WO2017014241A1 - 嵩高糸 - Google Patents
嵩高糸 Download PDFInfo
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- WO2017014241A1 WO2017014241A1 PCT/JP2016/071299 JP2016071299W WO2017014241A1 WO 2017014241 A1 WO2017014241 A1 WO 2017014241A1 JP 2016071299 W JP2016071299 W JP 2016071299W WO 2017014241 A1 WO2017014241 A1 WO 2017014241A1
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- Prior art keywords
- yarn
- sheath
- bulky
- loop
- fiber
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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
- 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
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
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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
- D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam
- D02G1/162—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam with provision for imparting irregular effects to the yarn
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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
- 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
- D02G3/42—Chenille threads
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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
- 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
- D02G3/36—Cored or coated yarns or threads
Definitions
- the present invention relates to a bulky yarn composed of a synthetic fiber having a plurality of loops consisting of a sheath yarn and a core yarn.
- Synthetic fibers made of thermoplastic polymers such as polyester and polyamide are characterized by high basic properties such as mechanical properties and dimensional stability, and excellent balance. Fiber materials utilizing these are widely used not only for clothing but also for interiors, vehicle interiors, and industrial applications by high-order processing of fibers obtained by spinning. It is no exaggeration to say that the development of new technologies related to synthetic fibers has been a technological innovation that has been motivated by imitation of natural materials. Therefore, various technical proposals have been made in order to express functions derived from natural complex structural forms with synthetic fibers. For example, by imitating the cross section of silk, a special texture such as creaking and flexibility is developed. Special colors are created by imitating morpho butterflies. Further, by imitating a lotus leaf, the fabric has water repellency. There are efforts to obtain a fiber structure having functions such as the soft texture of natural feathers, light weight and heat retention.
- yarn processing technology used for the purpose of increasing added value of fibers is, for example, fiber-twisting after actually twisting the fibers, or mixing one or two or more types of fibers with a fluid processing nozzle or the like
- a processed yarn having bulkiness can be produced. Since the processed yarn with such bulkiness is basically a long fiber, it can be processed into various forms, and it can be applied to batting materials by taking advantage of the bulkiness and soft texture of the processed yarn. Conceivable.
- Patent Document 1 discloses the following processed yarns. First, using two types of fibers, a yarn is fed to only one of the fibers while being fed to the waist gauge, and a real twist is applied together to form a loop with the fibers imparted with the yarn. Thereafter, it is further twisted by rubbing with two disks or the like to obtain a bulky processed yarn. Heat treatment is applied after the untwisting step, or the sheath yarns are fused together with a binder to strengthen the fixation of the sheath yarns. Certainly, the method disclosed in Patent Document 1 may obtain a bulky yarn having a loop made of a sheath yarn by adjusting the degree of yarn sway or the like in accordance with a conventional method.
- Patent Document 2 discloses a technique in which an excessively supplied sheath yarn is fixed with a yarn length difference by injecting compressed air from a vertical direction with respect to a running yarn in an entanglement nozzle, opening and entanglement. is doing.
- Patent Document 2 as in Patent Document 1, a processed yarn having a bulkiness in which a sheath thread having a loop shape exists can be obtained.
- Patent Document 3 discloses that, in a fluid jetted yarn, the loop portion is made of polytrimethylene terephthalate (3GT), thereby making the bulky processed yarn less likely to cause a fastener phenomenon by utilizing the elasticity of 3GT fiber. is there.
- 3GT polytrimethylene terephthalate
- JP 2011-246850 A JP 2012-67430 A Japanese Patent Laid-Open No. 11-1000074
- Patent Document 1 of the above-mentioned prior art there is a possibility that a binder is mixed in advance, and it can be applied as a batting material by fusing it after processing and fixing the loop.
- a real twist is applied to the loop yarn from which the sheath yarn partially protrudes and the yarn is opened by rubbing with rubber of a mechanical kneader or the like, the loop is partially broken or deteriorated.
- this processed yarn is used as batting, it is finally filled by bundling several to several tens.
- the sheath yarn is broken and becomes fluffed and entangled with the nearby sheath yarn of the processed yarn, which may worsen the unraveling process and process passability in the molding process.
- the size of the loop and the length of the sheath yarn forming the loop fluctuate in the fiber axis direction of the processed yarn to form a slack.
- the sheath yarn having a slack is likely to be entangled with the other sheath yarn, and the problems remain such that the process passability in high-order processing and the entangled portion of the sheath yarn lead to a foreign object feeling.
- Patent Document 3 uses a 3GT that elastically deforms and deforms, so that the sheath thread has an appropriate resilience, but the loop is compact even when the yarn length is different, and the fastener phenomenon May be suppressed.
- the loop is as small as about 0.6 mm, and when the number of loops is increased in order to aim for bulkiness, the density of the sheath yarn increases, so that the entanglement between the sheath yarns easily occurs and the fastener phenomenon may not be suppressed. is there.
- a material for batting that solves the conventional problems and has high bulkiness and compression recovery comparable to natural feathers but with reduced entanglement between processed yarns is desired.
- the present invention provides a bulky yarn excellent in lightness, heat retention, etc. in addition to a soft texture.
- the preferred embodiments of the bulky yarn include the following.
- the single yarn fineness ratio (sheath / core) of the core yarn and sheath yarn is in the range of 0.5 to 2.0,
- the crossing point of the core yarn and the sheath yarn is 1 / mm to 30 / mm in the fiber axis direction of the bulky yarn, 2.
- the above bulky yarn, wherein the crimped structure of the sheath yarn has a radius of curvature of 2 mm to 30 mm.
- the single yarn fineness of the fibers constituting the bulky yarn is 3.0 dtex or more,
- the bulky yarn according to any one of the above, wherein the inter-fiber static friction coefficient is 0.3 or less. 4).
- the bulky yarn according to any one of the above, wherein the core yarn has a three-dimensional crimp. 5).
- the bulky yarn according to any one of the above, wherein both or one of the core yarn and the sheath yarn is a hollow cross-section fiber having a hollow ratio of 20% or more. 6).
- the bulky yarn according to any one of the above, wherein the core yarn and the sheath yarn are the same kind of single component fiber.
- a textile product comprising at least a part of the bulky yarn described in any of the above.
- the bulky yarn of the present invention has a loop shape and is prevented from being entangled between bulky yarns, has good handleability in high-order processing, has a soft texture, and is lightweight. Excellent heat retention.
- Schematic side view of an example of the bulky yarn of the present invention Simulated diagram for explaining the processing thread center line measurement method Simulated diagram for explaining the three-dimensional crimped structure
- the schematic side view for demonstrating the suction nozzle used for the manufacturing method of the bulky yarn of this invention Schematic sectional view for explaining a discharge hole of a spinneret for hollow section used in the method for producing a bulky yarn of the present invention
- the bulky yarn of the present invention can be obtained by processing a multifilament, the bulky yarn and the material on the way to the production of the bulky yarn are sometimes expressed as “processed yarn”.
- the bulky yarn of the present invention is made of synthetic fiber and has a bulky structure. This structure is composed of a sheath yarn that forms a loop and a core yarn that substantially crosses the sheath yarn to fix the sheath yarn.
- the sheath yarn has a three-dimensional crimped structure.
