JPS62156333A - Production of polyester fabric - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention provides a non-stretched or almost non-stretched film obtained in one step of high-speed melt spinning only.

Using yarn made of polyester long fibers obtained without substantially drawing and having strength, elongation, thermal stability, and dyeability comparable to drawn yarn as the raw yarn, we can produce products with excellent quality, texture, etc. The present invention relates to a method for producing a polyester fabric having the following properties.

(Prior art) In recent years, much research has been conducted to reduce the manufacturing cost of v@ products. One of the targets of research into manufacturing methods is to reduce the manufacturing cost of polyester fabrics. That is, traditional polyester fabrics.

It is melt-spun at a low speed, wound up once, and then further stretched. Whereas drawn yarns (hereinafter referred to as rFDYJ) obtained by a so-called normal two-step process have been used as raw yarns for production, recent polyester fabrics are
We are attempting to manufacture yarn using a yarn that is obtained through a single process of high-speed melt spinning, which is simply spinning and winding at high speed, and has yarn quality performance comparable to that of FDY.

There is a lot of research on it. however.

In the case of yarn obtained by high-speed melt spinning, it is not possible to obtain a yarn with the required yarn quality performance simply by increasing the spinning speed.
In the case of yarn obtained by the conventional high-speed spinning method in which the spinning speed is increased to around 1.00 m/min, its elongation is high.
Due to its low strength, it requires a drawing process and is therefore only used as yarn for drawing and false twisting.

Even in the case of yarns obtained by conventional high-speed spinning methods of about 5000 m / min, the strength is still low and the elongation is high. Currently, it is not possible to use this yarn to produce woven fabrics such as tack, which is a general filament yarn fabric, and georgette and chiffon, which are strong twist yarn fabrics that require torque development. .

Therefore, various methods have been researched to produce yarn made of polyester fiber for clothing, which can be used in textile production and exhibits yarn quality performance comparable to FDY in terms of strength and elongation, in a single process using only melt spinning. It is.

There have been many proposals, but here are some representative ones: ■
1 strength 3.2 to 4.6 g in Japanese Patent Publication No. 35-3104
/d, a method for producing polyester fibers with an elongation of 38 to 72% is described, and
In order to obtain fibers with an elongation of 50% or less, the spun yarn is heat treated at a temperature of 80°C or higher before being taken up at a speed of 4000 m/min or higher.

The method for applying tension heat treatment after collection is described.

In addition, Japanese Patent Publication No. 55-11767 discloses a method of obtaining a large yarn with a strength of 1 by heating the yarn between a certain distance under the spinneret and a take-up roller, and Japanese Patent Publication No. 57-197- No. 161120.

A method for producing easily dyeable fibers by heat-treating polyethylene terephthalate fibers spun at a spinning speed of 4000 m/min or more is disclosed.

(Problems to be Solved by the Invention) However, in the method described in Japanese Patent Publication No. 35-3104 (1) above, heat treatment is not performed during manufacturing, so thermal shrinkage due to temperature changes during heat treatment in post-processing. Large fluctuations in stress.

This causes tension unevenness in the yarn, which causes thread unevenness such as crimp spots, thick/fine spots, and dyeing spots. Not only does it cause sink marks and dye spots, reducing the quality of the fabric.

There is a problem that it makes its operability unstable.
Furthermore, in the method described in Japanese Patent Publication No. 45-1932 (1), the first heat treatment is carried out after the running yarn is once cooled and solidified to a temperature of 80° C. or lower.

Furthermore, due to the high speed, the influence of the accompanying flow is large and it is difficult to uniformly heat the multifilament. There is a problem that the rate becomes unstable, and since two-step heat treatment is required, the yarn cost is high and it does not lead to a reduction in the textile cost. -117
In the method described in Publication No. 67, since the heating cylinder is installed directly below the cooling device, it is difficult to keep the temperature of the heating cylinder constant due to the introduction of cooling air, etc., which causes thread unevenness. The fabric manufacturing method using the yarn with many yarn irregularities obtained in this way has the problem of causing problems in terms of operation and quality of the fabric obtained, and furthermore, In the method described in Publication No. 161120, as is clear from the examples described in the publication, if heat treatment is performed for 0.1 seconds or more, the strength is 4.
A yarn with an elongation of 0 g/d or more and an elongation of 45% or less can be obtained, but because the heat treatment time is too long, the heat shrinkage stress becomes extremely small, which not only reduces the thermoplasticity at low temperatures, but also Because the fibers are thermoset, the method of manufacturing textiles using the obtained yarn can only produce hard textile products.

