US20190338448A1 - Wound Yard Body of Water Absorbent Polyester Fiber and Method for Manufacturing Same - Google Patents

Wound Yard Body of Water Absorbent Polyester Fiber and Method for Manufacturing Same Download PDF

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US20190338448A1
US20190338448A1 US16/468,935 US201616468935A US2019338448A1 US 20190338448 A1 US20190338448 A1 US 20190338448A1 US 201616468935 A US201616468935 A US 201616468935A US 2019338448 A1 US2019338448 A1 US 2019338448A1
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polyester fiber
yarn body
wound yarn
wound
weight
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Hiroyuki KINOUCHI
Junko Deguchi
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Asahi Kasei Corp
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Asahi Kasei Corp
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Assigned to ASAHI KASEI KABUSHIKI KAISHA reassignment ASAHI KASEI KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DEGUCHI, JUNKO, KINOUCHI, Hiroyuki
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic Table
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • 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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/38—Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn
    • 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
    • D01F11/00—Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/04—Chemical after-treatment of artificial filaments or the like during manufacture of synthetic polymers
    • D01F11/08—Chemical after-treatment of artificial filaments or the like during manufacture of synthetic polymers of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
    • D01F6/86—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from polyetheresters
    • 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
    • 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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • 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
    • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
    • D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32—Polyesters
    • 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
    • D10B2501/00—Wearing apparel
    • D10B2501/02—Underwear
    • 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
    • D10B2501/00—Wearing apparel
    • D10B2501/04—Outerwear; Protective garments

Definitions

  • the present invention relates to a wound yarn body of a water absorbent polyester fiber and a method for manufacturing the same. More particularly, the present invention relates to a wound yarn body of a water absorbent polyester fiber capable of rapidly absorbing perspiration when worn as a result of having semi-permanent water absorbency without requiring water absorbency processing and due to superior water absorbency, and can be preferably used in innerwear, sportswear or bedding and the like due to its superior comfort and softness and favorable feel on the skin.
  • synthetic fibers such as polyester or polyamide fibers are used as general-purpose materials in innerwear, sportswear and the like
  • these synthetic fibers are hydrophobic fibers, they require water absorbency processing when used in products around the skin and have the problem of decreased absorbency following repeated washing.
  • the loss of water absorbency processing agent is remarkable thereby requiring a need for improvement of washing durability.
  • PTL1 indicated below describes the production of a polyester fiber woven or knitted fabric having water absorbency by carrying out alkaline processing on polyester fiber followed by treating with a treatment solution containing a hydrophilic agent.
  • a treatment solution containing a hydrophilic agent since performance decreases due to repeated washing in the case of ordinary polyester subjected to alkaline processing and water absorbency processing, water absorbency having washing durability cannot be imparted.
  • water absorbency having washing durability can be imparted by carrying out alkaline treatment on a fabric containing polyester fiber containing 0.005% by weight to 0.5% by weight of elemental S in the case of PTL2, or carrying out alkaline treatment on a fabric containing polyester fiber containing 0.5 mol % to 5 mol % of an ester-forming sulfonate compound in the case of PTL3.
  • alkaline treatment cannot be carried out on fabric containing a blend of materials not having resistance to alkali, and in the case of blending yarn subjected to water repellency processing, there is the problem of the water repellency decreasing.
  • a problem to be solved by the present invention is to provide a material that demonstrates semi-permanent water absorbency even in the case of not subjecting to water absorbency treatment and is free of resistance to alkali, and a wound yarn body of a water absorbent polyester fiber enabling interknitting of yarn and the like subjected to water repellency processing, and to inhibit the generation of white powder that causes problems in processes using the wound yarn body.
  • the inventors of the present invention found that the aforementioned problem can be solved by preventing re-adherence of a cyclic oligomer that is the origin of a white powder to polyester fiber when alkaline treatment is carried out on a specific polyester fiber by a specific method, thereby leading to completion of the present invention.
  • n is an integer of 3 to 10.