- the sheath yarn is not substantially broken. That is, the sheath yarn is almost continuous with a bulky yarn.
- the sheath yarn continuously forms a plurality of loops.
- Synthetic fiber here is a fiber made of a polymer.
- a fiber produced by melt spinning or solution spinning can be employed.
- thermoplastic polymers that can be melt-molded are suitable for use in the present invention because the fibers used in the present invention can be produced by employing a melt spinning method with high productivity.
- thermoplastic polymer here means, for example, polyethylene terephthalate or a copolymer thereof, polyethylene naphthalate, polybutylene terephthalate, polytrimethylene terephthalate, polypropylene, polyolefin, polycarbonate, polyacrylate, polyamide, polylactic acid, thermoplastic polyurethane, etc. And a melt moldable polymer.
- thermoplastic polymers polycondensation polymers represented by polyesters and polyamides are crystalline polymers, and since they have a high melting point, they were heated at a relatively high temperature during post-processing, molding and actual use. Even in the case, there is no deterioration or settling, which is preferable. From the viewpoint of heat resistance, the melting point of the polymer is preferably 165 ° C. or higher.
- Synthetic fibers used in the present invention are various additives such as inorganic materials such as titanium oxide, silica and barium oxide, carbon black, colorants such as dyes and pigments, flame retardants, fluorescent brighteners, antioxidants, and ultraviolet absorbers.
- An agent may be included.
- the bulky yarn of the present invention is composed of a sheath yarn 1 that forms a loop and a core yarn 2 that substantially fixes the sheath yarn by crossing the sheath yarn. Yes.
- the core yarn is preferably a filament and is present in the range from the processed yarn center line 3 to 0.6 mm.
- the processed yarn center line means a straight line connecting the yarn path guide 4 when the processed yarn is threaded at a constant length between the pair of yarn path guides 4.
- a filament having a distance 5 from the processed yarn center line of 0.6 mm or less becomes the core yarn in the present invention, and becomes a support yarn for the loop of the sheath yarn.
- the sheath thread is preferably a filament and protrudes in a loop shape with a distance from the processed thread center line of 1.0 mm or more.
- the sheath yarn is responsible for the bulkiness of the yarn of the present invention.
- the core yarn fixes the sheath yarn forming the loop.
- This crossing point has a role of supporting the loop formed of the sheath yarn, which is a feature of the present invention, and it is preferable that the crossing point exists at a certain period. From this viewpoint, it is preferable that the intersection point of the core yarn and the sheath yarn in the bulky yarn is present at 1 / mm to 30 pieces / mm per 1 mm of the bulky yarn. Within such a range, even after the three-dimensional crimp is expressed in the sheath thread, the loop exists with an appropriate interval. From this viewpoint, it is more preferable that the intersection points exist at 5/15 to 15 / mm.
- a photoelectric fluff detection device In order to determine the core yarn and sheath yarn and to continuously evaluate the number of crossing points and the number of loops per unit length in the longitudinal direction of the bulky yarn, a photoelectric fluff detection device can be used.
- a photoelectric fluff measuring machine TORAY FRAY COUNTER
- TORAY FRAY COUNTER is used to evaluate distances of 0.6 mm and 1.0 mm from the center line of the processed yarn under conditions of a yarn speed of 10 m / min and a running yarn tension of 0.1 cN / dtex.
- the sheath yarn having the loop of the present invention has a form protruding in the cross section of the bulky yarn viewed from the longitudinal direction of the bulky yarn, and forms a large loop as compared with a general interlaced yarn or taslan yarn. ing.
- the size of the loop refers to the distance 5 from the processing thread center line 3 shown in FIG. 2 to the apex of each loop.
- the size of the loop is measured from the observed image of a bulky yarn threaded at a fixed length on a pair of yarn path guides 4. A single bulky yarn selected at random was photographed so that 10 or more loops formed on the bulky yarn could be observed, and the distance from the center line of the processed yarn to the top of the loop was 5 at 10 loops in the image. Measure. This operation is performed for a total of 10 images for one bulky yarn, and the size of a total of 100 loops per bulky yarn is measured to the second decimal place in millimeters. The average value of these numbers was calculated, and the value rounded to the second decimal place was taken as the loop size in the bulky yarn.
- the size of the loop protrudes in the range of 1.0 mm or more and 100.0 mm or less from the center line of the processed yarn, and in such a range, coupled with the crimped structure of the sheath yarn.
- the bulkiness and the effect of suppressing entanglement, which are the objects of the present invention, are improved.
- 3.0 mm or more and 70.0 mm or less is more preferable.
- the thickness be 5.0 mm or more and 60.0 mm or less.
- the shape of the loop made of sheath yarn referred to here is preferably a knurled loop (teardrop shape) rather than an arched loop formed by general entanglement.
- a knurled loop tunnel shape
- the intersection point of the core yarn and the sheath yarn is not fixed and the loop moves freely to some extent, so when the compression deformation is applied to this yarn, the intersection point is Will move. For this reason, since it is difficult to return to the original shape after compressive deformation, it may be disadvantageous from the viewpoint of bulky durability.
- the sheath yarn is not substantially broken in the present invention in order to achieve the contradictory properties of suppressing bulkiness and entanglement, which are not present in the past.
- the material is not substantially broken in the middle of the loop.
- the determination of loop breakage is made at 10 points randomly selected from one processed yarn consisting of a sheath yarn and a core yarn, from the intersection point of the core yarn and the sheath yarn to the next intersection point (that is, one Loop) is photographed and observed at a magnification at which 10 or more points can be confirmed in the longitudinal direction of the processed yarn. That is, in the 10 photographed images, the breaking points of the sheath yarn per millimeter of bulky yarn were counted for 10 loops each. The loop break points counted were averaged, and the second decimal place was rounded off to obtain the loop break point (pieces / mm).
- the number of broken points on the average of 100 loops is 0.2 pieces / mm or less, and the sheath yarn referred to in the present invention is not substantially broken, in other words, in the length of the bulky yarn.
- the sheath yarn is almost continuous. Within such a range, the sheath yarn with free yarn ends does not substantially exist, and a loop that does not entangle with other sheath yarns can be formed.
- the sheath yarn that controls bulkiness has a three-dimensional crimped structure, and continuously forms a loop without substantially breaking.
- the three-dimensional crimped structure in the present invention is that the filament single yarn has a spiral structure as illustrated in FIG.
- a fiber having such a three-dimensional crimped structure similar to a spring has a restoring force against stretching deformation and compression deformation.
- the bulky yarn of the present invention has a comfortable resilience because the sheath yarn has this structure.
- the unique resilience woven by the bulky yarns of the present invention expresses the good tactile feel of the filling and repeats compression recovery. Since the sheath thread that supports the spring is restored like a spring even when added, it is also suitable from the viewpoint of restraint.
- the three-dimensional crimp size of the latent crimp yarn obtained by a general production method such as a conventional side-by-side composite fiber or hollow fiber is generally on the order of microns (10 ⁇ 6 m). In the present invention, in order to enhance the effect, it is preferably a millimeter order (10 ⁇ 3 m) larger than that.
- the bulkiness and resilience of the cross section of the bulky yarn viewed from the longitudinal direction of the bulky yarn can be freely controlled by the size of the three-dimensional crimp, and naturally this resilience is utilized.
