering these balances, the lower limit of the area ratio of the sea part in the fiber cross section is 30%, preferably 35%, and more preferably 40%. The upper limit of the area ratio of the sea part is 70%, preferably 65%, more preferably 60%. Within such a range, it becomes easy to obtain a sea-island type composite fiber excellent in both lightness and dyeability.
本発明において、耐熱性について説明する。本発明の海島型複合繊維は、１７０℃の乾熱処理で溶融・融着が発生しないものであることが好ましい。通常、製織、製編された生地は、プレセットやファイナルセット等の乾熱処理を行う必要がある。ポリエステル繊維やポリアミド繊維を用いた生地の場合、通常１２０℃〜１８０℃で熱処理が行われる。その際に耐熱性が低い繊維を併用すると、乾熱処理時に繊維の融着・溶断が発生し、風合いの硬い生地や穴が開いた生地となってしまい、衣料用途や産業資材用途等に用いることができなくなる。この点から、耐熱性は高いほど良く、１７０℃の乾熱処理で溶融・融着が発生しないことが好ましい。 In the present invention, heat resistance will be described. It is preferable that the sea-island type composite fiber of the present invention does not cause melting and fusion in the dry heat treatment at 170°C. Usually, the woven or knitted material needs to be subjected to dry heat treatment such as presetting and final setting. In the case of a fabric using polyester fibers or polyamide fibers, heat treatment is usually performed at 120°C to 180°C. In that case, if fibers with low heat resistance are used together, the fibers will melt and melt during the dry heat treatment, resulting in a hard textured fabric or a fabric with holes, which can be used for clothing and industrial materials. Can not be. From this point of view, the higher the heat resistance, the better, and it is preferable that the heat treatment at 170° C. does not cause melting and fusion.
本発明の海島型複合繊維は、ステープル、紡績糸、フィラメント等の形態で用いることができる。本発明の海島型複合繊維は、特別な延伸方法をとらなくても、海部と島部の剥離が生じ難く、白化現象を抑制することができる。さらに、十分な強度や伸度を有しているため、長繊維としても、好適に使用できる。 The sea-island type composite fiber of the present invention can be used in the form of staple, spun yarn, filament and the like. The sea-island type composite fiber of the present invention is less likely to cause peeling between the sea part and the island part without using a special drawing method, and can suppress the whitening phenomenon. Furthermore, since it has sufficient strength and elongation, it can be suitably used as long fibers.
本発明の海島型複合繊維を用いて、種々の繊維構造物を得ることができる。繊維構造物としては、例えば、撚糸、組紐などの糸束、仮撚糸やタスラン加工糸などの加工糸、紡績糸、各種混繊糸、織編物や不織布等の布帛、詰め綿等の形態をとることができる。
特に、ポリエステル繊維やポリアミド繊維等の熱可塑性樹脂からなる繊維と混繊や交織や交編した織編物・不織布等の布帛とした繊維構造物であれば、染色性、耐熱性、軽量性などの特徴を、適宜、活用して用いることができる点で好ましい。
Various fiber structures can be obtained by using the sea-island type composite fiber of the present invention. Examples of the fiber structure include twisted yarns, yarn bundles such as braids, processed yarns such as false-twisted yarns and processed yarns of Taslan, spun yarns, various mixed yarns, cloths such as woven and knitted fabrics, and woven cotton. be able to.
In particular, in the case of a fiber structure made of a fabric such as a woven or knitted fabric or a non-woven fabric, which is a mixed fiber with a fiber made of a thermoplastic resin such as a polyester fiber or a polyamide fiber, a dyeing property, a heat resistance, a lightweight property, etc. The feature is preferable in that it can be appropriately utilized and used.
次に、本発明の海島型複合繊維を製造する方法の好適な例について説明する。 Next, a preferred example of the method for producing the sea-island type composite fiber of the present invention will be described.
まず、上記島成分のポリプロピレン樹脂および上記海成分の熱可塑性樹脂を準備する。
準備した海成分と島成分を別々に溶融して、上記断面形状となるように、紡糸口金より吐出し、冷却した後、延伸して、本発明の海島型複合繊維を得ることができる。
First, the island component polypropylene resin and the sea component thermoplastic resin are prepared.
