JPS5838537B2 - Tsumemonosozai ni Texita 3 Jigenkenshiyukuseni no seizouhouhou - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing three-dimensional crimped fibers suitable for materials for nails, and more specifically, the present invention relates to a method for producing three-dimensional crimped fibers suitable for materials for nails, and more specifically, it is possible to produce three-dimensionally crimped fibers using a simple device from synthetic fibers having self-oscillation ability based on the difference in elastic contraction after spinning and drawing. The present invention relates to a method for efficiently producing fibers with a low crimp count and a high degree of crimp, which have a three-dimensional shape suitable for use as a material for stuffing.

Conventionally, fibers for stuffing are strongly crimped fibers with a spiral shape due to so-called structural differential crimp, such as mechanically crimped fibers using a push-type crimper, eccentric composite fibers, or fibers that are asymmetrically cooled during melt spinning. Fibers with a crimp count of 15 to 40 per 10 crfL of stretched fiber length and a crimp degree of about 15 to 60% are generally used.

Figure 1A is a photograph showing the crimp form of mechanically crimped fibers, and Figure 1A is a photograph showing the crimp form of structurally crimped fibers.

However, although webs made of these fibers have some initial bulk, the bulk decreases due to the fibers intertwining with each other due to repeated loads and kneading effects during use, and the disadvantage is that it hardly recovers even after subsequent drying or so-called beating. There is.

Furthermore, the disadvantages of conventional fibers are that when they are used for stuffing, especially for quilts, they tend to sink less, are hard, and have strong compressive elasticity, giving them the feel of a rubber sponge.

In order to eliminate these drawbacks of conventional fibers, we investigated the crimp performance of fibers and found that the number of crimp ridges of fibers is 10
If it is about 2 to 12.5 per CrfL and has a low number of crimp threads and a high crimp degree of 50% or more, and has three-dimensional crimp, it will have a very high bulk. It was found that the web had properties similar to those of a down comforter, with a large amount of sinking due to compression, a soft feel, little loss of bulk due to wear, and complete recovery when beaten.

A crimped fiber with such a three-dimensional form and a low number of crimps and a high degree of crimping cannot be obtained by mechanical crimping using a conventional push-type crimper or by eccentric composite fibers, and therefore, it is not possible to obtain a crimped fiber using a method that can be manufactured. There are only a few false twisting methods and rubbing methods.

However, since the false twisting method and the rubbing method can only employ tow denier of 1000 deniers or less, productivity is poor and it is difficult to increase the degree of crimp.

The present invention eliminates all of the drawbacks of the prior art, and produces crimped fibers having a three-dimensional shape, low crimp count, and high degree of crimp, suitable for nail materials, using a simple device, efficiently, and at low cost. The purpose is to provide a method.

That is, the present invention uses a tow of 104 denier or more made of synthetic fibers that has an asymmetrical structure in the cross-sectional direction perpendicular to the fiber axis and has a self-oscillation ability based on the difference in elastic contraction after spinning and drawing, and a tow with a water content of 10 to 200. %, tow width density is I
The single fiber was guided into a tow bending device in a sufficiently converged state of 104 to 6 x 10' denier/cIrL, and the actual fiber length (T) per bend was 8 to 50 mm, and the single fiber was measured under free condition. At the same time or after bending, the relationship between the coil diameter 0 and the actual fiber length per bend (g) satisfies the following formula, based on the difference in elastic contraction at substantially the same pitch as the bend. Develop two-dimensional crimp, then apply 0.1 to 5 mI?/
A three-dimensional crimped fiber suitable for a material for stuffing, which is characterized by applying an action such as d to the tow to convert it into three-dimensional crimp, and then performing a relaxation heat treatment to fix the crimp form. The present invention relates to a manufacturing method.

The crimped form of the low crimped, high crimped skin fiber having a three-dimensional form obtained by the method of the present invention is shown in FIG. 1C.

