US3892021A - Process for producing crimped polyester fibers of high modulus - Google Patents

Process for producing crimped polyester fibers of high modulus Download PDF

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Publication number
US3892021A
US3892021A US411385A US41138573A US3892021A US 3892021 A US3892021 A US 3892021A US 411385 A US411385 A US 411385A US 41138573 A US41138573 A US 41138573A US 3892021 A US3892021 A US 3892021A
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Prior art keywords
tow
temperature
heat
fibers
crimp
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US411385A
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English (en)
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Nobuharu Izawa
Mutsuo Katsu
Yasuhiro Murase
Takamitsu Kondo
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Teijin Ltd
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Teijin Ltd
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/12—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes
    • D02G1/127—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes including drawing or stretching on the same machine

Definitions

  • ABSTRACT A process for producing crimped polyester fibers of high modulus, which comprises drawing an undrawn tow of polyester to 1.15 to 1.45 times the natural draw ratio, heat-treating the drawn tow under tension at a temperature T (C.), feeding it into a stuffer crimper to crimp the tow while maintaining it at a temperature of 80 to C, and heat-treating the tow at a temperature of T (C.) while allowing free shrinkage of the tow and maintaining the packing density of the tow at leat 200 Kg/m, the T, and T satisfying the relation specified in the specification.
  • T temperature
  • This invention relates to a process for producing crimped polyester fibers of high modulus which have good spinnability and can be spun into yarns of superior quality.
  • Polyester fibers are widely used as spun fibers prepared either alone or in mixture with other fibers such as cotton, flax or rayon.
  • polyester fibers In order to enhance the spinnability of polyester fibers, it is the general practice to impart high tenacity, low elongation, and high modulus to the fibers. This can lead to some extent to high spindle speed which is most required in the overall spinning process.
  • attempt to attain the high tenacity, low elongation and high modulus of the fibers in the manufacturing step inevitably results in the deterioration of crimp characteristics of the fibers and the extreme worsening of their spinnability in the pre-spinning step.
  • the heat shrinkage of the fibers increases, and when the fibers are woven, the fabric is shrunken to a great extent during heat-setting to cause a reduction in weaving efficiency.
  • a process for producing crimped polyester fibers of high modulus which comprises drawing an undrawn tow of polyester to 1.15 to 1.45 times the natural draw ratio, then heat-treating the drawn tow under tension at a temperature T,(C. feeding it into a stuffer crimper to crimp the tow while maintaining it at a temperature of 80 to 130C and heat-treating the tow at a temperature of T-,(C.) while allowing free shrinkage of the tow and maintaining the packing density of the tow at at least 200 kg/m, the T, and T satisfying the following relation 1.25T 21 S T, 5 240 2.0T, 470 5 T 5 -0.5T, 210
  • FIG. 1 is a graphic representation showing the range of the heat-treatment temperatures T
  • T is a graphic representation showing the relation between the modulus at stretch (abbreviated as M 0f the fibers and the temperature T with the temperature T, used as a parameter;
  • FIG. 3 is a graphic representation showing the relation between the dry heat shrinkage at 180C. of the fibers and the temperature T with the temperature T, used as a parameter;
  • FIG. 4 is a graphic representation showing the relation between the percent crimp of the fibers and the temperature T with the temperature T, used as a parameter.
  • the undrawn tow of polyester used in this invention is a bundle of undrawn filaments obtained by meltspinning a polyester-type polymer in a customary manner, and is usually used in a denier size of at least 10,000 denier, especially 50,000 to 4,000,000 denier.
  • polyester-type polymer or polyester denotes polyesters at least 85 mol of which consists of ethylene terephthalate units.
