Classifications

• • 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
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent

Definitions

• the present invention relates to a polyester conjugated yam, including two different types of polymers subjected to bi-component spinning so as to be longitudinally arranged in a side-by-side sectional structure, and a method of manufacturing the same.
• a conventional side-by-side type conjugated yam composed of two types of polymers has self-crimping properties, and thus, exhibits uniform spiral crimp tendency by a relaxation-heat treatment during a relaxing process in dyeing and finishing process. as in a bimetal having two metals with different thermal expansion coefficient.
• examples of selecting polymer pairs include the same polymers being different in only intrinsic viscosity, for instance, I.V. 0.65 regular polyester as a first component and I.V. 0.46 regular polyester as a second component, and the same kind of polymers having different shrinkage properties, for instance, general polyester as a first component and copolymerized polyester having high shrinkage as a second component.
• use of the copolymer which is generally low in physical properties, results in low spinnability and reduced crimping properties of tlie conjugated yam.
• there is required a specific spinnerette and it is difficult to mass-produce a conjugated ya .
• ya prepared using two kinds of polymers having different shrinkage properties so as to exhibit high crimping properties and high elasticity is disadvantageous in that the polymers should be subjected to two stages, for example, spinning at a slow rate (1000-1500 m/min) or a fast rate (2500 m/min or more), and drawing by use of a drawing machine having a first godet roller of 80-120°C and a thermosetting part of 180-250°C, whereby heat shrinkage difference between the polymers may be caused by relaxation-heat treatment using dry heat or moist heat in tlie dyeing and finishing process, thus crimps are formed.
• polyester conjugated ya can exhibit high self-crimping properties upon relaxation-heat treatment of the dyeing and finishing process.
• inherent characteristics of polytrimethyleneterephthalate can result in high softness to the touch, beautiful colors, and superior drapery and bulk properties of woven/knitted products.
• the polyester conjugated ya can have high spinnability and uniformity index.
• an object of the present invention is to provide a side-by-side type polyester conjugated yam.
• Another object of the present invention is to provide a method of manufacturing such a polyester conjugated yam.
• the present invention provides a method of manufacturing a polyester conjugated yam, including: subjecting two types of polymers having a large intrinsic viscosity difference to bi-component spinning in a spindraw manner by the use of an inclined circular spinnerette so as to cause the polymers to have a side-by-side sectional structure, the two types of polymers being polyethyleneterephthalate with intrinsic viscosity of 0.45-0.65 as a first polymer and polytrimethyleneterephthalate with intrinsic viscosity of 0.90-1.10 as a second polymer, wherein the polyester conjugated ya has a cross section satisfying Equations 1 and 2, below:
• line AB a length of a long axis of an interface between a high viscosity polymer and a low viscosity polymer
• line CD a length of a short axis of an interface between a high viscosity polymer and a low viscosity polymer
• line EF a maximum length of a long axis of a cross section of a ya
• line GH a maximum length of a short axis of a cross section of a ya .
• the present invention provides a polyester conjugated ya , including two types of polymers having a large intrinsic viscosity difference subjected to bi-component spinning so as to cause the polymers to have a side-by-side sectional structure, the two types of polymers being polyethyleneterephthalate with intrinsic viscosity of 0.45-0.65 as a first polymer and polytrimethyleneterephthalate with intrinsic viscosity of 0.90-1.10 as a second polymer, wherein the polyester conjugated yam has a crimp ratio not less than 20% and a circular cross section satisfying Equations 1 and 2, below: Equation 1
• line AB a length of a long axis of an interface between a high viscosity polymer and a low viscosity polymer
• line CD a length of a short axis of an interface between a high viscosity polymer and a low viscosity polymer
• line EF a maximum length of a long axis of a cross section of a yam
• line GH a maximum length of a short axis of a cross section of a yam.
• FIG. 1 is a schematic view of a spinning machine used for a manufacturing method of the present invention
• FIG. 2 is a schematic view of a bi-component spinning pack used for the present invention
• FIG. 3 is a schematic view of a conventional straight spinnerette
• FIG. 4 is a schematic view of a cross section of a polyester conjugated yam manufactured by the present invention.
• FIG. 5 is a schematic view of a modification of a cross section of a polyester conjugated yam, according to manufacturing conditions of the present invention.
