JPH10273829A - Polyester conjugate fiber for sleeping mat and solid fiber for sleeping mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a polyester conjugate fiber for sleeping mat capable of providing good solid fiber performance and excellent in washing resistance and elasticity and its solid fiber. SOLUTION: This polyester conjugate fiber is obtained by eccentrically conjugating of the polythylene terephthalate or a polyester A consisting essentially of the polyethylene terephthalate with a polyethylene terephthalate-based copolymer polyester B in which 1-4.5 mol% isophthalic acid and 1-5 mol% ethylene oxide adduct of bisphenol A are copolymerized. The conjugate fiber has 3-9 mol total of copolymerization of isophthalic acid with bisphenol A ethylene oxide adduct and <=20% percentage of hollowness and 15-60% dry heat shrinkage factor at 170 deg.C and has latent crimp performance capable of developing 50-100 numbers/2.5 cm spiral crimp by free shrinkage heat treatment at 170 deg.C.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyester composite fiber for a mattress, which is excellent in laundering resistance and elasticity, as well as having good solidification performance due to the development of crimp and adhesion between fibers by heat treatment, and the solidified cotton. It is about.

[0002]

2. Description of the Related Art Conventionally, polyester fibers have many excellent properties for futons, such as bulkiness, feeling, heat retention, air permeability, etc., and have been produced and sold in large quantities as synthetic fiber futons or futons. However, most of them are for comforters, and at present, only a limited amount is used for mattresses, either alone or as a blend with cotton. In other words, although polyester fiber exhibits excellent practical performance for use in comforters, it has a large sink in human body during use for mattresses and is superior in bulkiness compared to cotton. It is said that features for comforters often appear as defects, such as a decrease.

[0003] Various proposals have conventionally been made to improve such disadvantages. For example, Japanese Patent Application Laid-Open No. Sho 62-57326 proposes a dry heat shrinkage ratio and a specific volume after heat treatment at 140 ° C. for 1 minute. Lack of sex.

Japanese Patent Publication Nos. 3-010737 and 4-5769 disclose composite fibers of polyethylene terephthalate-based copolymerized polyester obtained by copolymerizing 5-sodium sulfoisophthalic acid component and polyethylene terephthalate. Further, Japanese Unexamined Patent Application Publication No. 7-54216
Discloses a composite fiber of a polyester obtained by copolymerizing isophthalic acid and an ethylene oxide adduct of bisphenol A with polyethylene terephthalate. However, in these composite fibers, if the number of latent crimps after the heat treatment is prioritized, the yarn is hardened by applying too much heat, and as a result, the feeling becomes hard. If the texture is prioritized, heat cannot be applied much, and the number of potential crimps will be insufficient, resulting in a non-recoverable mattress with a sense of bottom contact. Further, when the mattress is washed, it is unsuitable for washing because there are drawbacks such as uneven distribution of cotton and eventually a hard feeling.

[0005]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned drawbacks, and provides a polyester composite fiber for a mattress capable of obtaining a mattress with a small reduction in bulk, excellent recoverability, and good feeling, and a fiber made of the same. An object of the present invention is to provide solid cotton for mattresses which has a small decrease in bulk, is excellent in recoverability, has a good feeling, and has excellent washing resistance.

[0006]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve such problems, and as a result, by using a specific copolymerized polyester, the heat shrinkage characteristics and the number of latent crimps have been suppressed. The inventors have found that the above objects can be achieved, and have reached the present invention. That is, the first gist of the present invention is a polyethylene which is obtained by copolymerizing polyethylene terephthalate or a polyester A containing the same as a main component, 1 to 4.5 mol% of isophthalic acid and 1 to 5 mol% of an ethylene oxide adduct of bisphenol A. A composite fiber in which terephthalate-based copolyester B is eccentrically bonded, wherein the total copolymerization of ethylene oxide adduct of isophthalic acid and bisphenol A is 3 to 9 mol%, the hollow ratio is 20% or more, and 1
A mattress having a latent heat-crimping property of a dry heat shrinkage at 70 ° C. of 15 to 60% and a spiral crimp of 50 to 100 pieces / 2.5 cm by a free shrink heat treatment at 170 ° C. Polyester composite fiber. Further, a second aspect of the present invention is a solid cotton for a mattress, comprising 80 to 50% by weight of the polyester composite fiber for a mattress and 20 to 50% by weight of a crystalline polyester binder fiber.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail. Polyethylene terephthalate (hereinafter abbreviated as PET) is preferably used as polyester A which constitutes one component of the polyester composite fiber for mattress of the present invention, and isophthalic acid (hereinafter abbreviated as IPA), 1,4-
No particular limitation is imposed on copolymers of copolymer components such as butanediol, 1,6-hexanediol, diethylene glycol and polyethylene glycol as long as the objects of the present invention are not impaired.