  • Polyethylene terephthalate is used suitably as such as polyester.
  • it may contain copolymerized therein a third component such as isophthalic acid, para-hydroxybenzoic acid, or a glycol having at least 3 carbon atoms, or blended therein a small amount of other polymers such as nylon or a polyolefin.
  • the polyester may further contain a delusterant, coloring agent, stabilizer, or antistatic agent, etc.
  • the suitable intrinsic viscosity, as measured on an ochlorophenol solution at 35C., of the polyester is 0.50 to 0.70.
  • the first step of the process of this invention consist in drawing the undrawn tow of polyester to 1.15 to 1.45 times its natural draw ratio (NDR).
  • the natural draw ratio is measured as follows: An undrawn filament is allowed to stand for 24 hours in a chamber maintained at a temperature of 20 to 30C. and at a relative humidity of 50 to and then pulled at a rate of 1000 per minute in a chamber maintained at a temperature of 20C. and a relative humidity of 65 using an instron tensile tester. The draw ratio at which the neck of the filament disappears and the tensile stress abruptly increases is termed the natural draw ratio.
  • the natural draw ratio varies mainly according to the birefringence of the undrawn filament, but an undrawn filament prepared by a customary spinning technique usually has a natural draw ratio of 3.0 to 4.0. Accordingly, in the process of this invention, the undrawn tow having NDR of 3.0 is drawn to 3.45 to 4.35 times the original length, and when the NDR is 4.0, the undrawn tow is drawn to 4.60 to 5.80 times the original length.
  • the drawing is carried out in a water or steam bath held at 60 to 100C.
  • the drawing can be effected in one step.
  • a two-staged drawing is preferred in which a first drawing is carried out in a water bath held at 60 to C. and a second drawing is carried out in a water or steam bath held at a temperature of at least 80C.
  • the draw ratio it is essential at the draw ratio be 1.15 to 1.45 times the natural draw ratio. If the total draw ratio is below this range, fibers of high tenacity and modulus cannot be obtained, and on the other hand, if the total draw ratio is above this range, the drawing condition becomes poor, and stable production is impossible.
  • the drawn tow is then heat-treated under tension.
  • this step can be performed by (a) causing the tow to run in contact with a hot plate, (b) causing the tow to run in a zig-zag fashion through, and in contact with, a plurality of heated rollers, or (c) passing the tow through a heated chamber.
  • This heat-treatment under tension may be performed simultaneously with the second-stage drawing.
  • heat-treatment under tension denotes heattreatment which is carried out while maintaining the tow under stretch or at constant length, or allowing the tow to shrink 5 or less.
  • the drawn tow which is to be heat-treated at a temperature T,C. in the process of this invention generally has the property of shrinking 5 or more at this temperature. Accordingly, when the tow is heat-treated under conditions which do not allow a shrinkage of more than 5 it is always under tension. If the shrinkage in this treatment is in excess of 5 the modulus of the tow decreases, and the crimp characteristics are drastically deteriorated.
  • this tension heat-treatment temperature (T,C.) must be in the following range 1.25 T +2l 5 T, 5 240.
  • HT is less than (1.25 T, 21 polyester fibers of high modulus (a modulus at stretch of at least 3.0 g/d) intended by the present invention cannot be obtained.
  • T exceeds 240C, partial meltadhesion of the fibers occurs during the treatment.
  • T is preferably higher than 180C.
  • the tow is treated with oils, as required, and then crimped by a stuf'fer crimper at 80 to 130C.
  • the temperature raise of the tow at the time of crimping can also be accomplished by preheating it with a steam bath or plate heater, etc. prior to crimping. Or this can be achieved by introducing heated steam into a stuffing box of the stuffer crimper. If the temperature of the tow during crimping is lower than 80C., the crimp characteristics of the resulting fibers are poor, and good spinnability cannot be ensured. If it exceeds 130C, the modulus of the product decreases, making it unsuitable for high speed spindle rotation in the spinning process.