- the size of the crimp to the millimeter order, the entanglement between the sheath yarns is suppressed while the bulkiness and compressibility of the sheath yarns are compatible.
- the radius of curvature of the spiral structure swirling spirally is in the range of 1.0 to 30.0 mm.
- the radius of curvature of the spiral structure is the same method as that used to determine the presence or absence of the three-dimensional crimp described above, and an image that is observed two-dimensionally by a digital microscope or the like is used.
- the radius of the curvature 6 formed by the fiber having a spiral structure is defined as the radius of curvature.
- each sheath yarn is observed with a digital microscope or the like at a magnification that allows confirmation of the crimped form, for a total of 100 sheaths. Measure the yarn to the second decimal place in millimeters. A simple average of these measured values was calculated, and a value rounded to the first decimal place was taken as the radius of curvature of the three-dimensional crimped structure.
- the radius of curvature is more preferably 2.0 to 20.0 mm. If it is in such a range, the sheath yarns will be in contact with each other at a point while having a moderate repulsion feeling against the compression of the bulky yarn to the cross section viewed from the longitudinal direction of the yarn. A certain bulkiness will be exhibited. Furthermore, 3.0 to 15.0 mm is particularly preferable. In such a range, there is no problem with long-term durability, and the effect of the present invention is effective when applied to garment applications where repeated compression recovery is applied, particularly sports garments used in harsh environments. This is because the single yarn itself has a three-dimensional solid shape and has a spiral or a similar structure to the two-dimensional bending of the single yarn that can be applied by mechanical pushing. These crimped forms are micron-order and fine crimps, so that the fine spiral structures bite each other, thereby facilitating the fastener effect.
- the sheath yarn of the bulky yarn of the present invention has a space that can move depending on the size of the loop, and according to the definition of the present invention, the loop has a radius of 1.0 mm around the intersection point.
- the above hemispherical relatively large movable space is provided.
- sheath yarns with three-dimensional crimps that are overwhelmingly large with respect to the fiber diameter come in contact with each other at points and repel each other, so one sheath yarn exists independently without entanglement can do.
- the sheath yarn in addition to the movement space described above, the sheath yarn itself can further extend like a spring in the fiber axis direction, so that when the sheath yarn crosses, vibration occurs. It can be easily solved by adding.
- the three-dimensional crimp of the sheath yarn works effectively from the viewpoint of bulkiness which is a basic characteristic of the present invention.
- the point contact between the sheath yarns described above has an effect of repelling the sheath yarns even within one bulky yarn, and in addition to the initial bulkiness, the state in which the loop composed of the sheath yarns is radially opened is time-consuming. It can be maintained over time.
- the spring-like behavior of the sheath yarn of the present invention is difficult to achieve with conventional straight sheath yarns.
- the morphological feature that the sheath yarn of the present invention forms a loop and has a three-dimensional crimped structure also has an effect on lowering the friction coefficient. As described above, this is an effect of contact with other points, and is one of the effects of the bulky yarn having the unique structure of the present invention.
- the inter-fiber static friction coefficient is 0.3 or less in order to suppress entanglement between bulky yarns while having bulkiness.
- the inter-fiber static friction coefficient referred to here is measured by a radar friction coefficient tester according to the method described in “Friction coefficient” of “Test method for chemical fiber staples” in JIS L 1015 (2010). .
- the JIS since the JIS is intended for stapling, it prescribes that pre-operation such as opening is performed for measurement, but in the measurement of the present invention, processing such as opening is not performed, and a bulky yarn is used. It can be evaluated by arranging them in parallel with a cylindrical sliver.
- the texture increases when the fiber slips and moves appropriately during compression, so that the inter-fiber static friction coefficient is preferably low.
- the inter-fiber static friction coefficient is more preferably 0.2 or less, and particularly preferably 0.1 or less.
- the single yarn fineness ratio (sheath / core) of the sheath yarn and the core yarn is preferably in the range of 0.5 to 2.0. Within such a range, the fineness of the sheath yarn and the core yarn are close to each other, and it can be used without feeling a sense of foreign matter when compressed. Moreover, as a range which can be bulky efficiently, the single yarn fineness ratio (sheath / core) can be 0.7 to 1.5. Further, in the bulky yarn of the present invention, various fibers can be combined, but the core yarn and the sheath yarn are not allowed to feel the foreign matter feeling at the time of efficient fluid processing and compression described above.
- the single yarn fineness and the mechanical properties are the same.
- a fiber made of a resin is preferable.
- the core yarn has a three-dimensional crimped structure in the millimeter order in addition to the sheath yarn.
- the radius of curvature of the spiral structure of the core yarn is preferably in the range of 1.0 to 30.0 mm. If it is such a range, the interfilament space
- the fulcrum of the loop can move in a limited space in the longitudinal direction, so that the movement space of the sheath yarn is expanded, and the entanglement suppression and soft texture of the present invention are increased. This is because the effect becomes more prominent.
- the core yarn stretches, increasing the binding force at the intersection of the core yarn and the sheath yarn, preventing the loop from breaking and the sheath yarn from falling off. Effective in The three-dimensional crimp of the core yarn can also be confirmed by observing the core yarn collected at random according to the above-described method for evaluating the three-dimensional crimp of the sheath yarn.
- the radius of curvature of the spiral structure of the core yarn is more preferably 3.0 to 15.0 mm. In such a range, long-term durability is good, and the effect of the present invention is effective when applied to apparel applications and sports apparel in which bulky yarn is repeatedly stretched and deformed.
- the core yarn and / or sheath yarn used in the present invention is preferably a hollow cross-section fiber.
- the fiber having a three-dimensional crimped structure is more preferably a hollow cross-section fiber. This is because there is an advantage that the size of the three-dimensional crimp can be manufactured relatively freely from a large one to a small one.
- a hollow cross-section fiber is preferable from the viewpoint of loop protrusion.
- the loop made of the sheath yarn starts from the crossing point with the core yarn, and can protrude due to the rigidity of the sheath yarn.
- the mass of the sheath yarn itself is also small.
- a hollow cross-section fiber having a hollow ratio of 20% or more is preferable.
- the hollow ratio here is a volume ratio of a portion where no material is present in the fiber.
- the fiber cross section is photographed at a magnification at which the cross section of 10 or more fibers can be observed with an electron microscope (SEM).
- SEM electron microscope
- Ten randomly selected fibers are extracted from the photographed image, the equivalent circle diameters of the fibers and the hollow portion are measured using image processing software, and the area ratio of the hollow portion is calculated therefrom.
- the above operation is performed on 10 images taken, and the average value of the 10 images is defined as the hollow ratio of the hollow cross-section fiber of the present invention.
- the hollow ratio In the case of a circular hollow fiber, there are the following simple methods for evaluating the hollow ratio.
- the side surface of the hollow cross-section fiber is observed with an enlarging means such as a microscope, and the fiber diameter in terms of a round cross section is measured from the image. From the fiber diameter and the density of the fiber material, the ratio of the actually measured fineness to the fineness when the fiber is not hollow can be calculated as the hollow ratio.
- the hollow ratio is preferably such that the bulky yarn of the present invention contains more air, and the hollow ratio is more preferably 30% or more.
- the hollowness is 50% as a range in which the hollow portion can be stably produced without collapsing in the yarn production process or the fluid processing process described later. The following is preferred.