  • the wound yarn body of a water absorbent polyester fiber of the present invention can be preferably used in innerwear or sportswear and the like since it absorbs water semi-permanently even in the case of not subjecting to water absorbency processing without generating a white powder in the winding and knitting steps of wound yarn, is able to rapidly absorb perspiration when worn, demonstrates superior comfort and has a favorable soft feel on the skin.
  • FIG. 1 is a schematic diagram of a wrap reel used when measuring the adhered amount of a white powder.
  • FIG. 2 is UV chromatograph (240 nm) obtained during LC/MS measurement.
  • FIG. 3 is a drawing showing the estimated structures of characteristic peaks in the UV chromatogram of FIG. 2 .
  • the water absorbent polyester fiber composing the wound yarn body of the present embodiment has water absorbency (as determined by JIS L1907:2010) after washing 30 times according to Method 103 C of JIS L0217:1995 of 5 seconds or less when producing a knitted fabric using that fiber and measuring the water absorbency thereof.
  • Water absorbency after washing 30 times is preferably 3 seconds or less, more preferably 2 seconds or less and even more preferably 1 second or less.
  • Water absorbency after washing 15 times according to the same method is preferably 5 seconds or less, more preferably 3 seconds or less, even more preferably 2 seconds or less and particularly preferably 1 second or less.
  • the polyester fiber that composes the wound yarn body of the present embodiment is able to retain water absorbency even after washing in the same manner 50 times or 100 times, and water absorbency after washing 50 times or 100 times is more preferably 5 seconds or less.
  • Ordinary detergents such as neutral detergents or weakly alkaline detergents are preferably used for the detergent when washing.
  • the water absorbent polyester fiber composing the wound yarn body of the present embodiment also has the superior effect of sustaining water absorbency effects even during industrial washing.
  • Industrial washing refers to washing under severe conditions using a home washing machine that is applied to the laundering of work clothes or uniforms and the like, an example of a method thereof is defined by the F-2 medium temperature washer method of JIS L1096:2010 8.39.5b) 2.2.2), and an additive such as hydrogen peroxide or sodium silicate is normally added in addition to the detergent component.
  • a fabric of the present embodiment preferably has water absorbency of 5 seconds or less after washing 30 times for 30 minutes at 60° C. in accordance with the F-2 method of JIS L1096:2010.
  • the adhered amount of white powder is measured using the wrap reel shown in FIG. 1 (Model SSD-3, Daiei Kagaku Seiki Mfg. Co., Ltd.).
  • White powder adhered to the fiber surface can be collected by rubbing the yarn surface with a tensioner for applying tension when winding with the wrap reel. According to this method, although the adhered white powder cannot be completely collected from the yarn surface, whether or not there is a problem with the level at which the white powder is collected can be judged in terms of practical use.
  • yarn 2 that is drawn out from a wound yarn body 1 is wound with a bobbin frame 6 (bobbin frame circumference: 1.0 m) after passing through a snail guide 3 (Model A408067-R, Yuasa Yarn Guide Engineering Co., Ltd.), ring tensioner 4 (Model HRB6-12 Toyo Machine Works Co., Ltd.) and traverse guide 5 (Model A408132-R, Yuasa Yarn Guide Engineering Co., Ltd.) in that order.
  • a snail guide 3 Model A408067-R, Yuasa Yarn Guide Engineering Co., Ltd.
  • ring tensioner 4 Model HRB6-12 Toyo Machine Works Co., Ltd.
  • traverse guide 5 Model A408132-R, Yuasa Yarn Guide Engineering Co., Ltd.
  • the height from the floor on which the wound yarn body 1 is placed to the snail guide 3 was set at 800 mm, and the wound yarn body 1 was placed so that a vertical line extending from the center of the yarn guide hole of the snail guide 3 overlaps with the central axis of the wound yarn body 1 .