When dyeing the textile product, there is a problem in that it is difficult to obtain a full product using normal dyeing. Note that if the heat treatment time is less than 0.1 seconds, the above drawbacks will not occur, but the strength is less than 4.0 g/d and the elongation is less than 50 g/d.
% or more, it cannot be used as it is as a textile yarn. Even if the spinning speed is set to 6000 m/min or more, the results are as follows: Journal of Textile Science 33. T
-208 (1977) Chemiefasern/Te
Its strength is 6000 m/mi, as described in
Although it shows a maximum value near n, after that it gradually decreases as the spinning speed increases.

It has been found that the elongation decreases as the spinning speed increases, but not to the desired value.

The present invention solves the above problems, has strength and elongation comparable to FDY, and has less yarn unevenness.

The object of the present invention is to provide a method that makes it possible to manufacture inexpensive, high-quality textiles using yarn obtained by only one step of high-speed spinning that has excellent dyeability.

(Means for Solving the Problems) That is, the present invention provides the ability to
1 strength 3.5 melt spun at a speed of m/min or higher
g/d or more, the cutting elongation is 45% or less, the hot water shrinkage rate is 10% or less, and the Young's modulus at the second inflection point Y2 of the differential Young's modulus curve is Log/d or more, and the second Manufacture of a polyester woven fabric characterized by weaving yarns made of polyester long fibers that do not have a noticeable inflection point between the inflection point Y2 and the breaking point YB as the warp, weft, or warp. It's a method.

Two methods for producing polyester fabrics according to the present invention (hereinafter referred to as "the production method of the present invention") will be described in detail below.

The yarn used in the production method of the present invention is melt-spun at a speed of 4,700 m/min or more without being substantially stretched, and has a strength of 3.5 g/d or more and an elongation at break of 45% or less. , FDY with a hot water shrinkage rate of 10% or less
It has yarn quality performance of average or similar physical property values, and the Young's modulus of the secondary inflection point Y2 of its differential Young's modulus curve is 10 g/d or more, and the secondary inflection point Y
Weaving using a yarn made of polyester long fibers obtained by a one-step high-speed spinning method that does not have a noticeable inflection point between 2 and the breaking point YB as the warp, weft, or warp. This is a method for producing a fabric characterized by:

Note that the polyester long fibers used in the manufacturing method of the present invention are:
It is obtained by using a melt spinning machine such as that shown in FIG. , through a slit-type oil supply device 2 which is a concentrator, to a take-up roller 3 at a speed of 4,700 m/min or more. The yarn is heat-treated to promote crystallization and then wound onto the bobbin 5 without being substantially stretched between rollers. In this case, in order to improve the cohesiveness of the yarn Y, an interlacing treatment may be performed during the above process. .

Now, in order to make the polyester long fibers forming the yarn Y spun as described above have the above-mentioned conditions, that is, 1 strength elongation, hot water shrinkage, and differential Young's modulus characteristics, the spinneret 1 The spinning tension of the yarn Y is set to 0.8 g/d or more, preferably 1
．． 0g/d or more.

The spinning tension is higher than usual and the yarn is oriented all at once.

Then, while avoiding substantial stretching,
It is necessary to carry out heat treatment as described above to promote crystallization. However, Sengaku 34, T-93 (
1978).

Even if the spinning speed is 6000 m/min, the spinning tension is only 0.35 g/d at most.

In order to increase the spinning tension to the above-described high spinning tension, the position of the slit-type oil supply device 2, which is a concentrator, must be adjusted, or the yarn Y discharged from the spinneret must be adjusted.
Should the air resistance of the running yarn Y be increased by focusing it as far away from the spinneret as possible, or should air be strongly blown from the direction opposite to the running direction of the running yarn Y?

Alternatively, a method such as bringing the running yarn Y into contact with a friction body or the like is used.

Now, 1. The polyester long fibers used in the production method of the present invention are subject to various conditions as described above. First, one of the conditions is that the strength of the polyester long fibers is 3.5 g/d. What is there?

If the strength is less than 3.5 g/d, single yarn breakage or thread breakage is likely to occur due to insufficient strength, and when fabricated into a fabric, tear strength may decrease or problems such as pilling may occur. To prevent these, the strength must be 4.
It is preferable to set it to about 0 to 5.0 g/d.

Next, the elongation is set at 45% or less.

If the elongation exceeds 45%, sink marks may occur when woven into fabric, and operability during weaving may be impaired.

Furthermore, even if the dimensional stability is reduced, or even if the Young's modulus at the second inflection point Y2 of the differential Young's modulus curve is increased to 10 g/d or more, which will be explained in detail later, the distortion caused in the weaving process cannot be recovered. ni << Shitari.