- the bulky yarn of the present invention has excellent bulkiness, and it is preferable that the yarn constituting it has an appropriate resilience.
- the single yarn fineness of the synthetic fiber constituting the bulky yarn is preferably 3.0 dtex or more.
- the constituting filaments should preferably have appropriate rigidity, and the single yarn fineness is more preferably 6.0 dtex or more.
- the fineness referred to here means a value calculated from the obtained fiber diameter, the number of filaments and the density, or a value obtained by calculating a mass per 10,000 m from a simple average value obtained by measuring the weight of the unit length of the fiber a plurality of times. To do.
- the bulky yarn of the present invention preferably has a breaking strength of 0.5 to 10.0 cN / dtex and an elongation of 5% to 700%.
- the strength is a value obtained by obtaining a load-elongation curve of the yarn under the conditions shown in JIS L1013 (1999) and dividing the load value at break by the initial fineness.
- the elongation is a value obtained by dividing the elongation at break by the initial test length.
- the breaking strength of the bulky yarn of the present invention is preferably 0.5 cN / dtex or more in order to be able to withstand the process passability and actual use of the high-order processing step, and the upper limit that can be implemented.
- the breaking strength and elongation can be adjusted by controlling the conditions in the production process according to the intended application.
- the breaking strength is preferably 0.5 to 4.0 cN / dtex.
- the breaking strength is 1.0 to 6.0 cN / dtex.
- the bulky yarn of the present invention can be made into various fiber products such as fiber winding packages, tows, cut fibers, cotton, fiber balls, cords, piles, knitted and non-woven fabrics, and various fiber products.
- Textile products here are used for daily use such as general clothing, sports clothing, clothing materials, interior products such as carpets, sofas, curtains, vehicle interiors such as car seats, cosmetics, cosmetic masks, wiping cloths, health products, etc. It can be used for environmental and industrial materials such as filters and hazardous substance removal products.
- the bulky yarn of the present invention is preferably used as a batting because of its bulkiness and entanglement being suppressed.
- the batting is filled in the side fabric, it is preferable to form several to several tens of yarn bundles or a sheet-like material such as a nonwoven fabric.
- a sheet-like material such as a nonwoven fabric.
- the core yarn and sheath yarn used in the present invention may be synthetic fibers obtained by fiberizing a thermoplastic polymer by a melt spinning method.
- the spinning temperature of the synthetic fiber used in the present invention is a temperature at which the polymer used exhibits fluidity.
- the temperature showing the fluidity varies depending on the molecular weight, but the melting point of the polymer is a guideline, and may be set at a melting point or higher and a melting point + 60 ° C. or lower.
- a melting point of + 60 ° C. or lower is preferable because the polymer is not thermally decomposed in the spinning head or the spinning pack and the molecular weight reduction is suppressed.
- the discharge amount is generally 0.1 g / min / hole to 20.0 g / min / hole per discharge hole as a stable discharge range. At this time, it is preferable to consider the pressure loss in the discharge hole that can ensure the stability of the discharge.
- the standard of the pressure loss is preferably in the range of 0.1 MPa to 40 MPa, and can be adjusted by the melt viscosity of the polymer to be used, the specification of the discharge hole and the discharge amount.
- the melted polymer discharged in this manner is cooled and solidified, applied with an oil agent, and taken up by a roller to become a fiber.
- the take-up speed may be determined from the discharge amount and the target fiber diameter, but is preferably in the range of 100 to 7000 m / min for stable production.
- This synthetic fiber may be stretched after being wound once, or may be continuously stretched without being wound once, from the viewpoint of improving the mechanical properties with high orientation.
- the stretching conditions for example, in a stretching machine composed of a pair of rollers or more, in general, in the case of a polymer that can be melt-spun, a first roller set to a glass transition temperature or higher and a second roller set to a crystallization temperature or higher are used.
- the cross-sectional shape of the synthetic fiber of the present invention is not particularly limited, and by changing the shape of the discharge hole in the spinneret, a general round cross section, a triangular cross section, a Y type, an eight leaf type, a flat type It is possible to make it irregular such as various types and hollow types. Moreover, it does not need to consist of a single polymer, and may be a composite fiber composed of two or more types of polymers. However, from the viewpoint of expressing the three-dimensional crimp of the sheath yarn, which is an important requirement of the present invention, among the above, a side-by-side type composite fiber in which a hollow cross section and two kinds of polymers are bonded is used. Is appropriate.
- a three-dimensional crimp can be expressed due to the presence of foreign substances in the cross section of the single fiber by performing a heat treatment after the yarn production and the yarn processing. For this reason, at the time of fluid processing, which will be described later, although it is a so-called straight fiber, a three-dimensional crimp is developed by performing a heat treatment after passing through a loop forming step with a sheath yarn.
- the yarn can easily run stably without causing yarn clogging with a nozzle.
- the core yarn and the sheath yarn are efficiently swung, and each loop has a very close shape in the fiber axis direction of the processed yarn.
- the sheath yarn expresses a three-dimensional crimp and becomes a bulky yarn. This three-dimensional crimp of the sheath yarn expresses good bulkiness in both the circumferential direction and the cross-sectional direction of the processed yarn, and is suitably controlled according to the desired characteristics. is there.
- the fiber used is more preferably a hollow cross-section fiber made of a single component polymer.
- a hollow cross-section fiber it has an air layer with low thermal conductivity at the center of the fiber. For this reason, for example, after discharging from a spinneret that can form a hollow cross section, one side is forcibly cooled with excessive cooling air or the like, or one side is excessively heat treated with a heating roller or the like during stretching, so that the fiber cross-sectional direction This creates a structural difference.
- hollow cross-section fibers made of a single component polymer in addition to being capable of spinning with a single spinning machine, three-dimensional crimps can be obtained relatively easily from a large size to a small size by the operations described above. It is possible. For this reason, it is suitable for use in the present invention, and it is particularly preferable that the hollowness is 20% or more, and further 30% or more as described above from the viewpoint of crimp control by the above-described operation.
- the production method of the bulky yarn exemplified here mainly includes two steps.
- the first step is a bulky process in which a core yarn and a sheath yarn are crossed with a fluid to form a loop made of the sheath yarn.
- the second step is a heat treatment step in which a three-dimensional crimp is developed in the sheath yarn by heat treating the bulky processed yarn.
- a synthetic fiber 8 as a raw material is drawn out by a specified amount by a supply roller 7 having a nip roller or the like, and sucked as a core yarn and a sheath yarn by a suction nozzle 9 capable of jetting compressed air.
- the flow rate of the compressed air ejected from the nozzle is such that the thread inserted from the supply roller into the nozzle has the minimum necessary tension, and does not cause yarn swaying between the supply roller and the nozzle or in the nozzle. What is necessary is just to inject the flow volume which travels stably.
- the optimum amount of this flow rate varies depending on the hole diameter of the suction nozzle to be used, but the range in which the yarn tension can be applied and the loop formation described later can be smoothly formed has an air velocity of 100 m / s or more in the nozzle. It becomes a standard.
- a guideline for the upper limit value of the air flow speed is 700 m / s or less, and if it is within such a range, the traveling yarn does not cause yarn swaying due to excessively injected compressed air, and the nozzle can be stably formed. You will be traveling inside.
