JP6718532B2 - ポリエチレンテレフタレートバルキー連続フィラメント及びこれを含む自動車用タフテッドカーペット - Google Patents
ポリエチレンテレフタレートバルキー連続フィラメント及びこれを含む自動車用タフテッドカーペット Download PDFInfo
- Publication number
- JP6718532B2 JP6718532B2 JP2019023304A JP2019023304A JP6718532B2 JP 6718532 B2 JP6718532 B2 JP 6718532B2 JP 2019023304 A JP2019023304 A JP 2019023304A JP 2019023304 A JP2019023304 A JP 2019023304A JP 6718532 B2 JP6718532 B2 JP 6718532B2
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- JP
- Japan
- Prior art keywords
- polyethylene terephthalate
- weight
- molecular weight
- continuous filament
- bulky continuous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- -1 Polyethylene terephthalate Polymers 0.000 title claims description 74
- 229920000139 polyethylene terephthalate Polymers 0.000 title claims description 71
- 239000005020 polyethylene terephthalate Substances 0.000 title claims description 71
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 55
- 229920000642 polymer Polymers 0.000 claims description 32
- 238000004040 coloring Methods 0.000 claims description 28
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 28
- 230000000704 physical effect Effects 0.000 claims description 28
- 238000006116 polymerization reaction Methods 0.000 claims description 24
- 238000011084 recovery Methods 0.000 claims description 23
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims description 20
- 238000001816 cooling Methods 0.000 claims description 17
- 238000009826 distribution Methods 0.000 claims description 15
- 239000000126 substance Substances 0.000 claims description 15
- 239000006229 carbon black Substances 0.000 claims description 14
- 238000003856 thermoforming Methods 0.000 claims description 11
- 238000004804 winding Methods 0.000 claims description 7
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 6
- 239000007790 solid phase Substances 0.000 claims description 4
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 claims description 4
- XPJGXVKMLLVAQR-UHFFFAOYSA-N OCCC1=C(C(=O)O)C=CC(=C1)C(=O)O.C(C1=CC=C(C(=O)O)C=C1)(=O)OCCO Chemical compound OCCC1=C(C(=O)O)C=CC(=C1)C(=O)O.C(C1=CC=C(C(=O)O)C=C1)(=O)OCCO XPJGXVKMLLVAQR-UHFFFAOYSA-N 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 15
- 239000000975 dye Substances 0.000 description 14
- 238000009987 spinning Methods 0.000 description 13
- 239000000835 fiber Substances 0.000 description 12
- 238000004519 manufacturing process Methods 0.000 description 12
- 238000000034 method Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 10
- 239000004744 fabric Substances 0.000 description 9
- 229920001778 nylon Polymers 0.000 description 8
- 239000004677 Nylon Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000002245 particle Substances 0.000 description 6
- 238000005979 thermal decomposition reaction Methods 0.000 description 6
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000005227 gel permeation chromatography Methods 0.000 description 4
- 238000002074 melt spinning Methods 0.000 description 4
- 229920002994 synthetic fiber Polymers 0.000 description 4