The prepared sea component and island component are separately melted, discharged from the spinneret so as to have the above-mentioned cross-sectional shape, cooled, and then stretched to obtain the sea-island type composite fiber of the present invention.
紡糸温度は、ポリプロピレン樹脂と熱可塑性樹脂の耐熱性や紡糸性の点から２２０℃以上、３００℃以下が好ましく、２５０℃以上、２９０℃以下がより好ましい。紡糸速度は８００ｍ／ｍｉｎ以上、４５００ｍ／ｍｉｎ以下が好ましく、１０００ｍ／ｍｉｎ以上、３８００ｍ／ｍｉｎ以下がより好ましい。 The spinning temperature is preferably 220° C. or higher and 300° C. or lower, more preferably 250° C. or higher and 290° C. or lower from the viewpoint of heat resistance and spinnability of the polypropylene resin and the thermoplastic resin. The spinning speed is preferably 800 m/min or more and 4500 m/min or less, more preferably 1000 m/min or more and 3800 m/min or less.
本発明の海島型複合繊維は、海部と島部が繊維の長さ方向に連続した状態で途切れずに互いに接合していることが好ましい。この場合、延伸工程、製織編工程及び染色工程等で海部と島部の剥離が生じ難く、製糸安定性の悪化、白化現象を抑制し易い。一方、繊維の長さ方向において、島部の樹脂が途切れると、製糸安定性の悪化、白化現象等の染色斑を抑制することは困難となる傾向があるため好ましくない。 In the sea-island type composite fiber of the present invention, it is preferable that the sea part and the island part are continuously joined to each other in a continuous state in the length direction of the fiber. In this case, the sea part and the island part are less likely to be separated from each other in the stretching process, the weaving/knitting process, the dyeing process, etc., and the yarn-forming stability is deteriorated and the whitening phenomenon is easily suppressed. On the other hand, if the resin in the island portion is interrupted in the length direction of the fiber, it tends to be difficult to suppress dyeing stability such as deterioration of yarn-forming stability and whitening phenomenon, which is not preferable.
延伸温度は、製糸安定性の点から９０℃以上、１２０℃以下が好ましく、９５℃以上、１１０℃以下がより好ましい。延伸倍率は、安定的に海島型複合繊維の断面形状を得る点から２．０倍以上、３．５倍以下程度が好ましい。 The stretching temperature is preferably 90° C. or higher and 120° C. or lower, more preferably 95° C. or higher and 110° C. or lower, from the viewpoint of yarn-forming stability. The draw ratio is preferably 2.0 times or more and 3.5 times or less from the viewpoint of stably obtaining the cross-sectional shape of the sea-island type composite fiber.
なお、本発明の海島型複合繊維を製造する際には、溶融紡糸した後に一旦巻き取った後に延伸する方法や溶融紡糸した後、一旦巻き取ることなく延伸する直接紡糸延伸法など任意の方法を採用することができる。 In producing the sea-island composite fiber of the present invention, any method such as a method of melt spinning and then winding and then stretching, or a method of melt spinning and direct spinning and stretching without winding once may be used. Can be adopted.
このようにして、海部と島部の剥離がなく、製糸安定性が良好な本発明の海島型複合繊維を得ることができる。 In this way, the sea-island type composite fiber of the present invention can be obtained in which the sea part and the island part are not separated and the spinning stability is good.
このようにして得られた本発明の海島型複合繊維は、製糸安定性が良好で、耐熱性が良好なため、延伸工程、仮撚工程、製編織工程、精練工程、染色工程等の各工程でも、剥離しにくく、各工程での取り扱い性に優れる。特に、染色の際に、白化現象等の染色斑が生じたりしないため、濃色に染色ができる。 Islands-in-sea type composite fiber of the present invention obtained in this way, reeling stability is good, because the heat resistance is good, stretching step, false twisting process, knitting weaving process, spinning kneading step, each such dyeing process Even in the process, it is difficult to peel off and is easy to handle in each process. In particular, during dyeing, dyeing stains such as a whitening phenomenon do not occur, so that dark color can be dyed.