  • the optimum temperature of the tow in this crimping step is 90 to 120C. in order to maintain a good balance between the crimp characteristics and the modulus.
  • the crimped tow obtained is continuously forwarded through a chute, and placed on a conveyor, where it is heat-treated under free shrinkage.
  • T is more than (0.5 T, 210)C.
  • the crimp characteristics, especially, the percent crimp, of the fibers are deteriorated drastically, making it impossible to ensure good spinnability.
  • T, and T specified in this invention is the hatched portion in FIG. 1.
  • Lines A to E in FIG. 1 show the following equations, and the area surrounded by these lines is employed in the present invention.
  • the lines A, B and C in FIG. 1 show the critical conditions for obtaining the intended modulus, dry heat shrinkage, and crimp characteristics, respectively.
  • the line D shows the critical conditions for avoiding the melt-adhesion of the fibers, and the line B shows the critical conditions for obtaining good crimp elasticity.
  • polyethylene terephthalate fibers obtained by the present process have an M (modulus at 10 stretch) of at least 3.0 g/d, a dry heat shrinkage at 180C.
  • polyethylene terephthalate fibers can be obtained which have a tenacity of at least 6.5 g/d, an elongation of not more than 30 an M, of at least 4.5 g/d, a percent crimp of at least 10 a dry heat shrinkage at 180C. of not more than 6 and a crimp elasticity of at least These fibers are cut to suitable lengths to make staple fibers.
  • staple fibers are spun either alone or together with other fibers such as cotton, rayon or flax, the lap licking, and fiber wrappings on a cylinder of a carding machine, etc. in the pre-spinning step are improved, and the spinning step can be operated at high speed.
  • the rotating speed of spindles in the spinning step is 16,000 rpm at the highest, and the tenacity (lea tenacity) of the spun yarn is 29 kg at the highest.
  • the staple fibers obtained in this invention do not cause any trouble even when the rotating speed of spindles is increased to 20,000 rpm, and the tenacity (lea strength) of the spun yarn can be increased up to 34 to 35 kg.
  • the percent crimp, or the degree of crimp, of filaments was measured as follows:
  • the specimen filament of a given length (a) is placed under an initial load of 2 mg/denier. Then, a load of 50 mg/denier is exerted on the filament, and the length (b) of the filament is measured after a lapse of 30 seconds. The percent crimp is expressed by:
  • Example 2 The tow withdrawn from the crimper was continuously led to a heat-treating chamber of the hot air circulating type and heat-treated under free shrinkage at T,C. while maintaining the packing density of the tow at 300 EXAMPLE 3 k 5 Run No. 2 of Example 2 was repeated by varying the The temperatures T, and T were varied in the above o mper ure at the time Of rimping, the mp raprocedure, and the M,,,, dry heat shrinkage at 180C. ture T and the packing density of the tow at the time and percentage crimp of the resulting fibers were meaof heat-treatment under free shrinkage. The crimp sured. The results obtained were plotted in F168. 2 to characteristics of the fibers obtained were measured, 4. and the results are shown in Table 2 below.
  • EXAMPLE 4 fibers having an M of at least 3.0 g/d, a dry heat shrinkage at 180C. of not more than 6.0 and a percent crimp of at least 10 can be obtained only when An undrawn low of polyethylene terephthalate isothe temperatures T, and T, are within the range phthalate (containing 5 mol of isophthalic acid hatched in FIG. 1. units) having an intrinsic viscosity of 0.60 was drawn at EXAMPLE 2 a total draw ratio of 1.25 times the natural draw ratio 40 in the same way as in Example 2, Run No. 2.
  • the f f P y y tefepmhalale drawn tow was subjected the same heat-treatment 8 mmnslc of Obamed by y under tension, crimping, and heat-treatment under free tional melt-spinning, which had a natural draw rat o of Shrinkage as in Example 2
  • the fawning fib had a 3-43, was drawn in two stages at a 'f of monofilament denier of 1.26 denier, a tenacity of 6.68 1.10 to 1.25 times the natural draw ratio using a warm g/d, an elongation f 24.2 an Mm f 44 g/d, and a bath held at 70C.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Artificial Filaments (AREA)
US411385A 1972-11-06 1973-10-31 Process for producing crimped polyester fibers of high modulus Expired - Lifetime US3892021A (en)