The most important feature of the method of the present invention is to maintain a specific relationship between the bending pitch imparted by the tow bending device and the crimp pitch that oscillates due to the self-oscillation ability based on the difference in elastic contraction, so that the tow as a whole develops crimp. The purpose is to sufficiently converge the tow as shown in FIG.

Hereinafter, the method of the present invention will be explained in detail step by step.

In the present invention, synthetic fibers having an asymmetric structure in the cross-sectional direction perpendicular to the fiber axis are made of polyester, polyamide, polyolefin, polyacrylonitrile, etc., and in which polymers with different properties are in close contact with each other along the length of the fiber, Composite fibers that are arranged eccentrically in the cross-sectional direction perpendicular to the fiber axis, or fibers that have structural differences due to differences in cooling effect in the cross-sectional direction perpendicular to the fiber axis during spinning, and are combinations of composite fiber components. For example, differences in the degree of polymerization of the same polymer, polymers with different amounts of copolymerization, different types of polymers with bonding properties, or different types of polymers with insufficient bonding properties, but if peeling is not completed during the manufacturing process. Applicable.

Furthermore, the self-oscillation ability based on the difference in elastic contraction means that even at temperatures below the glass transition temperature of the polymer (in the case of composite yarns, the transition temperature of the polymer with the lower glass transition temperature) after spinning or drawing, the tension Crimp refers to the ability to spontaneously generate crimp when removed, and generally crimp occurs due to relaxation of strain due to heat treatment or chemical treatment after spinning or drawing, or due to shrinkage difference due to the inherent properties of the polymer. It can be distinguished from oscillation ability.

In the present invention, the oscillation ability based on the difference in thermal contraction is not essentially related at all, and even if used, it is an auxiliary one, and the present invention is characterized in that the oscillation due to the difference in elastic contraction is utilized to kill the oscillation due to the difference in thermal contraction. .

The present invention provides synthetic fibers having self-oscillation ability as described above, as a means of providing the above-mentioned characteristics, by bending each filament over the entire tow from before entering the bending device until the crimp is heat-set. The filament is held in a restrained state, and the tow as a whole develops a specific crimp without allowing the filament to freely crimp.

In order to converge the tow sufficiently, it is necessary to make the tow denier 104 denier or more; if it is less than 104 denier, the tow as a whole will not be restrained enough, and even if it is shaped with a bending device, it will separate into single fibers due to the tension action. During the heat-setting process, small crimps similar to conventional spirals appear due to the oscillation ability based on the difference in thermal contraction, regardless of the bending pitch.

Therefore, it is desirable that the tow denier be larger, and in particular, for stable production, a tow of 2×10' denier or more is desirable.

Furthermore, a well-converged state of the tow can be achieved by keeping the tow moist and increasing the tow density.

The wet state of the tow requires a tow moisture content of 10 to 200%; if it is less than 10%, the convergence will be insufficient, and if it exceeds 200%, slip will increase in the bending device.

At this time, in consideration of the state of convergence of the tow and the drying efficiency in the next step, the moisture content of the tow is particularly preferably 15 to 100%.

In order to improve the convergence state of the tow, it is also possible to use a convergence agent such as an organic liquid or a sizing agent together with water.

Here, the tow moisture content is expressed as the amount of moisture per dry fiber.

The tow density, expressed in denier per 1 crfL of tow width, is required to be 104 to 6 x 106 denier/cm, which is 104
If it is less than denier/cIfL, the convergence is insufficient and crimp occurs due to the difference in heat shrinkage during the heat setting process L, 6X10
If the filament exceeds a denier, the migration of the filament increases and becomes difficult to bend, and at the same time, when crimp occurs due to the difference in elastic contraction after leaving the bending device, the contact with the adjacent crimp increases. This is disadvantageous because it reduces the degree of crimp, which can lead to deep crimp.

Migration here is a phenomenon that inevitably occurs when the tow has a certain thickness, and while the velocity (or length) of each filament is the same when the tow enters the bending device, when the tow is bent, the This is a phenomenon in which a path difference occurs between the inner and outer layers, and when a particular filament is focused on, it fluctuates between the inner and outer layers in the length direction.