  • the height from the snail guide 3 to the yarn inlet hole of the ring tensioner 4 was set at 400 mm and the angle of the yarn 2 entering the yarn inlet hole of the ring tensioner 4 from the snail guide 3 was set at 90 degrees.
  • the load applied with the ring tensioner 4 used a total of 6 rings weighing 1.2 g each.
  • the location of the traverse guide 5 was a location at a horizontal distance from the yarn outlet hole of the ring tensioner 4 of 250 mm and 50 mm lower than the height of the yarn outlet hole of the ring tensioner 4 .
  • the location of the bobbin frame 6 was such that the height of the yarn guide hole of the traverse guide 5 and the center of the axis of rotation of the bobbin frame 6 are equal, and the distance from the traverse guide 5 to the center of the axis of rotation of the bobbin frame 6 was 533 mm.
  • the oscillating width of the traverse guide 5 was set to 50 mm, traverse speed was 120 mm/min, winding speed was 120 m/min, and approximately 1000 m of yarn were wound onto the bobbin frame 6 .
  • the amount of white powder adhered to the yarn was calculated based on the change in weight of the wound yarn using the following equation:
  • A weight (g) prior to rewinding onto the wound yarn body
  • B weight (g) after rewinding onto the wound yarn body
  • C weight (g) of the rewound yarn
  • the adhered amount of white powder is less than 0.3% by weight, preferably less than 0.2% by weight, and more preferably less than 0.1% by weight. If the adhered amount of white powder exceeds 0.3% by weight, unwinding becomes poor, adhesion of white powder to a knitting machine, weaving machine, winder or other guide or yarn path becomes severe, or the accumulation of white powder causes tension abnormalities and process problems.
  • the polyester fiber composing the wound yarn body of the present embodiment is characterized by the presence of a linear oligomer component having a carboxyl group on the terminal thereof (to also be referred to as a “terminal carboxylic acid linear oligomer component” in the present description) on the fiber surface.
  • a linear oligomer component having a carboxyl group on the terminal thereof to also be referred to as a “terminal carboxylic acid linear oligomer component” in the present description
  • Moisture absorbency demonstrates repeated washing durability due to the presence of the terminal carboxylic acid linear oligomer component on the fiber surface.
  • an example of a terminal carboxylic acid linear oligomer component is represented by the following formula (1):
  • a wound yarn body of a polyester fiber in which a terminal carboxylic acid linear oligomer component is present in this manner has superior water absorption performance.
  • the presence of the oligomer component can be confirmed by qualifying or quantifying according to the analytical methods described below.
  • a sample in the form of 100 mg of polyester yarn extracted from a wound yarn body was placed in a glass sample bottle having a volume of 20 mL (As One Laboran Pack Screw Tube Bottle 9-852-07 No. 5) followed by the addition of 3 mL of THF. After stirring for 6 hours at a rotating speed of about 800 rpm using a Yamato Magnetic Stirrer Model M-41, the sample was allowed to stand undisturbed for 4 days followed by extracting the sample by carrying out LC/MS on the THF solution and analyzing the components.
  • FIG. 2 indicates an example of the chart of a UV chromatogram (240 nm) of the THF solution.
  • FIG. 3 indicates the estimated structures of characteristic peaks in the UV chromatogram of FIG. 2 .
  • the mass spectrogram of a mass number of 785 (vertical axis: detection intensity of specific mass number, horizontal axis: retention time) is displayed, and whether or not the oligomer was present was able to be determined according to whether or not a detection intensity peak of the mass number in the vicinity of the retention time estimated from the example of the UV spectrum (approx. 4.5 min. in FIG. 2 ) was present.
  • the location of peak c corresponding to the internal standard substance is estimated by detecting the ion of that mass number in an ESI-mass spectrum of that peak.
  • the area of peak z of the sample in question can be converted to the area of peak x by using the area of peak z in the mass chromatogram having a mass number of 785 as previously described and determining the intensity ratio between x and z by measuring a different sample in which both peak x and peak z are clearly detected under the same conditions.
  • the intensity ratio with peak c can then be calculated by using the area of peak x of the sample in question determined in this manner.