Furthermore, even if the graininess of a strongly twisted yarn fabric is improved, taffeta tends to cause warp sink defects, so this is to prevent these, but if necessary, the elongation should be 25 to 25. Preferably, it is on the order of 35%.

Next, the hot water shrinkage rate is 10% or less.

If the hot water shrinkage rate exceeds 10%, especially when used for highly twisted fabrics, the graininess will be low, it will be difficult to obtain a hard grain or a uniform grain, and it will also cause tackiness and This is to avoid wrinkles and heat hardening during the dyeing process of highly twisted textiles, etc., and increased iron shrinkage during secondary processing. By doing so, it is possible to make the quality of the single-strongly twisted yarn fabric extremely excellent.

The degree of hot water shrinkage is preferably within the range of 2 to 6%. In addition, this hot water shrinkage rate is defined as a yarn that is wound up by a certain length with a recognition machine, and whose length under an initial load of 1 g/d is 10, and the heat that causes it to boil after being freed in the primary It is calculated by a quadratic formula when the length under an initial load of 1 g/d is 11 after being treated in water for 15 minutes and then air-dried.

Next, 1) The polyester long fiber used in the production method of the present invention has a Young's modulus value of 10 g/d or more at the second inflection point Y2 of its differential Young's modulus curve. The Young's modulus value at the secondary inflection point yz is 10 g.
/d, the orientation of the amorphous portion will not progress.

Because it is too relaxed, when yarns made of such polyester long fibers are used to weave textiles that are secondary products, they may cause sink marks or deteriorate the dimensional stability of the textiles. This is to prevent this, since not only will the fabric be dyed, but also dye spots will easily occur when dyeing the fabric. In other words, there is no significant inflection point between the second inflection point Y2 and the breaking point YB. This means that it is not completely stretched, and it does not have a point that is the boundary between the response area of the true and unstretched strands, but this has such a fiber structure. When yarns made of polyester long fibers are used as fabrics, this affects the quality and appearance of the fabric.

This is because it is an important factor that has a favorable influence on physical properties. The above differential Young's modulus is 2.A commercially available Instron Autograph DSS-500, which is a normal tensile tester, is used.
using a sample length of 30 cm and a tensile speed of 30 cm/
Measured at min. It is obtained by differentiating the stress at each point on the S-8 curve, which is a normal stress strain curve as shown in Figure 2, with respect to the elongation.

A differential Young's modulus curve is plotted with the differential Young's modulus (g/d) on the vertical axis and the stress in tension (g/d) on the horizontal axis, and this is shown in FIG.

The differential Young's modulus curve in the same figure is a typical example, and the curve relates to polyester long fibers forming yarns used in the manufacturing method of the present invention and comparative examples thereof described in the examples below. , N113. in the described sample. tt
h6. This is about Nl17.

The Young's modulus at the 71st point in FIG. 3 indicates the initial Young's modulus, and the 72nd point in the same figure indicates the normal S-8 modulus in FIG.
Corresponds to the elastic limit of 10 points on the curve ゜, and the 72
The stress at a point provides information about the cohesive force of molecular chains in the amorphous part.
In addition, the Young's modulus at the 72 points gives information on the orientation level of the molecular chains in the amorphous part, but the Young's modulus changes depending on the level of restraint tension of the molecular chains in the amorphous part, The Young's modulus at 3572 points is small, and conversely, the Young's modulus at 72 points is large when the restraint tension is high. In addition, YB in Figure 3 is 1, which is the intermediate stress value in Figure 2.
The stress at these 73 points corresponds to 2 points, and the stress at these 73 points determines the stretching tension or the stretching ratio.

This reflects information at the time of stretching, and the Young's modulus at these 73 points reflects the total orientation of molecular chains. Moreover, the stress at 78 points indicates strength.

(Function) The production method of the present invention uses, as raw yarn, yarn formed from polyester long fibers produced by a one-step high-speed spinning method that omits the drawing step in the conventional two-step method, and produces a woven fabric. It's something.

The strength, cutting elongation and hot water shrinkage rate of the yarn fiber are FDY
Although it is equivalent to the FDY fiber, its fiber structure is different from that of the FDY fiber. The Young's modulus of curve point Y2 is set to 10 g/d or more,
In addition, the fiber structure is such that there is no significant inflection point between the second inflection point Y2 and the breaking point YB.

As a result, the strong elongation and hot water shrinkage of the yarn fiber obtained by the one-step high-speed spinning method used in the production method of the present invention can be determined by FDY.
It can be equivalent to that of fiber.