• polyethyleneterephthalate hereinafter, abbreviated to 'PET'
• polytrimethyleneterephthalate hereinafter, abbreviated to 'PTT
• 'PTT polytrimethyleneterephthalate
• melt viscosity becomes different due to the difference of intrinsic viscosity directly under the nozzle upon a spinning process.
• an inclined circular spinnerette (FIG. 2) is applied for a conjugate spinning pack 3 of FIG. 1 so as to offset the difference of melt viscosity and to ensure stable spinnability without the bending of the ya .
• the first polymer having low intrinsic viscosity and a high flow rate is spun through a surface A of the inclined circular spinnerette
• the second polymer having high intrinsic viscosity and a low flow rate is spun through a surface B of tlie inclined circular spinnerette.
• the PET as the first polymer is composed of terephthalic acid and cthyleneglycol as first constitutive monomers, while the PIT as the second polymer includes terephthalic acid and propanediol as second constitutive monomers, in which the resulting polyester does not contain a third functional component copolymerized,
• the melt viscosity difference between the two polymers is controlled by varying thermal hysteresis of each molten polymer according to different temperature conditions of extruders 1 and 1-1 shown in FIG. 1 of each polymer component, or by adjusting spinning temperatures of a high viscosity polymer or a low viscosity polymer.
• the spinning temperatures are preferably adjusted in the range of 265-290°C. Therefore, it is preferred that the extruder 1 of PET is in the temperature range of 275-295°C, and the extruder 1-1 of PTT is in the temperature range of 250-270°C.
• the molten polymer passed through each extruder are fed into a spinning pack 3 through gear pumps 2 and 2-2.
• the ya spun by the polymers having the melt viscosity difference has a circular cross section as shown in FIGS. 4 and 5, in which an interface between the high viscosity polymer and the low viscosity polymer is formed to be round due to the melt viscosity difference therebetween.
• the high viscosity polymer has a convex interface in section
• the low viscosity polymer has a concave interface in section.
• the PET constitutes 30-70 wt% and the PTT constitutes 70-30 wt%, based on total weights of the polyester conjugated yam. Further, tlie shape of the cross section of the yam is changed in the range satisfying the following Equation 2 by the different throughput ratios: Equation 2
• a winding speed 6 amounts to 3000-5500 m/min, which is not particularly limited.
• a speed of a first godet roller 4 is set to 2000 m/min or more, and a speed of a second godet roller 5 is set to 4000 m/min or more, thereby increasing spinnability and crimp properties.
• a drawing temperature of the first godet roller is too low, uneveness is caused upon a dyeing process.
• tlie above drawing temperature is too high, a ya pass of godet roller is unstable, thus process performance is poor.
• the first godet roller is preferably in tlie temperature range of 70-100°C.
• the second godet roller has too low a temperature, settability of yams becomes inferior, and thus, the resultant yam has many defects when being fonued into woven/knit fabrics through the dyeing and finishing process.
• tlie extremely high temperatures of the second godet roller result in an unstable yam pass on godet roller, which negatively affects a spinning process.
• the second godet roller is preferably set to be in the range of 100 to 140°C.
• the conjugated yam of the present invention has a strength of 2.0-3.3 g/denier, and an elongation of 20-40%.
• the polyester conjugated yam having high self-crimping properties is composed of polyethyleneterephthalate as the first polymer and polytrimethyleneterephthalate as the second polymer, and has a crimp ratio of 20% or more. Also, the above conjugated yam has a circular cross section, which satisfies the following equations (FIGS. 4 and 5):
• line AB a length of a long axis of an interlace between a high viscosity polymer and a low viscosity polymer
• line CD a length of a short axis of an interface between a high viscosity polymer and a low viscosity polymer
• line EF a maximum length of a long axis of a cross section of a yam
• line GH a maximum length of a short axis of a cross section of a yam.
• a crimp ratio measured by a procedure as stated later, is preferably not less than 20%>. That is, when a side-by-side type conjugated yam of PET and PTT has a crimp ratio of 20% or more, it can be applied to the production of tlie woven/knit fabrics having desired elasticity. If the crimp ratio is less than 20%, elasticity of the woven/knit fabrics decreases. Also, the conjugated yam having self-crimping properties, which has the circular cross section satisfying the above equations, has a larger interface at which the two types of polymers are in contact with each other, compared to other conjugated ya s with non-circular cross sections.