- WVDDGKGOMKODPV-UHFFFAOYSA-N Benzyl alcohol Chemical compound OCC1=CC=CC=C1 WVDDGKGOMKODPV-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 238000004364 calculation method Methods 0.000 description 3
- 239000011247 coating layer Substances 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 238000004817 gas chromatography Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 229920001707 polybutylene terephthalate Polymers 0.000 description 3
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 3
- 239000012209 synthetic fiber Substances 0.000 description 3
- 238000004448 titration Methods 0.000 description 3
- BYEAHWXPCBROCE-UHFFFAOYSA-N 1,1,1,3,3,3-hexafluoropropan-2-ol Chemical compound FC(F)(F)C(O)C(F)(F)F BYEAHWXPCBROCE-UHFFFAOYSA-N 0.000 description 2
- ISPYQTSUDJAMAB-UHFFFAOYSA-N 2-chlorophenol Chemical compound OC1=CC=CC=C1Cl ISPYQTSUDJAMAB-UHFFFAOYSA-N 0.000 description 2
- BCBHDSLDGBIFIX-UHFFFAOYSA-N 4-[(2-hydroxyethoxy)carbonyl]benzoic acid Chemical compound OCCOC(=O)C1=CC=C(C(O)=O)C=C1 BCBHDSLDGBIFIX-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000002425 crystallisation Methods 0.000 description 2
- 230000008025 crystallization Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000004043 dyeing Methods 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- BDJRBEYXGGNYIS-UHFFFAOYSA-N nonanedioic acid Chemical compound OC(=O)CCCCCCCC(O)=O BDJRBEYXGGNYIS-UHFFFAOYSA-N 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000002040 relaxant effect Effects 0.000 description 2
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 1
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 1
- PXGZQGDTEZPERC-UHFFFAOYSA-N 1,4-cyclohexanedicarboxylic acid Chemical compound OC(=O)C1CCC(C(O)=O)CC1 PXGZQGDTEZPERC-UHFFFAOYSA-N 0.000 description 1
- VZSRBBMJRBPUNF-UHFFFAOYSA-N 2-(2,3-dihydro-1H-inden-2-ylamino)-N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]pyrimidine-5-carboxamide Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C(=O)NCCC(N1CC2=C(CC1)NN=N2)=O VZSRBBMJRBPUNF-UHFFFAOYSA-N 0.000 description 1
- HZAXFHJVJLSVMW-UHFFFAOYSA-N 2-Aminoethan-1-ol Chemical compound NCCO HZAXFHJVJLSVMW-UHFFFAOYSA-N 0.000 description 1
- OONPLQJHBJXVBP-UHFFFAOYSA-N 3-(2-phenylethenyl)phthalic acid Chemical compound OC(=O)C1=CC=CC(C=CC=2C=CC=CC=2)=C1C(O)=O OONPLQJHBJXVBP-UHFFFAOYSA-N 0.000 description 1
- LLLVZDVNHNWSDS-UHFFFAOYSA-N 4-methylidene-3,5-dioxabicyclo[5.2.2]undeca-1(9),7,10-triene-2,6-dione Chemical group C1(C2=CC=C(C(=O)OC(=C)O1)C=C2)=O LLLVZDVNHNWSDS-UHFFFAOYSA-N 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- JUJWROOIHBZHMG-UHFFFAOYSA-N Pyridine Chemical compound C1=CC=NC=C1 JUJWROOIHBZHMG-UHFFFAOYSA-N 0.000 description 1
- 238000005411 Van der Waals force Methods 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 125000003368 amide group Chemical group 0.000 description 1
- 239000001000 anthraquinone dye Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 125000000664 diazo group Chemical group [N-]=[N+]=[*] 0.000 description 1