- the propulsion jet flow in which the jet angle of compressed air (16 in FIG. 5) is jetted at less than 60 ° with respect to the running yarn. It is preferable that This is because loop formation by sheath yarn can be performed uniformly with high productivity.
- the vertical jet flow in which the fluid is injected at 90 ° to the traveling yarn, but the traveling yarn is opened by the jet flow injection from the vertical direction.
- processing by a propulsion jet is preferable. The processing by this propulsion jet can also suppress the formation of short arch-shaped loops that are easy to form in the case of a vertical jet.
- the jet angle of compressed air is more preferably 45 ° or less with respect to the running yarn.
- the stability and propulsive force of the jet airflow immediately after the nozzle is high. From this viewpoint, the jet angle is 20 ° or less with respect to the traveling yarn. It is particularly preferred that
- the yarn guided to the suction nozzle may be performed by one feed or two feeds, but in order to produce the bulky yarn of the present invention, it is preferable to perform the processing by two feeds.
- the term “two feeds” as used herein refers to a method in which the core yarn and the sheath yarn are supplied to the nozzle with different supply speeds (amounts) using different supply rollers. By utilizing the swirl force generated by the airflow described later, the excessively supplied yarn becomes a sheath yarn and forms a loop.
- a loop can be formed in the nozzle by using an interlacing nozzle or taslan processing nozzle that imparts the effect of disturbance, opening and entanglement to the running yarn in the nozzle. It's not impossible. However, in the processed yarn obtained by these processing nozzles, in addition to the loops being easily formed in a short period, the size is likely to be small.
- the process is a process in which the yarn to which compressed air is applied is swirled outside the nozzle to form a loop of sheath yarn.
- This is based on the concept that a loop can be formed by swiveling two yarns supplied at positions away from the nozzle.
- the ratio of the air velocity to the yarn velocity air velocity / yarn velocity
- a unique phenomenon has been found in which the sheath yarn rotates while opening outside the nozzle.
- the air velocity here means the velocity of the air jet injected from the suction nozzle outlet along with the running yarn. This speed can be controlled by the discharge diameter of the nozzle and the flow rate of the compressed air. Further, the yarn speed can be controlled by the rotating speed of a roller for picking up the yarn after the fluid processing nozzle. Since the turning force of the traveling yarn increases and decreases depending on the speed ratio between the air current and the yarn, the speed ratio should be close to 3000 when the intended intersection of bulky yarns is to be strengthened. If it is desired to make the intersection point slow, it may be close to 100. For example, the speed ratio can be changed in the degree of intersection by changing the flow rate of the compressed air intermittently or by changing the speed of the take-up roller.
- the air velocity / yarn velocity is preferably 200 to 2000.
- the air velocity / yarn velocity is set to 400 to 1500 from the viewpoint of imparting appropriate restraint and flexibility. Particularly preferred.
- a turning point 10 for changing the yarn path is arranged.
- the yarn path may be changed with a bar guide or the like. Then, by pulling the yarn at a prescribed speed, the sheath yarn turns around the core yarn to form a loop. From the viewpoint of obtaining the loosening due to the vibration of the sheath yarn using the space for causing the swirling and the diffusion of the airflow injected from the nozzle, the swiveling point of the running yarn may be at a position away from the nozzle discharge port. Is preferred.
- the distance between the nozzle and the turning point suitable for producing the bulky yarn of the present invention varies depending on the jet velocity, and the jet flow is from 1.0 ⁇ 10 ⁇ 5 to 1.0 ⁇ 10 ⁇ . It is preferable that the turning point 10 is present while traveling for 3 seconds. In order to form the crossing points of the core yarn and the sheath yarn at an appropriate period in balance with the diffusion of the air flow, the distance between the nozzle and the turning point is 2.0 ⁇ 10 ⁇ 5 to 5.0 ⁇ More preferably, it is present while traveling for 10-4 seconds.
- the cycle of the intersection point of the bulky yarn of the present invention can be controlled.
- the crossing point has a role of supporting the independence of the loop composed of the sheath yarn, which is a feature of the present invention, and it is preferable that the crossing point exists at a certain period. From this point of view, it is preferable to adjust the turning point so that the crossing point of the core yarn and the sheath yarn in the bulky yarn is 1 to 30 pieces / mm. Such a range is preferable because the loops exist at an appropriate interval even after the three-dimensional crimp of the sheath yarn is expressed. From this point of view, it is more preferable to adjust the turning point so that the crossing point exists at 5/15 to 15 / mm.
- the processed yarn 11 in which a loop made of a sheath yarn is formed is preferably subjected to heat treatment after being wound once or subsequent to the bulky processing in order to develop form fixation or three-dimensional crimp. .
- FIG. 4 illustrates a processing step in which heat treatment is performed subsequent to the loop formation step.
- This heat treatment is performed by, for example, the heater 13 (FIG. 4).
- the crystallization temperature of the polymer used is ⁇ 30 ° C. If the treatment is performed within this temperature range, the treatment temperature is away from the melting point of the polymer, so there is no part that is fused and cured between the sheath yarns or between the core yarns, there is no foreign matter feeling, and good tactile sensation is impaired. There is nothing.
- the heater used in this heat treatment step a general contact type or non-contact type heater can be adopted, but from the viewpoint of bulkiness before heat treatment and suppression of deterioration of sheath yarn, use of a non-contact type heater is preferable.
- Non-contact heaters mentioned here include air heaters such as slit heaters and tube heaters, steam heaters heated by high-temperature steam, halogen heaters using radiant heating, carbon heaters, microwave heaters, etc. To do.
- a heater using radiant heating is preferable.
- the heating time for example, the time for crystallization to progress and the fixation of the fiber structure of the fibers constituting the processed yarn, the fixed shape of the processed yarn, and the crimp expression of the sheath yarn to be completed, etc. will be considered.
- the processing temperature and time should be adjusted according to the required characteristics.
- the processed yarn for which the heat treatment process has been completed may be wound by a winder 15 having a tension control function, with the speed being regulated via a roller 14 (FIG. 4).
- the winding shape is not particularly limited, and can be a so-called cheese winding or bobbin winding. In consideration of processing into a final product, it is possible to combine a plurality of yarns in advance to form a tow or to make a sheet as it is.
- the bulky yarn of the present invention preferably has a silicone oil agent uniformly attached before and after the heat treatment step.
- the silicone to be adhered here is preferably formed by forming a silicone film on the sheath yarn and the core yarn by appropriately crosslinking the silicone by heat treatment or the like.
- examples of the silicone-based oil mentioned here include dimethylpolysiloxane, hydrodienemethylpolysiloxane, aminopolysiloxane, and epoxypolysiloxane, which can be used alone or in combination.
- a dispersant in order to form a uniform film on the surface of the bulky yarn, a dispersant, a viscosity modifier, a crosslinking accelerator, an antioxidant, a flame retardant, and an antistatic agent are added to the oil within a range that does not impair the purpose of silicone adhesion.
- This silicone-based oil can be used without a solvent, or in the form of a solution or an aqueous emulsion. From the viewpoint of uniform adhesion of the oil agent, it is preferable to use an aqueous emulsion.
- the silicone-based oil is preferably treated so that it can adhere to the bulky yarn in an amount of 0.1 to 5.0% by mass application using an oil guide, oiling roller or spraying.