Although other methods are conceivable for keeping the tow in a sufficiently converged state, the purpose of the present invention can generally be achieved by considering tow denier, tow moisture content, and tow density.

The tow, which has been sufficiently converged as described above, is then guided to a bending device by applying tension to the extent that it becomes substantially straight.

As the bending device, a pair of gears, a toothed wheel, a caterpillar, or the device shown in Japanese Patent Publication No. 33-10696 can be used, but the device is not limited to these, and any device that has the effect of buckling the tow can be used. Good to have.

The bending pitch imparted by the bending device is set such that the actual fiber length per bend is 8 to 501 m from the optimum range as described above for the filling material, that is, 2 m per actual fiber length 1OCrfL.
~12.5 peaks of bending.

Although the number of crimp ridges in the final fiber increases slightly compared to the bending imparted by the degree of tension and the thermal contraction of the fiber during heat-setting treatment, it almost satisfies the optimum range for a stuffing material.

What is important in this bending process is that the relationship between the actual fiber length per bend (Ljmrn) and the separately measured single fiber coil diameter (D) m11L under free conditions is controlled so that it satisfies the following equation. It means bending.

Here, the coil diameter of a single fiber is 0. Cut the single fiber into a length that is approximately semicircular to circular, disperse it in water at 20°C or water containing a surfactant to develop crimp, and measure the coil diameter. The so-called self-oscillation ability is the reciprocal of the coil diameter.

The range expressed by equation (1) is shown by diagonal lines in Figure 2. Outside this range, the bending applied by the bending device and the crimp that occurs based on the difference in elastic contraction do not match well. Good crimp is inevitable.

In other words, when - is 3 or less, the self-oscillation ability is insufficient compared to the given bend, so there is no crimp along the given bend, or even if it is slightly curled, the degree of crimp is low, The target crimped fiber cannot be obtained because it is completely stretched due to the tension action.

On the other hand, when - is 20 or more, the self-oscillation ability is too strong, so even if it is wound once along the given bend, its shape is very likely to collapse, and the fiber will completely collapse due to the tension action. Due to the subsequent heat treatment, fine crimps occur regardless of the bending pitch, making it impossible to obtain a low number of crimps with the targeted three-dimensional shape.

When the crimp becomes 15 mm or more, the crimp force as a whole becomes weak, and when tension is applied to the tow after it exits the bending device, the crimp tends to stretch even if the tension is less than 5772 fii'/d, which is the goal. Since it is difficult to obtain crimped fibers, D is 15.
Areas below the limit are preferred.

The tow that exits the bending device has two-dimensional crimps aligned in one direction by the bending device, so in order to convert these into three-dimensional crimps, the tow is 0.1 to 5 cm/d. After performing a treatment to impart tension, a relaxation heat treatment is performed to fix the three-dimensional crimp.

If the tension of the tow exceeds 5■/d, the tension becomes excessive and the bundled tow opens into single fibers, and the crimp of the tow after relaxation heat treatment becomes finer and the target crimp is not achieved. I can't get it.

In addition, if the tension is less than 0.1/d, the shape of the tow cannot be changed, and the two-dimensional winding and
The crimped form is fixed as it is by the relaxation heat treatment, making it impossible to obtain crimped fibers with the targeted three-dimensional form.

The crimped form of the crimped fiber obtained by the present invention is not affected by the form of bending imparted by the bending device. In other words, the bending form when the copper wire is passed through the bending device consisting of a pair of gears is as shown in Fig. 3. As shown in Figure 3, even when the fiber is passed through, the pitch differs slightly depending on the slip, but the shape is roughly as shown in Figure 3 A. On the other hand, when crimp is developed due to self-oscillation ability based on the difference in elastic contraction, the pitch is slightly different depending on the slip. It becomes a three-dimensional crimp shape, and by applying tension to make the crimp shape three-dimensional, it becomes a five-dimensional crimp shape as shown in Figure 3C.