以下、本発明の実施例を示して具体的に説明するが、下記実施例は本発明を例示するものであって、本発明を限定するものではない。なお、各種物性の測定及び評価の方法は下記のように行った。 Hereinafter, although an example of the present invention is shown and explained concretely, the following example illustrates the present invention and does not limit the present invention. The methods of measuring and evaluating various physical properties were as follows.
（１）融点
示差走査熱量計（ＤＳＣ）（リガク製 「ＤＳＣ ８２３０」）を用いて、窒素雰囲気中、昇温速度１０℃／ｍｉｎで３００℃まで昇温し、吸熱ピークのピークトップを熱可塑性樹脂の融点とした。
(1) Melting point Using a differential scanning calorimeter (DSC) (“DSC 8230” manufactured by Rigaku), the temperature was raised to 300° C. in a nitrogen atmosphere at a heating rate of 10° C./min, and the peak top of the endothermic peak was thermoplastic. It was the melting point of the resin.
（２）製糸安定性
１０ｋｇの糸を生産した際の平均糸切れ回数で製糸安定性を評価し、下記の基準でＢ以上を合格とした。
Ａ：糸切れ回数が１回未満の場合
Ｂ：糸切れ回数が１回以上、３回未満の場合
Ｃ：糸切れ回数が３回以上の場合
(2) Stability of yarn making Stability of yarn making was evaluated by the average number of times of yarn breakage when producing 10 kg of yarn, and B or more was judged to be acceptable according to the following criteria.
A: When the number of thread breaks is less than 1 B: When the number of thread breaks is 1 or more and less than 3 C: When the number of thread breaks is 3 or more
（３）島部状況（融合・剥離）の確認、及び海部の最小厚み
得られた海島型複合繊維の任意の２箇所を長さ方向に垂直に切断し、切断面を電子顕微鏡により１５００倍で観察し、島部の融合・剥離の発生状況を確認した。これらの欠点が未発生のものは「良好」とした。また、同様の切断面にて海部の最小厚みを測定した。
(3) Confirmation of island condition (fusion/delamination) and minimum thickness of sea part Two arbitrary parts of the obtained sea-island type composite fiber are cut perpendicularly to the length direction, and the cut surface is 1500 times with an electron microscope. It was observed and the occurrence of fusion and peeling of the island part was confirmed. Those in which these defects did not occur were evaluated as “good”. In addition, the minimum thickness of the sea part was measured on the same cut surface.
（４）繊維の強度・伸度
ＪＩＳ Ｌ１０１３に準じて、島津製作所製オートグラフＡＧＳを用いた引張試験を行い、測定長：２００ｍｍ、引張り速度：２００ｍｍ／分の条件下にて、繊維が破断したときの破断強度、および破断伸度をそれぞれ５回測定し、その平均値を求めた。
(4) Strength/Elongation of Fiber According to JIS L1013, a tensile test was performed using an autograph AGS manufactured by Shimadzu Corporation, and the fiber was broken under the conditions of measurement length: 200 mm, pulling speed: 200 mm/min. The breaking strength and breaking elongation at that time were measured 5 times, and the average value thereof was obtained.
（５）軽量性
得られた海島型複合繊維はＪＩＳ Ｋ７１１２ Ｄ法に準じた密度勾配管法により密度を算出した。密度勾配管に重液として塩化亜鉛水溶液、軽液としてエタノールを用いて調整した浸漬液を用意し、２３℃の恒温槽２４時間静置した。試料を密度勾配管にいれ１時間静置した後、浮沈状態を確認した。軽量性は下記の基準に基づいて評価した。
Ａ：比重が１．１ｇ／ｃｍ３未満の優れた軽量性を有する。
Ｂ：比重が１．１ｇ／ｃｍ３以上、１．２ｇ／ｃｍ３未満の良好な軽量性を有する。
Ｃ：比重が１．２ｇ／ｃｍ３以上で軽量性を有していない。
(5) Lightness The density of the obtained sea-island type composite fiber was calculated by the density gradient tube method according to JIS K7112 D method. An immersion liquid prepared by using an aqueous zinc chloride solution as a heavy liquid and ethanol as a light liquid was prepared in a density gradient tube, and left standing in a constant temperature bath at 23° C. for 24 hours. The sample was placed in a density gradient tube and allowed to stand for 1 hour, after which the floating state was confirmed. Lightness was evaluated based on the following criteria.