- This silicone-based oil agent can be attached in a plurality of times, and it is also preferable that the same type of silicone or different types of silicones are attached separately to form a strong silicone film.
- Fineness The 100-meter mass of the fiber was measured, and the fineness was calculated by multiplying by 100. This was repeated 10 times, and the value obtained by rounding off the second decimal place of the simple average value was defined as the fineness (dtex) of the fiber.
- the single yarn fineness was calculated by dividing the fineness by the number of filaments constituting the fiber. Also in this case, the value obtained by rounding off the second decimal place was defined as the single yarn fineness.
- the point where the sheath thread forming the apex of the loop at 1.0 mm or more from the processed thread center line 3 intersects the straight line located 0.6 mm from the processed thread center line 3 is an intersection point, Counted per millimeter of processed yarn.
- the crossing points (pieces / mm) of a total of 10 images were measured, and the average value was rounded off to the nearest decimal point.
- the radius of the curved single yarn curve 6 (FIG. 3) was measured using image processing software (WINROOF). As described above, 100 core yarns and 100 sheath yarns selected at random are measured to the second decimal place in millimeters, and the value obtained by rounding off the second decimal place of this simple average is a three-dimensional crimp. The radius of curvature of the structure was used.
- G Tactile feeling A drum around which a processed yarn is wound for 500 m or more was placed on a creel, and the yarn was unwound into a winding shape using a measuring machine in the cross-sectional direction of the drum to obtain a 10 m yarn cassette.
- a sample for texture evaluation was prepared by fixing one portion of the yarn cassette. The tactile sensation when gripping this sample was evaluated according to the following four levels.
- B Good texture with bulkiness and flexibility.
- C A good texture that is bulky and does not feel foreign matter.
- D Poor texture that is not bulky and feels a foreign body.
- Intrinsic viscosity of polymer (IV) 0.8 g of the polymer to be evaluated was dissolved in 10 mL of o-chlorophenol having a purity of 98% or more at a temperature of 25 ° C., and the intrinsic viscosity (IV) was determined using an Ostwald viscometer at a temperature of 25 ° C.
- PET Polyethylene terephthalate
- the wound undrawn yarn was drawn 3.0 times at a drawing speed of 800 m / min between rollers heated to 90 ° C. and 140 ° C. to obtain a drawn yarn having a fineness of 78 dtex, a filament count of 12, and a hollow rate of 30%.
- the hollow cross-section yarn thus obtained is supplied to each of two supply rollers, one hollow cross-section yarn, with one supply roller at a speed of 50 m / min and the other at a speed of 1000 m / min. Suctioned into a nozzle.
- the processed yarn was guided to a tube heater through a roller and heat-treated with heated air at 150 ° C. for 10 seconds to set a bulky yarn form and to develop a three-dimensional crimp on the sheath yarn.
- the bulky yarn was wound around a drum at 52 m / min by a tension control type winder installed after the tube heater.
- Example 1 The bulky yarn collected in Example 1 had a structure in which a loop made of sheath yarn protruded from the processed yarn center line by an average of 23.0 mm, and the loop was formed at a frequency of 13 pieces / mm. This protruding loop was excellent in uniformity in size and period.
- the sheath yarn formed a loop and was fixed by crossing from the core yarn.
- the core yarn and the sheath yarn had a three-dimensional crimped structure in the millimeter order with a curvature radius of 5.0 mm. There were no breaks in the sheath yarn, and a loop was formed continuously. (Break location: 0.0)
- the sheath yarn forming a continuous loop has a three-dimensional crimped structure, the inter-fiber static friction coefficient is 0.3, the bulky yarn has no problem of unwinding, and is not caught. It was possible to unwind from the drum wound up smoothly without waking up (unwinding property: B). Moreover, it had a good texture with bulkiness derived from the specific structure of the present invention (texture: B). The results are shown in Table 1.
- Example 2 Uniformly spray the bulky yarn collected in Example 1 with a silicone oil containing polysiloxane at a concentration of 8% by mass so that the final polysiloxane adhesion is 1% by mass with respect to the bulky yarn.
- the bulky yarn was collected by spraying and heat-treating at a temperature of 165 ° C. for 20 minutes.
- Example 2 by forming a film made of silicone, compared to the bulky yarn of Example 1, the tactile sensation was smooth and had a comfortable slime feeling coupled with the bulkiness of the bulky yarn. It was found that the inter-fiber static friction coefficient of this bulky yarn was 0.1, which was further reduced as compared with Example 1. When the influence on the form of the bulky yarn due to the silicone treatment was examined, it almost coincided with the form characteristics of Example 1, and other functions were maintained. The unwindability and texture were also excellent.
- this bulky yarn was cut into 10 pieces with a length of 50 cm to make one bundle, and both ends were squeezed and rubbed. The thread separation was good so that it could be easily removed from the bundle. The results are shown in Table 1.
- Comparative Examples 1 and 2 In order to verify the effect of the bulky processing of the present invention, the same procedure as in Example 1 was performed except that a nozzle in which the jet angle of compressed air was changed to 90 ° was used and a swivel point by a ceramic guide was not provided. However, in Comparative Example 1, at the same compressed air flow rate as in Example 1, the entanglement of the core yarn and the sheath yarn was excessive, and stable yarn processing was difficult due to nozzle clogging. When the travel speed was reduced to 200 m / s, the running of the yarn became possible, so that the obtained processed yarn was collected and the characteristics were evaluated (Comparative Example 1).
- the loop size of the sheath yarn was smaller than that of Example 1 before the heat treatment, and was formed in a very short cycle.
- the sheath yarn formed a loop, but was not bulky.
- each loop size was uneven, and there were relatively many break points that could not be recognized with the processed yarn extracted before heat treatment (break “Yes”: break point) 0.5).
- Comparative Example 2 Using the processed yarn obtained in Comparative Example 1, an opening twist treatment was performed by rubbing with a pair of rubber disks (Comparative Example 2). Although the bulkiness seemed to be improved, the loop breakage was further increased as compared with Comparative Example 1, the entanglement between the sheath yarns was promoted, and a foreign object sensation was felt when compressed. Further, even when compared with Comparative Example 1, the yarn was caught more often during unwinding, and the unwinding property was reduced. The results are shown in Table 2.
- Comparative Example 3 Using the processed yarn of Comparative Example 1, silicone treatment was performed in the same manner as the treatment performed in Example 2 to obtain a processed yarn.
- Comparative Example 4 In order to verify the effect of the bulky processing of the present invention, a comparative example is used except that a nozzle in which the jet angle of compressed air is changed to 60 ° is used and a ceramic guide is arranged so that the yarn can be discharged immediately after the nozzle discharge hole. It carried out according to 3.
- Comparative Example 4 a small loop and a relatively large loop were mixed before heat treatment.
- the core yarn and the sheath yarn contracted to express a three-dimensional crimped structure, but the overall bulkiness was greatly reduced as compared with Example 1.
- the spots of the loop before the heat treatment were promoted, and a portion where the loop was partially slackened was observed.
- the jet angle of the compressed air was large, the yarn was disturbed and opened in the nozzle, and the single yarn was abraded at a high frequency on the inner wall of the nozzle and deteriorated. For this reason, after the heat treatment, although there was a slight improvement tendency as compared with Comparative Example 3, the breaking point of the loop was partially seen.