Note that if the crimp developed based on the difference in elastic contraction and the crimp developed based on the difference in thermal contraction are in the same direction, there is no problem in heating the bending device auxiliary.

The tow is subjected to tension in order to convert its two-dimensional crimp into a three-dimensional form due to its self-oscillation ability based on the difference in elastic contraction, and is then subjected to relaxation heat treatment while each filament is converged to the extent that it is sufficiently constrained. to fix the crimped form.

The heat setting temperature must be higher than the glass transition temperature,
If the product is heated above the heat-setting temperature, fine crimp will occur due to the difference in heat shrinkage, which may affect the desired bulk, texture, etc. Determine the fixed temperature.

FIG. 4 shows an example of the process of carrying out the method of the present invention, in which unstretched tow 1 is bundled to have a stretched denier of 104 denier or more, and then a group of feed rollers 2 and a group of draw rollers 4 are assembled. It has a self-oscillating ability based on the difference in elastic contraction.

Hot water is used in the stretching bath 3 to impart sufficient moisture to the tow at the same time as stretching, but if the moisture content is less than 10%, stretching water is removed or a suitable binding agent is applied.

The stretched tow leaving the group of draw rollers 4 is transferred to the dancer roller 5
Alternatively, tension is applied by a tension applying guide (not shown) to the extent that it becomes substantially straight.

Subsequently, the tow density is adjusted through the tow width control guide 6, and the tow is guided to the bending device 7 and bent.

The bent tow is lifted by the nip roller 8, and during this time, it becomes three-dimensional due to the two-dimensional crimp and tension action developed by the self-oscillation ability based on the difference in elastic contraction, and the tow as a whole becomes as shown in Figure 3. Develops crimp.

The tow with completed crimp formation is transferred onto a net 9, and the crimp form is heat-set in a relaxation heat treatment device 10.

EXAMPLES The present invention will be specifically explained below with reference to Examples.

The definition and measurement method of crimp characteristics used in the present invention are as follows.

Number of crimp ridges: Number of crimps per actual fiber length 1oC111 (crest/10
C1n).

Here, 1° is the length when the fiber is placed in a free state on a flat surface, and ■ is the length when the fiber is subjected to a load of 9300 mm per denier.Example 1 Dissolved in 0-chlorophenol, Two types of polyethylene terephthalate with an intrinsic viscosity [η] of 0.65 and 0.55 measured at 25°C were prepared with a discharge hole diameter of 0.6 mm and a discharge hole number of 4.
Spinning temperature from 8 composite spinnerets: 280°C, polymer discharge rate: 143 f/m, spinning speed: 1600 m/rtm
Composite spinning was carried out into a bimetal type to obtain an undrawn yarn of 16.6 denier.

Next, this undrawn yarn has a drawn yarn denier of approximately 105
Gather it into denier and form a tow. Using a hot water drawing bath at 80°C, the drawing speed is 100ml/min, and the drawing ratio is changed to 2.5x, 2.8x, 3.1x, and 3.6x. The coil diameters of the single fibers, which were stretched and measured under free conditions, were 16.0 mg, 1.0.3 mm, and 4.6, respectively.
Drawn yarn tows of 2.3 mm and 2.3 mm were obtained.

Subsequently, the tow was heated to a tow moisture content of 20% and a tow width density of 4×1.
After keeping the tow in a sufficiently converged state of 0' denier/crrt and sending it to a bending device consisting of a pair of gears with a tow tension of 40 m9/d, and bending it under the conditions shown in Table 1, the tow was held under a tension of 3 m9/d. The tow was lifted by about 2 m to give a three-dimensional shape to the crimped shape, and a relaxation heat treatment was performed at 155° C. for 30 minutes.

L As a result, as shown in Table 1, when L and - satisfy the tree climbing condition, crimp characteristics having the desired crimp form were obtained.

However, L is smaller than 8 ho In this case, 4° is 50m thicker.