• the circular conjugated yam has great numbers of crimps per unit length through relaxation-heat treatment of the dyeing and finishing process, which cause the increase of elasticity of the woven/knit fabrics.
• the circular cross section thereof causes soft and comfort wearing.
• An inclined circular spinnerette was used for a side-by-side type bi-component spinning process of PET and PTT with a maximized difference of intrinsic viscosity.
• PET having intrinsic viscosity of 0.460, 0.550 and 0.635 was used, and PTf having intrinsic viscosity o ⁇ 1.00 was used as a polymer B, as shown in Table 1 , below.
• a conjugated yam was manufactured through a one-staged process by use of the inclined circular spinnerette.
• a cooling air of 23°C at 5-120 cm directly under the nozzle was fed at 0.35 m/sec, and 0.5-1.1 wt% of a spinning oil was used.
• the resultant yam was woven in warp and weft directions to manufacture a woven fabric of 100 g/m 2 , which was then dyed at 120°C.
• MN. Melt Viscosity
• T c , %> A yam sample of 3000 denier in the state of tensile force of 50 mg/denier being applied was treated in boiling water (100°C) for 20 min under a load of 0.5 mg/denier to the extent of each piece of the sample not being tangled. Thereafter, the sample was allowed to stand for 24 hours under no load for natural dry. Subsequently, 1 min after the sample was subjected to a load of 2 mg/denier, a length LI was measured. In addition, 1 min after 200 mg/denier were further applied to the sample under the load of 2 mg/denier, a length L2 was measured. The measured values were introduced into Equation 3, below, to determine a crimp ratio:
• T C (%) (L2-Ll)/L2 x l00
• the viscosity difference is 2500 poise or more, the kneeling phenomenon occurs, thus spinning processability decreases. Further, as tlie intrinsic viscosity difference between PET and PTT increases, it is possible to manufacture a yam having high crimp properties. Different from a bi-component spinning process using the regular PET polymer pairs with only the intrinsic viscosity difference, the one-staged spindraw process using PET & PTT can exhibit higher crimp properties than a two-staged process of comparative examples as mentioned below, and can be applied to manufacture the conjugated yam having high crimping properties.
• an inclined circular spinnerette was used to offset the intrinsic viscosity difference between two types of polymers in extruders of a spinning machine of FIG. 1 .
• a polymer A was exemplified by PET having different intrinsic viscosities
• a polymer B was exemplified by PET having intrinsic viscosity of 0.635 and PTT having intrinsic viscosity of 0.990, as represented in Table 3, below.
• 50% of the polymer A and 50%> of the polymer B were spun to be a conjugated ya at spinning temperatures of 280-290°C through a one-staged process or a two- staged process.
• a cooling air of 23°C at 5-120 cm directly under the nozzle was fed at 0.35 m/sec, and 0.5-1.1 wt% of a spinning oil was used.
• the prepared yarn was woven in warp and weft directions to obtain a woven fabric of 100 g/m 2 , which was then dyed at 120°C.
• the woven fabric was measured for properties as in the above examples. The results are shown in Table 4, below.
• the present invention provides a polyester conjugated yam, and a manufacturing method thereof.
• the polyester conjugated yam having a circular cross section can be manufactured even by a one-staged process using an inclined circular spinnerette, which is advantageous in tem s of superior self-crimping properties.
• the conjugated ya can be applied to manufacture woven/knit fabrics exhibiting softness of the touch, beautiful colors, high drapery and bulk properties, due to inherent characteristics of polytrimethyleneterephthalate as a constitutive component thereof.
• the polyester conjugated ya can have high spinnability, no kneeling, and improved uniformity index.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Multicomponent Fibers (AREA)
• Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

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• 2003
  • 2003-04-24 KR KR10-2003-0026094A patent/KR100481093B1/ko not_active IP Right Cessation
• 2004
  • 2004-04-21 JP JP2006507811A patent/JP2006524295A/ja active Pending
  • 2004-04-21 US US10/554,329 patent/US20070257404A1/en not_active Abandoned
  • 2004-04-21 WO PCT/KR2004/000913 patent/WO2004094706A1/en active Application Filing
  • 2004-04-21 TR TR2005/04245T patent/TR200504245T2/xx unknown
  • 2004-04-21 CN CNB2004800108716A patent/CN100344809C/zh not_active Expired - Fee Related
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