On the other hand, as the polyester B constituting the other component of the conjugate fiber, it is necessary to copolymerize IPA in an amount of 1 to 4.5 mol%, mainly composed of ethylene terephthalate units. Further, it is more preferable to copolymerize 2 to 4 mol% of IPA. Further, it is necessary to copolymerize ethylene oxide adduct of bisphenol A (hereinafter abbreviated as BA-EO) at 1 to 5 mol%. Furthermore, 1 to 4 mol% of BA-EO
Copolymerization is more preferred. The sum of the copolymerization amounts of IPA and BA-EO needs to be 3 to 9 mol%. More preferably, it is 4 to 8 mol%. IPA, BA-EO,
If the sum of the copolymerization amounts of IPA and BA-EO is less than 3 mol%, the crimping property becomes insufficient, and when it is made of cotton, the recovery rate becomes small, which is not preferable. On the other hand, if it exceeds 8 mol%, the fiber strength is significantly reduced due to the decrease in the melting point,
The elasticity of the solid cotton is lost, which is not preferable.

As BA-EO, bisphenol A1
Those obtained by adding 2 to 10 moles, more preferably 2 to 5 moles of ethylene oxide to the moles are suitable. The polyesters A and B constituting the composite fiber of the present invention are not particularly limited as long as they do not impair the object of the present invention even if they contain a stabilizer, a fluorescent agent, a pigment, a reinforcing agent, and the like. Absent.

The polyester composite fiber of the present invention is a hollow fiber, and its hollow ratio needs to be 20% or more. More preferably, it is at least 25%.
If it is less than 20%, there is no elasticity, which is not preferable. 20%
Although there is no particular limitation on the above, if the hollow ratio increases, hollow cracks occur and spinning operability deteriorates. Therefore, it is preferably about 35% or less.

[0011] The polyester composite fiber of the present invention comprises 170
It is necessary that the dry heat shrinkage at 15 ° C. is 15 to 60%. More preferably, it is 25 to 40%. 15%
If the amount is less than 60%, the crimp development property is reduced. If the amount exceeds 60%, the crimp becomes too fine and the feeling of the solid cotton becomes hard, which is not preferable. This heat shrinkage characteristic can be controlled by the copolymerization amount of IPA and BA-EO and the stretching ratio in the stretching step. To increase the dry heat shrinkage, increase the copolymerization amount or increase the draw ratio. To make it smaller, perform the reverse operation. The copolymerization amount is adjusted within the range specified in the claims. The draw ratio is 6% from the draw ratio at which the residual elongation of the yarn is 30%.
It is adjusted within a range of a draw ratio of 0%. With this operation, the dry heat shrinkage can be changed in the range of about 15 to 60%.

The polyester fiber of the present invention needs to exhibit a spiral crimp of 50 to 100 pieces / 2.5 cm by a free shrinkage heat treatment at 170 ° C. Furthermore, 60 to 90 pieces / 2.
Preferably it is 5 cm. If it is less than 50 pieces / 2.5 cm, it is not preferable because the recovery rate is small and sufficient cotton performance cannot be obtained when it is made into solid cotton. If it exceeds 100 pieces / 2.5 cm, the feeling of solid cotton becomes hard, which is not preferable.