  • the amount of the cyclic oligomer represented by formula (2) can also be analyzed by LC-MS (liquid chromatography-mass spectroscopy) by dissolving in THF with respect to cyclic oligomers having a comparatively low molecular weight, and the concentration thereof as converted from the internal standard can be determined from the peak intensity ratio relative to the internal standard.
  • LC-MS liquid chromatography-mass spectroscopy
  • Peak b can be confirmed to be derived the cyclic oligomer component (molecular weight: 576.13) as a result of an ion [(M+NH4)]+) having a mass number of 594.16 being detected in the ESI-mass spectrum of that peak (electrospray ionization, positive ion mass spectrum).
  • the amount of this oligomer present can be measured with the value of the peak area in the UV chromatogram, and that value can be converted to a concentration based on the ratio with the value of the peak area of peak (peak c) in the UV chromatogram of the methyl benzoate added as internal standard.
  • the wound yarn body of the present embodiment preferably retains a comparatively high molecular weight terminal carboxylic acid linear oligomer that is not extracted with THF on the surface of the polyester fiber composing the wound yarn body even after having extracted the aforementioned oligomer components that are soluble in THF. Since this terminal carboxylic acid linear oligomer demonstrates high adhesiveness with fiber and is resistance to elimination even after repeated washing, it is thought to demonstrate considerable effectiveness due to its water absorbency after repeated washing.
  • There are no particular limitations on the method used to make these oligomers present and although they may be imparted by a method such as coating a terminal carboxylic acid linear oligomer component on a fabric or mixed into an ester polymer, they are preferably imparted to the vicinity of the fiber surface by subjecting a specific polyester fiber to a specific alkali treatment.
  • the wound yarn body of the present embodiment is preferably characterized by containing polyester fiber containing 0.005% by weight to 1% by weight of elemental S (elemental sulfur).
  • elemental S elemental sulfur
  • a water absorbency effect is obtained by carrying out a specific alkali treatment on polyester fiber containing 0.005% by weight to 1% by weight of elemental S, resulting in a line of yarn that exhibits hardly any change in that effect even after repeated washing.
  • the content of elemental S is less than 0.005% by weight, the effect of enhancing the durability of water absorbency after alkali treatment diminishes, while in the case the amount of elemental S contained in the polyester fiber is 1% by weight or more, fiber strength decreases making spinning difficult.
  • the content of elemental S in the polyester fiber is more preferably 0.01% by weight to 0.8% by weight and even more preferably 0.015% by weight to 0.7% by weight.
  • ICP-AES inductively coupled plasma-optical emission spectrometry
  • An example of a polyester fiber containing 0.005% by weight to 1% by weight of elemental S is a polyester fiber containing 0.5 mol % to 5 mol % of an ester-forming sulfonate compound.
  • ester-forming sulfonate compounds contained at 0.5 mol % to 5 mol % in a polyester fiber include sodium 5-sulfoisophthalate, potassium 5-sulfoisophthalate, sodium 4-sulfo-2,6-naphthalene dicarboxylic acid, sodium 2-sulfo-4-hydroxybenzoic acid, 3,5-dicarboxylic acid benzenesulfonic acid tetramethyl phosphonium salt, 3,5-dicarboxylic acid benzenesulfonic acid tetrabutyl phosphonium salt, 3,5-dicarboxylic acid benzenesulfonic acid tributylmethyl phosphonium salt, 2,6-dicarboxylic acid naphthalene-4-sulfonic acid tetrabutyl phosphonium salt, 2,6-dicarboxylic acid naphthalene-4-sulfonic acid tetramethyl phosphonium salt, 3,5-dicarboxylic acid n
  • the polyester fiber preferably contains a metal sulfonate group-containing isophthalic acid component such as sodium 5-sulfoisophthalic acid or potassium 5-sulfoisophthalic acid, and among these, sodium dimethyl 5-sulfoisophthalate is particularly preferable.