A: It has excellent lightness with a specific gravity of less than 1.1 g/cm 3 .
B: specific gravity of 1.1 g / cm 3 or more, having a good light weight of less than 1.2 g / cm 3.
C: It has a specific gravity of 1.2 g/cm 3 or more and does not have light weight.
（６）耐熱性評価
得られた海島型複合繊維で作製した筒編地を開反した後、２０ｃｍ×２５ｃｍの枠で固定し、１７０℃の熱風にて１分間乾熱処理を行った。乾熱処理後の布帛を電子顕微鏡により１０００倍で観察し、下記の基準により評価した。
○：糸融着や溶断がなく、風合いが硬くならない場合
×：糸融着や溶断があり、風合いが硬くなる場合
(6) Heat resistance evaluation After opening the tubular knitted fabric made of the obtained sea-island type composite fiber, it was fixed with a frame of 20 cm×25 cm, and dry heat treatment was performed for 1 minute with hot air at 170° C. The cloth after the dry heat treatment was observed with an electron microscope at 1000 times and evaluated according to the following criteria.
○: When the texture does not become hard due to no thread fusion or fusing. ×: When the texture becomes hard due to thread fusion or fusing.
（７）染色性評価
得られた海島型複合繊維で作製した筒編地を、７０℃で２０分間の精練を行い、水洗、風乾し、分散染料（ダイアニックス（登録商標） ブルー ＡＣＥ）２．０％ｏ．ｗ．ｆ、浴比１：５０、１３０℃で１時間の高圧染色後、還元洗浄を常法で行い、下記の基準により評価した。
○：白化現象がない場合
×：白化現象がある場合
(7) a tubular knitted fabric produced in dyeability evaluation obtained sea-island type composite fiber, performs a fine mixing for 20 minutes at 70 ° C., washed with water, air dried disperse dye (Dianix ® Blue ACE) 2 0.0% o. w. f, bath ratio 1:50, high-pressure dyeing at 130° C. for 1 hour, reduction washing was carried out by a conventional method, and evaluation was made according to the following criteria.
○: When there is no bleaching phenomenon ×: When there is bleaching phenomenon
（８）蓄熱保温色性評価
得られた海島型複合繊維で作製した筒編地と基準とした繊維の筒編地の裏面に５ｍｍの空間を設け、黒紙を配置し、黒紙中央部に熱電対温度センサーを取り付け、試料表面より５０ｃｍ上部から５００Ｗのレフランプを１０分間照射した。基準とした繊維の筒編地との温度差の測定を行い、下記の基準により評価した。
○：照射１０分後に温度差が＋５℃以上、かつ消灯１分後に温度差が＋３℃以上ある場合
×：照射１０分後に温度差が＋５℃未満、または消灯１分後に温度差が＋３℃未満の場合
(8) Evaluation of heat storage and heat retention color property A 5 mm space was provided on the back surface of the tubular knitted fabric made of the sea-island type composite fiber and the tubular knitted fabric of the reference fiber, and black paper was placed at the center of the black paper. A thermocouple temperature sensor was attached, and a reflex lamp of 500 W was irradiated from 50 cm above the sample surface for 10 minutes. The temperature difference between the standard fiber and the tubular knitted fabric was measured and evaluated according to the following criteria.