The eccentric joining of two kinds of polyesters with the conjugate fiber of the present invention includes the use of an eccentric core-sheath type spinneret and a side-by-side type spinneret. Examples are as follows,
There is no particular limitation as long as the two components are bonded in a biased manner.

[0014] In addition, when the composite fiber of the present invention is formed into a solid cotton, in order to improve the permeability in the carding process,
It is preferable to provide a mechanical crimp of 6 to 12 pieces / 2.5 cm. The method of applying the mechanical crimp is not particularly limited, and examples thereof include a method using a press-in type crimping device.

A second gist of the present invention is that the above-mentioned polyester composite fiber for mattress is used as a main fiber in an amount of 80 to 50% by weight, and a crystalline polyester binder fiber of 20 to 50% is used.
It is a cotton for mattresses which can be obtained by mixing and mixing at a temperature of not less than the melting point of the binder component of the binder fiber. More preferably, the composition ratio of the solid cotton is 70 to 60% by weight of the main fiber and 30 to 40% by weight of the crystalline polyester binder fiber. If the content of the binder fiber is less than 20% by weight, the recovery rate is small and the washing resistance is poor, so that it is not preferable. If the content of the binder fiber is 50% by weight or more, the feeling becomes hard, which is not preferable.

The crystalline polyester binder fiber used for the solid cotton in the present invention comprises, for example, an aromatic polyester and an aliphatic polyester as binder components, and has a crystallization onset temperature of 90 to 130 ° C. and a melting point of 130 to 1 °.
A fiber having a copolymerized polyester at 80 ° C.,
Even a fully-melted fiber composed of only the binder component is a core-sheath type composite fiber having a polyalkylene terephthalate having a melting point of 220 ° C. or higher as a core component and the binder component described above as a sheath component. Alternatively, a side-by-side type composite fiber composed of the above two components may be used. As a specific example, a copolymer having a 50/50 molar ratio of PET / PBT (polybutylene terephthalate) as a core component and PET / PBT (polybutylene terephthalate) as a sheath component and poly-ε-
A core-sheath type composite fiber provided with a copolymerized polyester obtained by copolymerizing caprolactone in an amount of 10 to 25 mol% is exemplified.

[0017]

[Function] In the case of a composite latent crimped fiber having a normal eccentric structure, the crimping performance is enhanced to improve the solid cotton performance. However, if the number of crimps is too large, the bulk will not appear and the feeling will be reduced. Hard and paper-like. In addition, even if ordinary amorphous binder fibers are mixed to produce solid cotton for mattress, the binder softens due to drying after washing and the form of solid cotton changes, resulting in poor washing resistance. It is. The composite fiber using the copolymerized polyester of the present invention exhibits a spiral crimp with excellent compression recovery, so that the decrease in bulk is small,
It is possible to obtain solid cotton having excellent recovery properties, and it is possible to obtain solid cotton which is hardly deformed when dried after washing and has excellent washing resistance by using the cotton mixed with the crystalline binder fiber.

[0018]

Next, the present invention will be described specifically with reference to examples. The method for measuring the characteristic values is as follows. (1) Intrinsic viscosity [η] Measured at a concentration of 0.5 wt% at 20 ° C. using an equal weight mixture of phenol and ethane tetrachloride as a solvent. (2) Fineness The fineness was measured by a method specified in JIS L-1015 7-5-1A. (3) Strength Measured by the method specified in JIS L-1015 7-7. The test was judged to be acceptable at 2 g / d or more. (4) Number of latent crimps The stretched tow is cut to a length of 51 mm, heat-treated at 170 ° C for 5 minutes in a state where it can be freely shrunk, and then subjected to JIS L-
The number of crimps was measured by the method specified in 1015 7-21-1.