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Application Number Priority Date Filing Date Title
JP47110228A JPS526368B2 (ro) 1972-11-06 1972-11-06

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US (1) US3892021A (ro)
JP (1) JPS526368B2 (ro)
BR (1) BR7308648D0 (ro)
CS (1) CS202028B2 (ro)
DE (1) DE2355140A1 (ro)
FR (1) FR2205589B1 (ro)
GB (1) GB1415966A (ro)
IT (1) IT1003171B (ro)
NL (1) NL7315185A (ro)
PH (1) PH10107A (ro)
RO (1) RO71188A (ro)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4359557A (en) * 1980-09-11 1982-11-16 Eastman Kodak Company Process for producing low pilling textile fiber and product of the process
US4835956A (en) * 1980-04-02 1989-06-06 Teijin Limited Bulky flat yarn of silky touch and a process for manufacturing the same
US4912821A (en) * 1988-01-22 1990-04-03 Teijin Limited Method of forming crimps in high tensile modulus filaments
US5256020A (en) * 1992-02-20 1993-10-26 Katsumi Ikeda Fastening member, fastening machine element set, and method of connecting fastening machine element

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5123348A (en) * 1974-08-15 1976-02-24 Toyo Boseki Horiesuterusenitono kenshukukakoho
JPS5545443A (en) * 1978-09-28 1980-03-31 Toray Industries Polyester fiber staple for mattress
JPS6099027A (ja) * 1983-10-31 1985-06-01 帝人株式会社 ポリエステル捲縮繊維及びその製造方法
JPS62197698U (ro) * 1986-06-06 1987-12-16
JPS63148643U (ro) * 1987-03-18 1988-09-30
US5759926A (en) * 1995-06-07 1998-06-02 Kimberly-Clark Worldwide, Inc. Fine denier fibers and fabrics made therefrom
KR100445769B1 (ko) 1995-11-30 2004-10-15 킴벌리-클라크 월드와이드, 인크. 극세섬유 부직웹

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3491420A (en) * 1967-10-17 1970-01-27 Techniservice Corp Strand crimping
US3499953A (en) * 1966-04-05 1970-03-10 Techniservice Corp Strand treatment
US3553803A (en) * 1969-01-03 1971-01-12 Schwarza Chemiefaser Process and device for crimping and heat-setting of yarns made from synthetic linear high polymers
US3667094A (en) * 1970-05-27 1972-06-06 Polymer Processing Res Inst Method for heat-setting of crimps of artificial filament tows
US3719976A (en) * 1971-05-04 1973-03-13 Teijin Ltd Process for producing crimped polyester filaments

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4923247B1 (ro) * 1970-05-07 1974-06-14

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3499953A (en) * 1966-04-05 1970-03-10 Techniservice Corp Strand treatment
US3491420A (en) * 1967-10-17 1970-01-27 Techniservice Corp Strand crimping
US3553803A (en) * 1969-01-03 1971-01-12 Schwarza Chemiefaser Process and device for crimping and heat-setting of yarns made from synthetic linear high polymers
US3667094A (en) * 1970-05-27 1972-06-06 Polymer Processing Res Inst Method for heat-setting of crimps of artificial filament tows
US3719976A (en) * 1971-05-04 1973-03-13 Teijin Ltd Process for producing crimped polyester filaments

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4835956A (en) * 1980-04-02 1989-06-06 Teijin Limited Bulky flat yarn of silky touch and a process for manufacturing the same
US4359557A (en) * 1980-09-11 1982-11-16 Eastman Kodak Company Process for producing low pilling textile fiber and product of the process
US4912821A (en) * 1988-01-22 1990-04-03 Teijin Limited Method of forming crimps in high tensile modulus filaments
US5256020A (en) * 1992-02-20 1993-10-26 Katsumi Ikeda Fastening member, fastening machine element set, and method of connecting fastening machine element

Also Published As

Publication number Publication date
GB1415966A (en) 1975-12-03
FR2205589A1 (ro) 1974-05-31
RO71188A (ro) 1982-05-10
PH10107A (en) 1976-08-26
BR7308648D0 (pt) 1974-09-05
FR2205589B1 (ro) 1976-10-01
NL7315185A (ro) 1974-05-08
JPS526368B2 (ro) 1977-02-22
IT1003171B (it) 1976-06-10
JPS4968012A (ro) 1974-07-02
CS202028B2 (en) 1980-12-31
DE2355140A1 (de) 1974-05-16

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