  • polyester fiber containing 0.005% by weight to 1% by weight of elemental S is polyester fiber containing a non-ester-forming sulfonate compound.
  • a non-ester-forming sulfonate compound refers to a polyester fiber containing a sulfonate compound without forming a polyester as a result of a sulfonate compound undergoing polycondensation by undergoing a direct esterification reaction with polyester, and examples thereof include polyester fiber obtained by a method consisting of mixing a master chip incorporating 0.5 mol % to 5 mol % of a sulfonate compound with a polyester chip in which an ordinary ethylene terephthalate component is 95 mol % or more, and polyester fiber obtained by adding 0.5 mol % to 5 mol % of a sulfonate compound.
  • Examples of a non-ester-forming sulfonate compound include alkaline metal salts of an alkyl sulfonic acid, and alkaline metal salts of an alkyl benzenesulfonic acid.
  • Examples of alkaline metal salts of an alkyl sulfonic acid include sodium dodecyl sulfonate, sodium undecyl sulfonate and sodium tetradecyl sulfonate.
  • alkaline metal salts of an alkyl benzenesulfonic acid include sodium dodecyl benzenesulfonate, sodium undecyl benzenesulfonate and sodium tetradecyl benzenesulfonate.
  • Sodium dodecyl benzenesulfonate is particularly preferable from the viewpoint of processing stability.
  • the total fineness of the water absorbent polyester fiber is preferably about 8 decitex (dtex) to about 167 dtex and more preferably about 22 dtex to about 110 dtex. Although there are no particular limitations on single yarn fineness, it is preferably about 0.5 dtex to about 2.5 dtex from the viewpoints of feel on the skin and texture.
  • the water absorbent polyester fiber may also contain a matting agent such as titanium dioxide, stabilizer such as phosphoric acid, ultraviolet absorber such as a hydroxybenzophenone derivative, crystallization nucleating agent such as talc, lubricant such as fumed silica, antioxidant such as a hindered phenol derivative, flame retardant, antistatic agent, pigment, fluorescent whitening agent, infrared absorber or antifoaming agent.
  • a matting agent such as titanium dioxide, stabilizer such as phosphoric acid, ultraviolet absorber such as a hydroxybenzophenone derivative, crystallization nucleating agent such as talc, lubricant such as fumed silica, antioxidant such as a hindered phenol derivative, flame retardant, antistatic agent, pigment, fluorescent whitening agent, infrared absorber or antifoaming agent.
  • the water absorbent polyester fiber is preferably a false twisted yarn. Crimping of the false twisted yarn is preferably such that the crimp elongation rate is 30% to 150%. Furthermore, crimp elongation rate is measured under the conditions indicated below.
  • Length (A) is measured after 30 seconds by immobilizing the upper end of the crimped yarn and applying a load of 1.77 ⁇ 10 ⁇ 3 cN/dtex to the lower end. Next, the load of 1.77 ⁇ 10 ⁇ 3 cN/dtex is removed, a load of 0.088 cN/dtex is applied and length (B) is measured after 30 seconds followed by determining crimp elongation rate according to equation (3) indicated below.
  • Crimp elongation rate (%) [( B ⁇ A )/ A ] ⁇ 100 (3)
  • the wound yarn body of the present embodiment is preferably obtained by subjecting the water absorbent polyester fiber to alkali treatment while in the state of a wound yarn body.
  • alkali treatment can be carried out using a cheese dyeing machine.
  • the wound yarn body of the present embodiment can be manufactured by a method that includes a step for carrying out alkali treatment on a polyester fiber containing 0.005% by weight to 1% by weight of elemental S at a reduction rate of 0.6% to 9% relative to the polyester fiber.
  • a chelating agent is preferably used in combination in the step for carrying out alkali treatment, and an oligomer dispersant is further preferably used in combination during soaping and neutralization.
  • a linear oligomer can be formed when a polymer on the surface of the polyester fiber is subjected to alkali treatment (hydrolysis).