(5) Dry heat shrinkage The fiber was subjected to an initial load of 50 mg / d, and the yarn length l ₀ was measured.
After treatment at 70 ° C. for 15 minutes, the yarn is stretched under a load of 50 mg / d, and the yarn length l ₁ is measured. Dry heat shrinkage (%) = 100 × (l ₀ −l ₁ ) / l ₀

(6) Hand feeling of solid cotton The main fiber and the binder fiber are mixed, and the basis weight is adjusted with a card.
The web laminated at 000 g / m ² was heated at 180 ° C.
After the heat treatment for 5 minutes, a sensory test was performed and evaluated in three stages. The evaluation criteria are as follows. Note that a score of 合格 or more was considered a pass. ○ Resilient and moderate hardness △ Slightly soft × Hard

(7) Hollow ratio (%) The cross section of a single fiber of the yarn was measured by an image processing apparatus using a microscope. The hollow ratio is calculated by the following formula, and the average value of the measured values of all the single fibers (single fibers with hollow cracks) constituting the yarn is calculated, and the average value of the number of spindles attached to the spinneret (below the decimal point) (Rounded off). Hollow ratio (%) = (area of hollow part / area of entire single fiber) ×
100

(8) Washing resistance A miniature futon is made using the solid cotton produced in the manner described in (6), and washed with a commercially available detergent for 10 minutes, rinsed for 10 minutes, dewatered for 5 minutes, and dried at 70 ° C. × 5 minutes. After that, evaluation was made in three stages.
The evaluation criteria are as follows. It should be noted that "O" was accepted. ○ There is no unevenness of the solid cotton and the shape is good. △ × There is unevenness and the shape is poor.

(9) Specific volume at initial load (cc / g) The solid cotton produced according to the procedure of (6) is cut into a size of 20 cm × 20 cm and stacked to obtain 80 g. 20cm × 2
Place the plate weighs 170g in size of 0 cm, the height of the four corners of the sample is measured in cm, and the average value H _1, and the initial load during specific volume by the following equation. Specific volume at initial load (cc / g) = (20 × 20 × H ₁ ) / 80

(10) Specific volume under heavy load (cc / g) After measuring the specific volume under initial load, a weight with a load of 5230 g is placed and left for 5 minutes. After 5 minutes, load 5230g
Remove the weight and leave for 5 minutes. This operation was repeated five times, placed the weight of the load 5230G, allowed to stand for 5 minutes the height of the four corners of the sample is measured in cm units, with an average value H _2, a heavy load during the specific volume by the following formula And Specific volume at heavy load (cc / g) = (20 × 20 × H ₂ ) / 80

(11) Recovery rate (%) After measuring the specific volume at the time of initial load, place a 230 g plate and
Left, the height of the four corners of the sample is measured in cm, the average value H ₃ minutes. After measuring the specific volume under heavy load,
Remove the weight of 230 g, left for 5 minutes, the height of the four corners of the sample is measured in cm, an average value H _4, and the recovery rate by the following equation. In addition, 94% or more was considered as a pass. Recovery rate (%) = {(H ₄ −H ₂ ) / (H ₃ −H ₂ )} × 10
0

(12) Comprehensive Evaluation The spinning operability, the feeling of solid cotton, the washing resistance, and the futon performance were all evaluated. The evaluation criteria are as follows. In addition,
○ The above was regarded as a pass. ◎ The spinning operability, hand feeling of solid cotton, washing resistance, and cotton futon performance were all passed, and the hand feeling was good. ○ The spinning operability, hand feeling of cotton, washing resistance, and cotton futon performance were all passed, and the feeling was △. △ One of the spinning operability, hand feeling of solid cotton, washing resistance, and futon performance was rejected. × Two or more of the spinning operability, hand feeling of solid cotton, washing resistance, and futon cotton performance were rejected.