- 150000001991 dicarboxylic acids Chemical class 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 239000000706 filtrate Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- NYGZLYXAPMMJTE-UHFFFAOYSA-M metanil yellow Chemical group [Na+].[O-]S(=O)(=O)C1=CC=CC(N=NC=2C=CC(NC=3C=CC=CC=3)=CC=2)=C1 NYGZLYXAPMMJTE-UHFFFAOYSA-M 0.000 description 1
- 125000000896 monocarboxylic acid group Chemical group 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000006864 oxidative decomposition reaction Methods 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000001003 triarylmethane dye Substances 0.000 description 1
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
- D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
- D01F6/92—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/042—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
- C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
- C08G63/16—Dicarboxylic acids and dihydroxy compounds
- C08G63/18—Dicarboxylic acids and dihydroxy compounds the acids or hydroxy compounds containing carbocyclic rings
- C08G63/181—Acids containing aromatic rings
- C08G63/183—Terephthalic acids
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
- C08G63/78—Preparation processes
- C08G63/80—Solid-state polycondensation
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/20—Compounding polymers with additives, e.g. colouring
- C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
- C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
-
- 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/04—Pigments
-
- 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/06—Dyes
-
- 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
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/12—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes
- D02G1/122—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes introducing the filaments in the stuffer box by means of a fluid jet
-
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
- D05C17/02—Tufted products
- D05C17/026—Tufted products characterised by the tufted pile surface
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/04—Floor or wall coverings; Carpets
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/12—Vehicles
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Textile Engineering (AREA)
- General Chemical & Material Sciences (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Transportation (AREA)
- Artificial Filaments (AREA)
- Carpets (AREA)
- Passenger Equipment (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
Description
(a)50,000〜70,000の重量平均分子量
(b)1.6〜2.0の分子量分布(PDI)
(c)20meq/kg以下のカルボキシル末端基(CEG)の含量
(d)1.5重量%以下のジエチレングリコール(DEG)含量
(a)30,000〜70,000の重量平均分子量
(b)1.0〜2.0の分子量分布(PDI)
(C)1.5重量%以下のジエチレングリコール(DEG)含量
弾性回復率=自動車用カーペット熱成形後のフィラメントのパイル(パイル層)の高さ/自動車用カーペット熱成形前のフィラメントのパイル(パイル層)の高さ
ポリエチレンテレフタレート重合物を固状重合を実施し、液状重合物の分子量を上げる。一般的な固状重合の過程の中、バッチ固状重合機を用いて、真空条件下で140℃、4時間で水分除去のための乾燥を進め、235℃まで4時間から6時間にかけて昇温を施し、235〜245℃の温度範囲で実施例それぞれの最終目標分子量まで固状重合を実施した。また、ポリエチレンテレフタレート重合体にカーボンブラックを30重量%投入し、前記ポリエチレンテレフタレート重合物の固相重合温度の条件より低い温度の条件で固相重合を実施し、それぞれの最終目標の重量平均分子量まで固相重合を実施することにより、着色用マスターバッチチップを製造した。