  • alkali treatment hydrolysis
  • a linear oligomer is formed by hydrolysis of a polymer on the surface of the polyester fiber on the fiber surface (while adhered to the fiber surface) without the immediate generation of a white powder component in the form of a cyclic oligomer due to alkali treatment (hydrolysis), and that the linear oligomer is converted to the cyclic oligomer by a dehydration-condensation reaction after being eliminated from the fiber surface.
  • the cyclic oligomer observed on the fiber surface basically re-adheres to the fiber surface.
  • the reduction rate of the polyester fiber as a condition of alkali treatment for demonstrating water absorbency is preferably 0.6% to 9%, more preferably 1% to 8%, and even more preferably 1.5% to 7%.
  • Reduction rate can be calculated from the weight of the polyester fiber before and after alkali treatment. In the case the reduction rate is less than 0.6%, water absorbency attributable to alkali treatment is not demonstrated thereby making this undesirable, while if the reduction rate exceeds 9%, alkali reduction proceeds excessively resulting in inferior durability of water absorbency, thereby making this undesirable.
  • Polyester fiber containing 0.5 mol % to 5 mol % of an ester-forming sulfonate compound has a faster rate of alkali reduction in comparison with ordinary polyester fiber, thereby making this preferable since it is possible carry out treatment by adjusting the alkali to a lower concentration.
  • the wound amount of the polyester fiber containing 0.005% by weight to 1% by weight of elemental S is preferably 0.5 kg to 4 kg, more preferably 1 kg to 3.5 kg and even more preferably 2 kg to 3 kg. If the wound amount is less than 0.5 kg, productivity is inferior, thereby making this undesirable. If the wound amount exceeds 4 kg, liquid passage through the cheese dyeing machine becomes poor when carrying out alkali treatment, and in addition to increased susceptibility to variations, winding diameter also increases, thereby resulting in poor handling.
  • the winding density of the polyester fiber containing 0.005% by weight to 1% by weight of elemental S is preferably more than 0.1 ⁇ g/cm 3 to less than 1.2 ⁇ g/cm 3 , more preferably more than 0.2 ⁇ g/cm 3 to less than 1.0 ⁇ g/cm 3 , even more preferably more than 0.3 ⁇ g/cm 3 to less than 0.8 g/cm 3 , and particularly preferably more than 0.4 ⁇ g/cm 3 to less than 0.6 ⁇ g/cm 3 . If winding density is 0.1 ⁇ g/cm 3 or less, the wound state collapses during alkali treatment with a cheese dyeing machine and defective unwinding occurs during knitting. In addition, if winding density is 1.2 g/cm 3 or more, liquid passage during alkali treatment becomes poor thereby preventing uniform treatment and unevenness in water absorbency.
  • knit-deknitting is an example of a technique consisting of first knitting a polyester containing 0.005% by weight to 1% by weight of elemental S into a knitted fabric by using knit-deknitting and subjecting to alkali treatment followed by rearranging to obtain a wound yarn body, crimps in the form of knit loops end up being imparted to the polyester fiber.
  • Knit loops referred to here refer to crimps in the form of loops formed in the yarn when rearranging the knitted fabric after having immobilized stitches formed during knitting by heat treatment, and result in a peculiar texture when using this yarn to form a knitted fabric or woven fabric, thereby making this not very desirable.
  • hank treatment is a technique consisting of forming the polyester fiber containing 0.005% by weight to 1% by weight of elemental S into a hank and subjecting to alkali treatment with a jet dyeing machine and the like followed by rewinding with a winder to obtain a wound yarn body, not only does this technique require labor and high costs in the hanking step and rewind step, but since the haniks also contain alkali treatment solution, crimps of the false twisted yarn end up stretching due to their own weight, thereby making this undesirable.
  • a cyclic oligomer in the form of a white powder is generated when the polyester fiber is hydrolyzed by alkali treatment.