Example 1 Copolymerized polyester of intrinsic viscosity [0.70] obtained by copolymerizing 4 mol% of PET (A) and IPA of intrinsic viscosity [0.67] with 2 mol% of adduct of ethylene oxide of bisphenol A 2 mol After drying the two types of chips (B) under reduced pressure by a conventional method, the diameter of the chips is reduced to 1.
6 (outer diameter) /1.3 (inner diameter) mm with a hollow cross-section nozzle using a spinneret having 80 holes, a spinning temperature of 270 ° C.
At a total discharge rate of 350 g / min, the two kinds of components were composite-spun side-by-side (weight ratio 1: 1). After the spun yarn was cooled with air, it was taken off at a speed of 1000 m / min to obtain an undrawn yarn. Next, the obtained yarns are bundled, made into a 100,000-denier tow, drawn at a temperature of 70 ° C., and drawn at a draw ratio.
3.65 times, after tension heat treatment, mechanical crimping of 8 pieces / 25mm is applied by indentation type crimping machine, cut into 51mm, and the mattress of the present invention whose fiber cross section is Fig. 1 (a). A polyester composite fiber for use was obtained. Subsequently, a web obtained by blending the conjugate fiber and (what kind of) binder fiber and laminating with a card so as to have a basis weight of 2,000 g / m ² was obtained.
Heat treatment was performed at 0 ° C. for 5 minutes to obtain solid cotton for mattress of the present invention.

Examples 2 to 6 and Comparative Examples 1 to 6 Short fibers and solid cotton were prepared in the same manner as in Example 1 except that the copolymerization amount of IPA and BA-EO was changed to the number shown in Table 1. Obtained.

Examples 7 and 8, Comparative Examples 7 and 8 Short fibers and solid cotton were obtained in the same manner as in Example 1 except that the mixing ratio of the main fiber and the binder was changed to the numbers shown in Table 1.

Comparative Example 9 Short fibers and solid cotton were obtained in the same manner as in Example 1 except that the hollow ratio of the conjugate fiber was changed to the number shown in Table 1.
Table 1 shows the evaluation results of the fibers and the solid cotton obtained in the above Examples and Comparative Examples.

[0031]

[Table 1]

The fibers obtained in Examples 1 to 8 have no problem in spinning operability, and the futon cotton is excellent in feeling and washing resistance.
The futon cotton performance was also satisfactory. In contrast, in Comparative Example 1, IPA was excessively copolymerized, the fiber strength was low, and the dry heat shrinkage was high, so that the feel of the solid cotton was hard. In Comparative Example 2, IPA and IPA + BA-EO
Was insufficient and the recovery rate was low. In Comparative Example 3, the amount of BA-EO was insufficient, and the solidified cotton had a small recovery rate. In Comparative Example 4, since the IPA and BA-EO were excessive, the fiber strength was low, and the dry heat shrinkage was high, the feel of the solid cotton was hard. In Comparative Example 5, the IPA was insufficient, the crimp was small, and the recovery rate was low. In Comparative Example 6, BA-EO was excessive, the fiber strength was low, and the dry heat shrinkage ratio was high, so that the feeling of the solid cotton was hard.
In Comparative Example 7, the binder fiber was insufficient, and the washing resistance and the recovery rate were insufficient. In Comparative Example 8, the amount of binder fiber was excessive, and the feeling became hard. In Comparative Example 9, the feeling was hard because the hollow ratio was too low.

[0033]

According to the present invention, there is provided a latently crimpable polyester fiber having excellent stretchability by heat treatment. When this is made into solid cotton, solid cotton with excellent elasticity and good feeling can be obtained.

[Brief description of the drawings]

FIG. 1 is an example of a cross-sectional shape of a conjugate fiber of the present invention.

[Explanation of symbols]

 A Polyester A B Polyester B

Claims (2)

[Claims] (1) Polyethylene terephthalate or a polyester A containing the same as a main component and isophthalic acid in an amount of 1 to 4.
A composite fiber eccentrically bonded to a polyethylene terephthalate-based copolyester B obtained by copolymerizing 5 mol% and an ethylene oxide adduct of bisphenol A with 1 to 5 mol%. The total of the polymerization is 3 to 9 mol%, the hollow ratio is 20% or more, and the dry heat shrinkage at 170 ° C. is 1
5 to 60% and 50 ° C by free shrink heat treatment at 170 ° C
Polyester composite fibers for mattresses having latent crimping performance capable of expressing a spiral crimp of up to 100 pieces / 2.5 cm. 2. A solid cotton for a mattress comprising 80 to 50% by weight of the polyester composite fiber for a mattress according to claim 1 and 20 to 50% by weight of a crystalline polyester binder fiber.