◯: When the temperature difference is +5° C. or more after 10 minutes of irradiation, and the temperature difference is +3° C. or more after 1 minute of turning off ×: The temperature difference is less than +5° C. after 10 minutes of irradiation, or the temperature difference is less than +3° C. after 1 minute of turning off in the case of
（９）遮熱性評価
得られた海島型複合繊維で作製した筒編地と基準とした繊維の筒編地の中央部に熱電対温度センサーを取り付け、試料表面より５０ｃｍ上部から５００Ｗのレフランプを３０分間照射した。基準とした繊維の筒編地との温度差の測定を行い、下記の基準により評価した。
○：照射３０分後の温度差が−２℃未満の場合
×：照射３０分後の温度差が−２℃以上の場合
(9) Evaluation of heat shield property A thermocouple temperature sensor was attached to the center of the tubular knitted fabric made of the obtained sea-island type composite fiber and the reference tubular knitted fabric, and a reflex lamp of 500 W from 50 cm above the surface of the sample was used. Irradiated for minutes. The temperature difference between the standard fiber and the tubular knitted fabric was measured and evaluated according to the following criteria.
◯: When the temperature difference after 30 minutes of irradiation is less than −2° C. ×: When the temperature difference after 30 minutes of irradiation is −2° C. or more
〔参考例１〕
島成分にポリプロピレン（日本ポリプロ製「ＳＡ０１Ａ（登録商標）」、ＭＦＲ９ｇ／１０ｍｉｎ、融点１６４℃）、海成分にポリエチレンテレフタレート（融点２５８℃）を用い、海部：島部の面積比率が４０：６０となるように供給し、図１のように１９個の島成分が繊維中央に配置される口金から２８８℃で紡出し、延伸倍率２．５倍で延伸し、３０００ｍ／ｍｉｎの速度で巻取り、６６ｄｔｅｘ／２４ｆの海島型複合繊維を得た。得られた海島型複合繊維の繊維横断面における海部の最小厚みは１．１μｍであり、海部と島部の界面での剥離は認められず、製糸安定性は良好であった。１７０℃で１分間の乾熱処理後も融着や溶断はなく耐熱性に優れたものであった。染色性は白化現象の発生がなく、軽量性も優れていた。得られた結果を表１に示す。
[ Reference Example 1]
Polypropylene (“SA01A (registered trademark)” manufactured by Japan Polypro, MFR 9 g/10 min, melting point 164° C.) is used as the island component, and polyethylene terephthalate (melting point 258° C.) is used as the sea component, and the area ratio of the sea part to the island part is 40:60. As shown in FIG. 1, 19 island components were spun at 288° C. from a die arranged in the center of the fiber, drawn at a draw ratio of 2.5 times, and wound at a speed of 3000 m/min. A sea-island type composite fiber of 66 dtex/24f was obtained. The minimum thickness of the sea part in the fiber cross-section of the obtained sea-island type composite fiber was 1.1 μm, no peeling was observed at the interface between the sea part and the island part, and the spinning stability was good. Even after the dry heat treatment at 170° C. for 1 minute, there was neither fusion nor fusing, and the heat resistance was excellent. As for the dyeing property, the whitening phenomenon did not occur, and the lightness was excellent. The results obtained are shown in Table 1.
〔参考例２〕
海部：島部の面積比率を６０：４０とした以外は実施例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維の繊維横断面における海部の最小厚みは１．５μｍであり、海部と島部の界面での剥離は認められず、製糸安定性は良好であった。１７０℃で１分間の乾熱処理後も融着や溶断はなく耐熱性に優れたものであった。染色性は白化現象の発生がなく、軽量性も良好であった。得られた結果を表１に示す。
[ Reference Example 2]
A sea-island type composite fiber was produced in the same manner as in Example 1 except that the area ratio of sea area to island area was 60:40. The minimum thickness of the sea portion in the fiber cross section of the obtained sea-island type composite fiber was 1.5 μm, no peeling was observed at the interface between the sea portion and the island portion, and the spinning stability was good. Even after the dry heat treatment at 170° C. for 1 minute, there was neither fusion nor fusing, and the heat resistance was excellent. As for the dyeing property, the whitening phenomenon did not occur, and the lightness was good. The results obtained are shown in Table 1.