  • the cyclic oligomer is susceptible to the effects of metal ions present in the washing solution during alkali treatment, and since it more easily adheres to the fiber surface as a result of chelation, it is preferable to add a chelating agent.
  • chelating agent examples include polycarboxylic acid, nitrotriacetic acid (NTA), ethylene diamine tetraacetic acid (EDTA), nitrilotrimethylene phosphonic acid, hydroxyethylidiene diphosphonic acid (NTMP), phosphonic acid, glutamine diacetate, glutamic acid diacetic acid and salts thereof.
  • NTA nitrotriacetic acid
  • EDTA ethylene diamine tetraacetic acid
  • NTMP nitrilotrimethylene phosphonic acid
  • NTMP hydroxyethylidiene diphosphonic acid
  • the chelating agent is preferably added at 0.5 ⁇ g/L to 2.0 ⁇ g/L in an aqueous solution during alkali treatment.
  • cyclic oligomer present in an aqueous alkaline solution dissolves in the case of a high temperature, it precipitates in the case the solution temperature is lower than 90° C. On the basis thereof, precipitation and adhesion of the cyclic oligomer can be inhibited by draining the solution at a high temperature of 90° C. to 95° C. following alkali treatment.
  • washing is preferably carried out by injecting water into the cheese dyeing machine following drainage, adding oligomer dispersant in the form of sodium hydrosulfite at 0.5 ⁇ g/L to 2.0 ⁇ g/L, and washing for 10 minutes at 80° C. followed by washing at normal temperature after having washed twice for 10 minutes with warm water at 40° C. to 60° C.
  • oligomer dispersant components such as amino-based ionic compounds, alkylene oxide adducts of fatty acids, polycyclic nonionic compounds, alkyl sulfonates, polyvalent alcohol fatty acid esters, alkylene oxide adducts of polyvalent alcohol fatty acids, aromatic polyester resins, carboxylates or polyaminocarboxylic acids can be used alone or in combination.
  • An amphoteric surfactant is preferably used to prevent adhesion of oligomer and remove adhered oligomer.
  • the oligomer dispersant is preferably added at 0.5 ⁇ g/L to 3.0 ⁇ g/L during soaping.
  • Oxalic acid or acetic acid is preferably used for the acid used in neutralization. Oligomer precipitation and adhesion can be inhibited when the treatment solution has become acidic by combining the use of an oligomer dispersant at that time.
  • an amphoteric surfactant is used preferably since adhesion of oligomer is prevented under alkaline or acidic conditions.
  • the wound yarn body of the present embodiment may be dyed.
  • cheese dyeing may be carried out directly after having carried out alkali treatment with a cheese dyeing machine.
  • softening treatment for softening texture or oiling treatment for improving yarn unwinding and knitting organization may be carried out in the bath, it is not preferable to use that which impairs water absorbency such as a cationic softening agent or silicon oil.
  • wound yarn body of the present embodiment may be rewound with a winder after having undergone alkali treatment with a cheese dyeing machine to obtain a wound yarn body.
  • wound yarn bodies obtained in the examples were evaluated using the methods indicated below.
  • Yarn was drawn out from the wound yarn body and the state of the yarn was observed in the state of not applying a load. The presence of loop-shaped crimps originating in the knitted fabric was confirmed at that time.
  • the tube wound with the yarn was placed in a cheese dyeing machine and subjected to alkali treatment for 60 minutes at a liquid temperature of 95° C. with an aqueous alkaline solution using 10 ⁇ g/L of sodium hydroxide and 2 ⁇ g/L of chelating agent in the form of Marpon A-47 (Matsumoto Yushi-Seiyaku Co., Ltd.) while raising the temperature of the aqueous alkaline solution under conditions of 2° C./min.
  • the tube wound with the yarn was removed from the cheese dyeing machine and dehydrated with a centrifugal dehydrator followed by drying with a cheese dryer to obtain a wound yarn body.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was less than 1 second, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 2 seconds.