Although it was within the range of formula (1), the crimp shape retention was poor and the desired crimp characteristics could not be obtained.

In addition, when - is 3 or less, the crimp elongation occurs due to the tension action due to insufficient D → oscillation ability, and a fiber having the desired crimp characteristics could not be obtained.

Moreover, when - is 20 or more, the oscillation ability becomes excessive and the fibers are completely separated by the action of tension, resulting in only fibers having fine crimps as seen in the past.

Note that the gear module is the value obtained by dividing the gear outer diameter by (number of teeth + 2).

Example 2 Two types of polyethylene terephthalate similar to those in Example 1 were spun from a composite spinneret with a discharge hole diameter of 0.6 mm and a discharge hole number of 24 at a spinning temperature of 280°C and a polymer discharge rate of 146 y.
/=, the spinning speed was 1150 m/m, and composite spinning was performed in a bimetal type to obtain an undrawn yarn of 47.5 denier.

Next, this undrawn yarn was bundled into a tow to have a denier of about 05 in terms of drawn yarn denier, and was drawn at a drawing rate of 10°rrL/Nn using an 80°C hot water drawing bath at a drawing ratio of 2.0°. 8.3.2. The coil diameter 0 of the single fiber measured under free conditions after stretching at 3.5 and 3.8 times was 16.2 mm, 13.1 mm, 7.2 mm, and 4.8 mm, respectively.
A drawn yarn of 2 mm was obtained.

Subsequently, L was processed in the same manner as in Example 1 except for the conditions shown in Table 2. As a result, as shown in Table 2, L and - were
* *Fibers with the desired crimp characteristics were obtained only when the brightness was satisfied.

Example 3 The undrawn yarn obtained in Example 2 was bundled into a tow to have a denier of approximately 105 in terms of drawn yarn denier.
Stretching speed 100 m/mvt using 0°C hot water stretching bath
Then, a drawn yarn having a single fiber coil diameter 0 of 7.2 mm was obtained by drawing at a drawing ratio of 3.5 and measured under free conditions.

This drawn yarn has a tow moisture content of 20% and a tow width density of 4×104
Table 3 shows the tow tension for guiding the sufficiently converged denier/cIrL to the bending device of the gear module 6, bending it so that the bending pitch peaks are 37 peaks/peak, and then converting it to three-dimensional crimp. Change as shown, 155℃ x 30
Relaxation heat treatment was performed for 30 minutes.

Note that - was 5.1.

As is clear from Table 3, the tow tension for converting the crimp form into three dimensions is 0.
If it is less than 1 ml/d, the degree of crimp will be low, and if it is less than 5 ml/d.
If the number exceeds 0.1 to 5, the number of crimps will become too large.
/d.

Comparative Example 1 The undrawn yarn of Example 1 was bundled into a tow to have a drawn yarn denier of 105 denier, stretched at 3.1 times, cut to 90 mm, and heat-treated at 155°C for 30 minutes. did.

The obtained fiber was spirally crimped as shown in Figure 1, the number of crimps was 21.2/10crIl, and the degree of crimp was 58.3%.

Example 4 ※※
Among the samples obtained in each example, samples A 4 (A), s, 5 (B) of Example 1, sample 3 (CI, cliff 6 (D), A, 10 (E) of Example 2) 90m
The bulk properties of the webs cut into lengths of 50 mm and opened with a card were measured, and the results shown in Table 4 were obtained.

For comparison, the web and feathers obtained by opening the raw cotton obtained in Comparative Example 1 with a card were also measured.

The webs A to D obtained by the present invention have very thick initial bulk, high compression ratio, are soft, have little loss of bulk due to repeated use, and have high recovery properties when beaten, and have properties close to that of feathers. Ta.

Here, the bulk characteristics of the web are measured using a cotton cloth with a circumference of 7
Sample 40f made by making a 0 crrL cylindrical bag and passing a card into it in advance! Packed evenly over the entire surface, exposed to a compression tester (Tensilon manufactured by Toyo Soiki Co., Ltd.), and performed a compression test at a compression load of 0 to 10 tiI/crj to create a compression-force saccurve as shown in Figure 5. , the following values were obtained from this compression-force surcurve.