〔参考例３〕
島成分が７個配置される口金を用いた以外は実施例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維における海部の最小厚みは１．２μｍであり、海部と島部の界面での剥離は認められず、製糸安定性は良好であった。１７０℃で１分間の乾熱処理後も融着や溶断はなく耐熱性に優れたものであった。染色性は白化現象の発生がなく、軽量性も優れていた。得られた結果を表１に示す。
[ Reference Example 3]
A sea-island type composite fiber was produced in the same manner as in Example 1 except that a die in which seven island components were arranged was used. In the obtained sea-island type composite fiber, the minimum thickness of the sea part was 1.2 μm, no peeling was observed at the interface between the sea part and the island part, and the spinning stability was good. Even after the dry heat treatment at 170° C. for 1 minute, there was neither fusion nor fusing, and the heat resistance was excellent. As for the dyeing property, the whitening phenomenon did not occur, and the lightness was excellent. The results obtained are shown in Table 1.
〔参考例４〕
ポリプロピレンに対して、赤外線吸収剤としてアンチモンドープ酸化スズ（ＡＴＯ）を２質量％を添加すること以外は実施例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維における海部の最小厚みは１．２μｍであり、海部と島部の界面での剥離は認められず、製糸安定性は良好であった。１７０℃で１分間の乾熱処理後も融着や溶断はなく耐熱性に優れたものであった。染色性は白化現象の発生がなく、良好であった。また、実施例１を基準とした蓄熱保温性評価も良好であった。得られた結果を表１に示す。
[ Reference Example 4]
A sea-island composite fiber was produced in the same manner as in Example 1 except that 2% by mass of antimony-doped tin oxide (ATO) was added to polypropylene as an infrared absorber. In the obtained sea-island type composite fiber, the minimum thickness of the sea part was 1.2 μm, no peeling was observed at the interface between the sea part and the island part, and the spinning stability was good. Even after the dry heat treatment at 170° C. for 1 minute, there was neither fusion nor fusing, and the heat resistance was excellent. The dyeability was good with no whitening phenomenon. The heat storage heat retention evaluation based on Example 1 was also good. The results obtained are shown in Table 1.
〔実施例５〕
ポリプロピレンに対して、赤外線遮蔽剤として重量平均粒子径１．０μｍの大粒子径酸化チタンを８質量％を添加すること以外は実施例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維における海部の最小厚みは１．１μｍであり、海部と島部の界面での剥離は認められず、製糸安定性は良好であった。１７０℃で１分間の乾熱処理後も融着や溶断はなく耐熱性に優れたものであった。染色性は白化現象の発生がなく、良好であった。また、参考例１を基準とした遮熱性も良好であった。得られた結果を表１に示す。
[Example 5]
A sea-island type composite fiber was produced in the same manner as in Example 1 except that 8% by mass of large particle size titanium oxide having a weight average particle size of 1.0 μm was added to polypropylene as an infrared shielding agent. The minimum thickness of the sea part in the obtained sea-island type composite fiber was 1.1 μm, no peeling was observed at the interface between the sea part and the island part, and the spinning stability was good. Even after the dry heat treatment at 170° C. for 1 minute, there was neither fusion nor fusing, and the heat resistance was excellent. The dyeability was good with no whitening phenomenon. Further, the heat shield property based on Reference Example 1 was also good. The results obtained are shown in Table 1.
〔比較例１〕
通常の芯鞘糸（単芯）となる口金を用いた以外は参考例１と同様の方法で複合繊維を作製した。得られた複合繊維は芯成分と鞘成分の界面で剥離がみられた。また、染色後は白化現象が生じた。得られた結果を表２に示す。
[Comparative Example 1]
A composite fiber was produced in the same manner as in Reference Example 1 except that a spinneret that was a normal core-sheath yarn (single core) was used. The obtained composite fiber was peeled off at the interface between the core component and the sheath component. Also, a whitening phenomenon occurred after dyeing. The results obtained are shown in Table 2.
〔比較例２〕
図２のように１９個の島成分が繊維全体に均一に配置される口金を用いた以外は参考例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維の一部の島部は表面へ露出していた。また、海部と島部との界面で剥離がみられ、製糸安定性は不良であり、染色後は白化現象が生じた。１７０℃で１分間の乾熱処理で融着や溶断が発生し耐熱性は良くなかった。得られた結果を表２に示す。
[Comparative Example 2]
A sea-island type composite fiber was produced in the same manner as in Reference Example 1 except that a spinneret in which 19 island components were uniformly arranged on the entire fiber as shown in FIG. Some islands of the obtained sea-island type composite fiber were exposed to the surface. Further, peeling was observed at the interface between the sea part and the island part, the spinning stability was poor, and a whitening phenomenon occurred after dyeing. The dry heat treatment at 170° C. for 1 minute caused fusion and fusing, and the heat resistance was not good. The obtained results are shown in Table 2.