  • the adhered amount of white powder was 0.10% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of using 1 ⁇ g/L of a chelating agent in the form of Marpon A-47 during alkali treatment, using 1 ⁇ g/L of an oligomer dispersant in the form of Marpon PS-K7 during soaping, and using 0.5 ⁇ g/L of an oligomer dispersant in the form of Marpon PS-K7 during neutralization.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was less than 1 second, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 2 seconds.
  • the adhered amount of white powder was 0.23% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of using 2 ⁇ g/L of oligomer dispersant in the form of Marpon PS-K7 during neutralization.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 4 seconds, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 15 seconds.
  • the adhered amount of white powder was 0.05% by weight.
  • Alkali treatment was carried out for 60 minutes at a liquid temperature of 95° C. with an aqueous alkaline solution using 10 ⁇ g/L of sodium hydroxide while raising the temperature of the aqueous alkaline solution under conditions of 2° C./min.
  • soaping was carried out for 15 minutes at a liquid temperature of 80° C. followed by draining and washing twice with hot water for 3 minute at a water temperature of 60° C.
  • the tube wound with the yarn was removed from the cheese dyeing machine and dehydrated with a centrifugal dehydrator followed by drying with a cheese dryer to obtain a wound yarn body.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 15 seconds, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 15 seconds.
  • the adhered amount of white powder was 0.73% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Comparative Example 1 with the exception of using 2 ⁇ g/L of oligomer dispersant in the form of Marpon A-47 during soaping.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was less than 1 second, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 2 seconds.
  • the adhered amount of white powder was 0.64% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Comparative Example 1 with the exception of using 2 ⁇ g/L of oligomer dispersant in the form of Marpon A-47 during soaping and using 1 ⁇ g/L of oligomer dispersant in the form of Marpon PS-K7 during neutralization.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was less than 1 second, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 2 seconds.
  • the adhered amount of white powder was 0.52% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Comparative Example 1 with the exception of using 2 ⁇ g/L of oligomer dispersant in the form of Marpon A-47 during alkali treatment.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was less than 1 second, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 2 seconds.
  • the adhered amount of white powder was 0.47% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of setting the draining temperature following alkali reduction to 70° C.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 6 seconds, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 13 seconds.
  • the adhered amount of white powder was 0.82% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of using 6 ⁇ g/L of oligomer dispersant in the form of Marpon PS-K7 during neutralization.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 7 seconds, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 15 seconds.
  • the adhered amount of white powder was 0.03% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of using 6 ⁇ g/L of oligomer dispersant in the form of Marpon PS-K7 during soaping.
  • the reduction rate of the water absorbent polyester yarn of the resulting wound yarn body was 6.0%, water absorbency after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 8 seconds, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 15 seconds.
  • the adhered amount of white powder was 0.03% by weight.
  • a wound yarn body was obtained by carrying out treatment using the same method as Example 1 with the exception of using 84 dtex/36 f polyester false twisted yarn having a round cross-section and composed of regular polyester not containing sulfonic acid.
  • Water absorbency of the water absorbent polyester fiber of the resulting wound yarn body after washing 30 times in accordance with Method 103 C of Attached Table 1 of JIS L0217:1995 was 180 seconds or more, and water absorbency after washing 30 times in accordance with the F-2 medium temperature washer method of JIS L1096:2010 was 180 seconds or more.
  • the adhered amount of white powder was 0.02% by weight.
  • the wound yarn body of a water absorbent polyester fiber of the present invention absorbs water semi-permanently even in the case of not subjecting to water absorption processing without generating white powder in the wound yarn rewinding step and knitting step, is able to rapidly absorb perspiration when worn, demonstrates superior comfort, and has a favorable soft feel on the skin, thereby enabling it to be preferably used in innerwear, sportswear and the like.

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JP2006225644A (ja) * 2005-01-19 2006-08-31 New Japan Chem Co Ltd ポリエステル樹脂用溶融粘度低減剤及びこれを含有してなるポリエステル樹脂組成物、該樹脂組成物より得られる成形体、並びに溶融粘度低減方法
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