It is possible to make the appearance and physical properties such as the texture of the fabric woven by this method comparable to that of the 16 f4i fabric made using FDY, and if the Young's modulus at the second inflection point Y2 is Log/d If it is lower than There is a relationship between the strength and elongation of the forming fiber, hot water shrinkage rate, and differential Young's modulus characteristics, and there is also a close relationship between these and the quality and appearance of the product fabric. In order to obtain a good woven fabric, the value of Young's modulus at the second inflection point Y2 of the differential Young's modulus curve should be set to 1.
It is an essential requirement that the value be 0 g/d or more, and the fiber structure itself has a Young's modulus value of 72 points of Log/d or more.

In the production method of the present invention, this is the most important factor in producing a fabric that is comparable to the use of FDY.

(Example) Using a melt spinning machine as shown in Fig. 1, the relative viscosity ηr1
．． No. 38 polyethylene terephthalate semidal chips were spun under various conditions shown in Table 1.

A polyester long fiber of 75d/36f was obtained which was used in both the production method of the present invention and the comparative example, and had the physical properties shown in the same table. At this time, the melting temperature is kept constant.

The temperature was set at 290°C.

Using the yarns made of polyester long fibers of each sample in Table 1 as raw yarns, one typical fabric, taffeta (common fabric), and one fabric were produced using the manufacturing method of the present invention and the method of the comparative example. Zet (strongly twisted yarn fabric) was woven under the following conditions (a) and (b), and dyed. The results are shown in Table 2.

(a) Taffeta weaving conditions: Finished warp density: 98 pieces/inch Finished weft density: 85 pieces/inch Dyeing conditions: Normal dyeing processing method (B) Georgette twisting conditions: Number of heating cycles: 2500 times/m Weaving conditions: Finished warp density: 103 Finished weft density 80 pieces/inch, 5-22 lines for both warp and warp yarns Dyeing conditions: Relax - Normal dyeing process Table 2 [Note] Each of the quality, texture, physical properties, and graininess in the above table Judgment 19 is as follows.

Quality: ○No sink marks, ×Sink marks, texture;
○ Soft, somewhat stiff, × stiff (opening softness) Physical properties; ○ Elongation/stretch rate, × High elongation/stretch (fabric elongation, shrinkage stability) Graining; ○ Graining is uniform and deep, × Less grain and no restrictions - As is clear from Table 2, the cutting elongation, hot water shrinkage, differential Young's modulus characteristics, and the quality of the woven products.

It can be seen that there is a close relationship between physical properties and graininess. Among these, it is essential that the Yz point Young's modulus value be 10 g/d or more. Namely.

Sample No. 1. As seen in Ik6, those having a 72-point Young's modulus value of less than Log/d are completely unsuitable for both general textiles and two-strong twist fabrics, regardless of other physical properties. In addition, even though the 72-point Young's modulus value of Sample Sara 5 is Log/d, the elongation exceeds 45%, so
It is not suitable for weaving taffeta because it is difficult to recover from distortions sustained in the fabric manufacturing process, and even though georgette has good graining, taffeta causes warp sink defects. In contrast, sample No. 2 according to the manufacturing method of the present invention. Th3. No
, 4 has a softer texture than that using FDY of sample grade 7, and is comparable in quality, physical properties, and graininess.

(Effects of the Invention) As described above, the production method of the present invention is characterized by the Young's modulus at the second inflection point Y2 of the differential Young's modulus curve of polyester long fibers obtained by the one-step high-speed spinning method, which has been completely overlooked in the past. As a result, we focused on the values and found appropriate values for the fabric's strength, elongation at break, hot water shrinkage rate, etc. As a result, we used yarn produced by the one-step high-speed spinning method that omitted the drawing step, and compared to the conventional two-step method. The manufacturing method of the present invention greatly contributes to cost rationalization and quality improvement. This is the manufacturing method.

[Brief explanation of drawings]

FIG. 1 is a simplified side view of only the main parts of a melt spinning machine used in the manufacturing method of the present invention, and FIG. 2 is an SS curve. FIG. 3 shows the differential Young's modulus curves. ■...Spinneret 2...Collecting tool 3...Take-up roller 4...Heating roller 5...Bobbin

Claims (1)

[Claims] (1) Melt-spun at a speed of 4,700 m/min or more without substantially stretching, with a strength of 3.5 g/d or more, a cutting elongation of 45% or less, and a hot water shrinkage rate of 10% or less, and its differential Young's modulus curve The Young's modulus of the second inflection point Y_2 is 10g/
d or more and from the second inflection point Y_2 to the breaking point Y_
A method for producing a polyester fabric, which comprises weaving yarns made of polyester long fibers that do not have a noticeable inflection point up to B as warp, weft, or warp yarns.