- Table 2 The results are shown in Table 2.
- Example 3 The supply speed was all the same as in Example 2, except that the core yarn was changed to 50 m / min for core yarn and 500 m / min for sheath yarn in Example 3, and 20 m / min for core yarn in Example 4 and 1000 m / min for sheath yarn. .
- Example 3 the loop size was slightly reduced to 12 mm as compared with Example 2, but the unraveling property was excellent and the texture was good.
- Example 4 although the size of the loop was increased to 59 mm as compared with Example 2, there was almost no slack in the loop.
- the texture although it had excellent bulkiness with flexibility, the structure was also excellent in unwinding because it had a structure in which cutting of the sheath yarn and sagging were suppressed. The results are shown in Table 3.
- Example 5 The spinneret used was changed to 6 holes, and the yarn was produced so as to have a hollow rate of 20%, and drawn yarns having changed single yarn fineness and hollow rate were collected (fineness 78 dtex, filament number 6 (single yarn fineness 13 dtex), Hollow rate 20%). The same procedure as in Example 1 was performed except that the drawn yarn was used as a sheath yarn.
- Example 5 by increasing the thickness of the sheath yarn, the rigidity of the loop was improved, and the bulky yarn was excellent in rebound. Although the flexibility decreased compared to Example 1, it has sufficient bulkiness, and in actual use, the tactile sensation as a product can be adjusted by adjusting the number of yarns to be combined. There was no level. The results are shown in Table 3.
- Example 6 Changed to a spinneret with 24 holes for hollow cross-section with four slits with a width of 0.1 mm concentrically arranged to make a yarn, and drawn filaments with different single yarn fineness and hollow ratio were collected. (Fineness 78 dtex, number of filaments 24 (single yarn fineness 3.3 dtex), hollow rate 40%). The same procedure as in Example 1 was performed except that the drawn yarn was used as a sheath yarn.
- Example 6 the loop made of the sheath yarn was self-supporting due to the crossing with the core yarn, and the sheath yarn became thinner than in Example 1, so that the bulky yarn excellent in flexibility was obtained. Due to the increase in the number of filaments of the sheath yarn and the reduction in the radius of curvature of the crimp (1.5 mm), a slight yarn dance was observed when unwinding from the drum. It can be solved by adjusting, and it was at a level where there is no problem in actual use. The results are shown in Table 3.
- Example 7 Change to a spinneret with 12 round holes drilled so as to form a general round cross-section fiber, and spin with excessive cooling from one side with 20 ° C. cooling air in the same manner as in Example 1.
- the drawn yarn was collected under the same conditions.
- the crimped form after the heat treatment of the drawn drawn yarn was a gentle form as compared with Example 1, and the radius of curvature of the crimp was 28 mm. Except that the drawn yarn was used as a sheath yarn, all the steps were performed according to Example 2.
- Example 7 the crimped form of the sheath thread became gentle, and the loop of the sheath thread became a tufted form, and an excellent texture with moderate resilience was achieved.
- the results are shown in Table 4.
- Example 8 This was carried out in accordance with Example 7 except that the round cross-section fiber used in Example 7 was used for the core yarn in addition to the sheath yarn.
- Example 8 the loop composed of the sheath thread formed a tuft-like structure due to the expression of the loosely crimped form of the sheath thread.
- the crimped form of the core yarn becomes loose, the constraint at the intersection of the core yarn and the sheath yarn is weakened, and the sheath yarn can move laterally even when a bulky yarn is loaded in the fiber axis direction. It was. During unwinding, the lateral movement sometimes caused the yarn to be caught although it was less frequent than in Example 7, but this level was not particularly problematic for practical use.
- Table 4 The results are shown in Table 4.
- Comparative Example 5 In order to verify the effect of the three-dimensional crimped form of the core yarn and the sheath yarn, the core yarn and the sheath yarn were changed from the conditions of Example 2 to perform yarn processing. First, in the core yarn, the spinneret for the general round-section fiber used in Example 7 is used, and in the sheath yarn, the three slits having a width of 0.1 mm used in Example 1 are arranged concentrically. The spinneret was provided with a hollow cross-section discharge hole, and the cooling air speed was changed to 20 m / min. Other conditions were the same as in Example 1, and drawn yarn was collected.
- the drawn yarns for core yarn and sheath yarn had a fineness of 78 dtex and a filament count of 12, and none of them exhibited the three-dimensional crimped form referred to in the present invention even after heat treatment. Except for using these drawn yarns, all processed yarns were collected according to Example 1.
- the loop could be formed by providing a turning point outside the nozzle, but the crimp of the sheath yarn did not appear even after the heat treatment, and the straight state was maintained. Moreover, since there was no crimp by a sheath thread, compared with the comparative example 1, a spot was seen in the loop size and it was a loop which became partially slack. In Comparative Example 5, although the sheath yarn does not develop a three-dimensional crimp, it may form a loop, so that the entanglement of the sheath yarn is more likely to occur than in Example 1, and At that time, many yarns were caught. Further, the processed yarn released from the drum was compressed and deformed, and the bulk was lowered by fixing the loop while it was slid and moved laterally. The results are shown in Table 4.
- a processed yarn was collected in accordance with Comparative Example 1 except that the drawn yarn was used as the sheath yarn and the round cross-section fiber used in Comparative Example 5 was used as the core yarn.
- the sheath yarn developed a three-dimensional crimped shape after the heat treatment, but it was very fine with a radius of curvature of several tens of micrometers, and in some places the sheath yarn (Breaking: 0.4 / mm). Moreover, by expressing this crimped form, the loop of the sheath yarn was greatly reduced as compared with that before the heat treatment, and there were few that exceeded 0.6 mm from the processed yarn center line. For this reason, although the tactile sensation of the processed yarn is rubber-like and unique, it does not have the bulkiness and flexibility that are the object of the present invention.