Note that the compression test is repeated 50 times.

The initial bulk is the bulk at a load of 0.29/cst on the compression bulk curve in the second compression test, and the bulk under compression is the bulk at a load of 10'if/crtl, and the compression ratio is [(initial bulk - bulk under compression) /Initial umbrella]
×100.

The 50th compression rear sa is the bulk at the compression-bulb curve load of 0.25'/ca in the 500th compression test, and after recovery from hitting, the sample after 50 compressions was sufficiently tapped by hand and the compression test was performed again. This is the bulk at the second compression-bulk curve load of 0.2 fl/crA.

Umbrella retention rate is [(Umbrella after hit recovery/Initial Umbrella)] x 100
In FIG. 5, A is the compression-bulk curve of Comparative Example 1, the mouth is the blade, and C is the compression-bulk curve of Sunflu A and D.

Example 5 Polymer A consisting of polycaproamide with a relative viscosity of 2.50
and Copolymer B, which has a relative viscosity of 280 and is composed of 80 parts of polycaproamide and 20 parts of polyhexamethylene adipamide, are each melted at 260°C, discharged from a bimetallic composite spinneret, treated with steam, and then untreated. The drawn yarn was wound onto a drum for winding.

The fineness of the undrawn yarn tow is 1100 denier (20 filaments).

360 of these undrawn yarn tows were bundled and stretched 3.6 times, and in a sufficiently converged state with a tow moisture content of 20% and a tow width density of 4.4 x 104 denier/crn, a module was prepared in the same manner as in Example 1. After being guided through a bending device consisting of 0.6 gears and bent, crimp is developed based on the difference in elastic contraction, and then 0.5
A tension of η/d is applied to the tow to make the contracted form three-dimensional,
Relaxation heat treatment was performed at 150° C. for 30 minutes in that state.

Note that the coil diameter 0 measured when the drawn fiber is free is 5.
2. The bending pitch L was 36, and the - was 6.9, satisfying the range of wood grains. The number of crimp threads of the obtained fiber was 7.2 threads/10 cIfL, and the degree of crimp was 59%. The target characteristics were obtained.

The relative viscosity is 98% H2S04 (25°C) 25CC
The measurement was performed by dissolving 0.25f of polymer in the water.

[Brief explanation of drawings]

Figure 1 is a photograph showing the crimped form, 42 fibers are fibers obtained by the conventional method, C are fibers obtained by the method of the present invention, and Figure 2 is the coil diameter 0 and bending of the single fiber in the method of the present invention. Graph showing the relationship with pitch (I), Figure 3 A is the form when the copper wire is bent with a bending device, the mouth is the crimp form when the fiber comes out from the bending device, and C is the form when the fiber is bent Figure 4 is a schematic diagram illustrating an example of the process of carrying out the method of the present invention, and Figure 5 is a diagram showing the compression and umbrella lines of various webs. It is a diagram.

Claims (1)

[Claims] 1 A tow of 1 x 104 denier or more made of a synthetic fiber that has an asymmetrical structure in the cross-sectional direction perpendicular to the fiber axis and has a self-oscillation ability based on the difference in elastic contraction after spinning and drawing, and a tow moisture content of 10 to 200%. , tow width density is 1×104~6
×104 denier/cIrL, which is a sufficiently converged state, is guided to a tow bending device, and the actual fiber length per bend (when the fiber length is 8
The coil diameter of the single fiber measured under free conditions so that the diameter is ~50 mm and the actual fiber length per bend (T)
Simultaneously or after bending so that the relationship between
3 by applying an action to the tow that gives a tension of ~5■/d.
3. Suitable for materials for nails, which is characterized by converting into dimensional crimp, followed by relaxation heat treatment to fix the crimp form.
A method for producing dimensional crimped fibers.