原糸の固有粘度、重量平均分子量、分子量分布、CEG及びDEGの含量と着色用マスターバッチ重合物の重量平均分子量、分子量分布、DEG含量を下記表1に記載されたように調整したことを除いては、実施例1-1と同一な過程を経てポリエチレンテレフタレートBCF原糸及びカーペットをそれぞれ製造した。
1)重量平均分子量、分子量分布及び低分子物質の含量
原糸及び着色用マスターバッチをそれぞれヘキサフルオロイソプロパノール(HFIP)に溶解した後オルト-クロロフェノール(OCP)0.1wt%の希釈溶液をゲル透過クロマトグラフィー(Gel Permeation Chromatography)を用いて、低分子物質の含量、数平均分子量と重量平均分子量を測定した後、分子量の分布は数平均分子量に対する重量平均分子量の相対値で示した。
原糸及び着色用マスターバッチのカルボキシル末端基(CEG、Carboxyl End Group)は、ASTM D664及びD4094の規定により、試料0.2gを50mLの三角プラスクに入れた後、ベンジルアルコール20mLを加え、ホットプレート(hot plate)を利用して180℃まで上げ、5分間保持して試料を完全に溶解させた後、160℃に冷却して135℃に達した時に、フェノールプタルレン5〜6滴を加え、0.02N KOHで滴定し無色でピンクに変わる滴定点で下記の計算式1によってCEG含量(COOH million equiv./試料kg)を計算した。
[計算式1]
CEG=(A-B)×20×1/W
上記計算式1において、Aは試料の滴定に消費されたKOHの量(mL)であり、Bは空試料の滴定に消費されたKOHの量(mL)であり、Wは試料の重さ(g)である。
強度、伸度等の既存の繊維物性を適用せずに熱を加えながら応力(stress)を与える分析方法であるDMA(Dynamic Mechanical Analysis)を用いて、バルキー連続フィラメントの物性を測定する弾性モジュラス(Elastic modulus)概念を導入して、その結果を表1に図示しており、これにより、自動車用カーペットのパイルの回復率を測定及び予想することができる。
比較例1、2の場合、マスターバッチ内に臨界分子量以下の低分子物質が多数分布することによって、フィラメントの物性が低下したことがわかる。また、比較例2のフィラメント及びマスターバッチ重合物の重量平均分子量が比較例1よりも高くても、相対的に高いCEG又はDEG含量で熱に敏感な特性を有するため、弾性モジュラスの値には大きな差がないことをわかる。また、図4を参照すると、比較例1に基づいて製造された自動車用カーペットは、物性が不足して損傷を受けたことを確認することができ、実施例に基づいて製造された自動車用カーペットは、比較例に比べクッション感及びボリューム感に優れたことがわかる。
3:冷却区域 4:フィニッシュアプリケーター
5:供給ローラ 6:延伸ローラ
7:テクスチャユニット 8:冷却ドラム
9:弛緩ローラ 10:交絡機
11:最終取巻機 12:表糸(BCF)
13:第1基布 14:コーティング層
15:2次コーティング層
Claims (13)
- ポリエチレンテレフタレートチップ及び着色用マスターバッチチップを溶融紡糸、多段延伸して、テクスチャノズルを通過させた後、冷却及び巻取工程を含んで製造され、
10〜200℃の温度区間で1.00E+07〜5.00E+09Paの弾性モジュラス(elastic modulus)を有し、
50,000〜70,000の重量平均分子量を有する、ポリエチレンテレフタレートバルキー連続フィラメント。 - 前記ポリエチレンテレフタレートバルキー連続フィラメントは、下記の物性を有する、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
(b)1.6〜2.0の分子量分布(PDI)
(c)20meq/kg以下のカルボキシル末端基(CEG)の含量
(d)1.5重量%以下のジエチレングリコール(DEG)含量 - 前記フィラメントは、前記着色用マスターバッチチップをフィラメント全体の重量を基準に1〜8重量%含む、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップの重合物は、下記の物性を有する、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
(a)30,000〜70,000の重量平均分子量
(b)1.0〜2.0の分子量分布(PDI)
(C)1.5重量%以下のジエチレングリコール(DEG)含量 - 前記着色用マスターバッチチップの重合物は、重量平均分子量が8,000以下である低分子物質の含有量が10重量%以下である、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップの重合物は、重量平均分子量が8,000以下である低分子物質の含有量が5重量%以下である、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップの重合物は、テレフタル酸(TPA)、モノヒドロキシエチルテレフタレート(MonoHydroxyEthylTerephthalate)及びビス2-ヒドロキシエチルテレフタレート(Bis(2-HydroxytEthyl Terephthalate)の合計含有量が150ppm以下である、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップは、固相重合によって製造される、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップの重量平均分子量は、前記ポリエチレンテレフタレートバルキー連続フィラメントの重量平均分子量対比80〜120%である、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 前記着色用マスターバッチチップは染料としてカーボンブラックを前記着色用マスターバッチチップの全体重量を基準に1〜40重量%含む、請求項1記載のポリエチレンテレフタレートバルキー連続フィラメント。
- 請求項1〜10のいずれかの一項に記載されたポリエチレンテレフタレートバルキー連続フィラメントを含むパイル層;及び少なくとも一つ以上のバッキング(Backing)層を含み、
熱成形の前のパイル層の高さ対比、熱成形後のパイル層の高さである弾性回復率が35%以上である自動車用タフテッドカーペット。 - 前記バルキー連続フィラメントの繊度が700〜1500デニールである、請求項11記載の自動車用タフテッドカーペット。
- 前記パイル層は重量が180gsm〜700gsmである、請求項11記載の自動車用タフテッドカーペット。
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