〔比較例３〕
図３のように花弁型で、島成分が繊維表面に露出するように配置される口金を用いた以外は参考例１と同様の方法で海島型複合繊維を作製した。熱可塑性樹脂が繊維表面に露出しているため、製糸安定性が悪く、複合繊維を得ることはできなかった。得られた結果を表２に示す。
[Comparative Example 3]
A sea-island type composite fiber was produced in the same manner as in Reference Example 1 except that a spinneret that was petal type and was arranged so that the island component was exposed on the fiber surface was used as shown in FIG. Since the thermoplastic resin was exposed on the surface of the fiber, the spinning stability was poor and the composite fiber could not be obtained. The results obtained are shown in Table 2.
〔比較例４〕
海部：島部の面積比率を２５：７５とした以外は参考例１と同様の方法で海島型複合繊維を作製した。得られた海島型複合繊維は島成分が融合し、１つの芯を有する芯鞘型繊維となっていた。染色後は白化現象が生じた。得られた結果を表２に示す。
[Comparative Example 4]
A sea-island type composite fiber was produced in the same manner as in Reference Example 1 except that the area ratio of sea part: island part was 25:75. The sea-island type composite fiber thus obtained was a core-sheath type fiber having one core by fusing island components. A whitening phenomenon occurred after dyeing. The obtained results are shown in Table 2.
参考例１〜４、実施例５で得られた海島型複合繊維は、耐剥離性、染色性、耐熱性が良好であったが、比較例から得られた海島型複合繊維は耐剥離性、染色性、耐熱性の少なくとも一つが不良であった。 The sea-island composite fibers obtained in Reference Examples 1 to 4 and Example 5 had good peel resistance, dyeability, and heat resistance, but the sea-island composite fibers obtained from Comparative Examples had peel resistance, At least one of dyeability and heat resistance was poor.
本発明の海島型複合繊維は、種々の繊維構造体とすることができ、インナーやスポーツウェア等の衣料用のみならず、傘地やテント地のアウトドア用品等の産業資材に好適に用いることができる。 The sea-island type composite fiber of the present invention can be made into various fiber structures, and can be suitably used not only for clothing such as innerwear and sportswear, but also for industrial materials such as outdoor products for umbrellas and tents. it can.
ａ 海部
ｂ 島部
ｐ 繊維外周の接点
ｑ 繊維外周の法線と島部外周の交点
Ｘ 海部の最小厚み
a sea part b island part p contact point of fiber periphery q intersection point of normal line of fiber periphery and island periphery X minimum thickness of sea part
Claims (6)
（ａ）島成分がポリプロピレンを主成分とするポリプロピレン樹脂
（ｂ）海成分が染色可能な熱可塑性樹脂
（ｃ）繊維横断面における海部の面積比率が３０％以上、７０％以下
（ｄ）繊維横断面における海部の最小厚みが１μｍ以上
（ｅ）重量平均粒子径が０．８μｍ以上、１．８μｍ以下の酸化チタンが、島成分のポリプロピレンに対し５質量％以上含有する A sea-island type composite fiber comprising a sea part and two or more island parts, having a sea-island structure in which the joint surface between the sea part and the island part is continuous in the fiber length direction, and satisfying the following (a) to ( e ).
(A) Polypropylene resin whose island component is polypropylene as a main component (b) Thermoplastic resin in which sea component is dyeable (c) Area ratio of sea part in fiber cross section is 30% or more and 70% or less (d) Fiber crossing The minimum thickness of the sea area on the surface is 1 μm or more
(E) Titanium oxide having a weight average particle size of 0.8 μm or more and 1.8 μm or less is contained in an amount of 5% by mass or more based on the island component polypropylene.
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