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Abstract
Description
1.3次元的な捲縮構造を有する鞘糸、
および該鞘糸との交錯で鞘糸を固定している芯糸からなり、
前記鞘糸が、実質的に破断しておらず、連続的にループを形成している、
合成繊維からなる嵩高糸。
2.そして上記嵩高糸の好ましい態様として以下のものがある。
芯糸と鞘糸の単糸繊度比(鞘/芯)が0.5から2.0の範囲であり、
芯糸と鞘糸との交錯点が嵩高糸の繊維軸方向に1個/mmから30個/mm存在し、
鞘糸の捲縮構造が2mmから30mmの曲率半径をもつ、上記の嵩高糸
3.嵩高糸を構成する繊維の単糸繊度が3.0dtex以上であり、
繊維間静摩擦係数が0.3以下である、上記いずれかに記載の嵩高糸。
4.芯糸が3次元的な捲縮を有している、上記いずれかに記載の嵩高糸。
5.芯糸および鞘糸の両方または一方が中空率20%以上の中空断面繊維である、上記いずれかに記載の嵩高糸。
6.芯糸および鞘糸が同種の単成分繊維である、上記いずれかに記載の嵩高糸。
7.前記いずれかに記載の嵩高糸を少なくとも一部に含む繊維製品。
本発明の嵩高糸は、合成繊維からなり嵩高となる構造を有している。この構造は、ループを形成する鞘糸と、該鞘糸と交錯することで実質的に鞘糸を固定する芯糸とから構成される。そして鞘糸が3次元的な捲縮構造を有していることが特徴である。また、本発明においては、鞘糸が実質的に破断していない。すなわち鞘糸は嵩高糸でほぼ連続している。そして鞘糸は連続的に複数のループを形成している。
この芯糸や鞘糸の確定や、交錯点や単位長さあたりのループの個数を嵩高糸の糸長手方向に連続的に評価するには、光電型の毛羽検知装置を活用することができる。例えば、光電型毛羽測定機(TORAY FRAY COUNTER)を用い、糸速度10m/分、走行糸張力0.1cN/dtexの条件で、加工糸中心線からの距離0.6mmならびに1.0mmを評価する。
中空断面繊維の側面を顕微鏡等の拡大手段で観察し、その画像から丸断面換算の繊維径を測定する。この繊維径と繊維の素材の密度から、中空でない繊維としたときの繊度に対する実測した繊度との比率を中空率として算出することも可能である。
実施例および比較例では、下記の評価を行った。
繊維の100mの質量を測定し、100倍することで繊度を算出した。これを10回繰り返し、その単純平均値の小数点第2位を四捨五入した値をその繊維の繊度(dtex)とした。単糸繊度とは、繊度をその繊維を構成するフィラメント数で除することにより、算出した。この場合も、小数点第2位を四捨五入した値を単糸繊度とした。
繊維をオリエンテック社製引張試験機“テンシロン”(登録商標) UCT-100型を用い、試料長20cm、引張速度100%/minの条件で引張り、応力-歪曲線を求める。破断時の荷重を読みとり、その荷重を初期繊度で除することで破断強度(cN/dtex)を算出する。また、破断時の歪を読みとり、試料長で除した値を100倍することで、破断伸度(%)を算出した。いずれの値も、この操作を水準毎に5回繰り返し、得られた結果の単純平均値を求め、小数点第2位を四捨五入した値である。
試料となる糸にたるみが出ないように0.01cN/dtexの荷重をかけ、図2に例示されるように定長で一対の糸道ガイド4に糸掛けする。糸掛けした嵩高糸の側面を(株)キーエンス社製マイクロスコープVHX-2000にてループを10箇所以上が観察できる倍率で撮影した。この画像から無作為に選定したループ10箇所について、画像処理ソフト(WINROOF)を用いてループ先端の加工糸中心線3からのループ頂点までの距離5(図2)を測定した。この作業を加工糸1本について画像を計10箇所撮影し、加工糸1本あたり合計100箇所のループをミリメートル単位で小数点第2位までを測定する。この数値の平均値を算出し、小数点第2位以下を四捨五入した値を嵩高糸におけるループの大きさとした。
加工糸から無作為に選んだ10箇所において、(株)キーエンス社製マイクロスコープVHX-2000にて、単糸の捲縮形態が確認できる倍率で観察した。この10画像において、芯糸10本、鞘糸10本を観察してらせん状に旋回した形態(スパイラルな構造)を有している場合には、3次元的な捲縮構造有り(各実施例、比較例の説明ならびに表1、表2および表3においては「有り」と記載)と判定し、そうでない場合には捲縮構造無し(各実施例、比較例の説明および各表においては「無し」と記載)と判定した。また、同じ画像から、画像処理ソフト(WINROOF)を用いて、捲縮した単糸の湾曲6(図3)の半径を測定した。前述の通り無作為に選んだ芯糸100本、鞘糸100本をミリメートル単位で小数点第2位までを測定し、この単純平均の小数点第2位を四捨五入した値を、3次元的な捲縮構造の曲率半径とした。
レーダー式摩擦係数試験機により、JIS L 1015(2010年)に準じた方法で測定した。なお、開繊等の前処理は行わず、試料を円筒に平行に並べることで評価するものである。
加工糸を500m以上巻き付けたドラムをクリールに仕掛け、ドラムの断面方向に30m/min速度で5分間解除し、ファスナー現象による糸の踊り、引っ掛かり等を目視により確認し、下記の4段階で評価した。
A:糸の踊りが見られず、良好に解舒できる。
B:わずかに糸の踊りが見られる問題なく解舒できる。
C:糸の踊り及びわずかに引っ掛かりが見られるが解舒はできる。
D:糸の踊り及び引っ掛かりが起こり解舒できない。
加工糸を500m以上巻き付けたドラムをクリールに仕掛け、ドラムの断面方向に検尺機を用いて、糸を解舒して巻き形態とすることで10mの糸カセとした。糸カセの一箇所を固定して風合い評価用サンプルを作成した。このサンプルを握った場合の触感を下記の4段階で評価した。
A:嵩高性及び柔軟性に優れ、異物感を感じない優れた風合い。
B:嵩高性及び柔軟性を有した良好な風合い。
C:嵩高性を有し、かつ異物感を感じない程度の良好な風合い。
D:嵩高性がなく、異物感を感じる不良な風合い。
25℃の温度の純度98%以上のo-クロロフェノール10mL中に、評価するポリマーを0.8g溶かし、25℃の温度でオストワルド粘度計を用いて固有粘度(IV)を求めた。
ポリエチレンテレフタレート(PET:IV=0.65dl/g)を290℃で溶融後、計量し、紡糸パックに流入させ、図6に示す3つのスリット17(幅0.1mm)が同心扇状に配置された中空断面用吐出孔から吐出した。吐出された糸条に20℃の冷却風を100m/minの流れで片側から吹き付けて冷却固化した。糸条に非イオン系の紡糸油剤付与し、紡糸速度1500m/minで未延伸糸を巻き取った。引き続き、巻き取った未延伸糸を90℃と140℃に加熱したローラ間で延伸速度800m/minで3.0倍延伸し、繊度78dtex、フィラメント数12、中空率30%の延伸糸を得た。
得られた中空断面糸を図4に示すように、2個の供給ローラにそれぞれ1本ずつ中空断面糸を供給し、一方の供給ローラを速度50m/min、他方を速度1000m/minとして、サクションノズルへ吸引した。サクションノズルでは走行糸条に対して20°で気流速度を400m/sになるように圧縮空気を噴射し、芯糸と鞘糸が交錯しないように随伴気流とともにノズルから糸条を噴出させた。ノズルから噴射した糸条を気流と共に1.0×10-4秒間走行させ、セラミックガイドを利用して糸道を変更し、鞘糸からなるループが形成された加工糸とし、引取ローラで50m/minで引き取った。
該嵩高糸では連続的なループを形成する鞘糸が3次元的な捲縮構造を有しており、繊維間静摩擦係数0.3であり、嵩高糸の解舒性は問題なく、引っ掛かりなどを起こすことなくスムーズに巻き取ったドラムから解舒することができた(解舒性:B)。また、本発明の特異的な構造に由来した嵩高性を有した良好な風合いを有したものであった(風合い:B)。結果を表1に示す。
実施例1で採取した嵩高糸に、ポリシロキサンが濃度8質量%で含まれたシリコーン系油剤を、最終的なポリシロキサン付着量が嵩高糸に対して1質量%になるようにスプレーで均一に散布し、165℃の温度で20分間熱処理しで嵩高糸を採取した。
実施例2においては、シリコーンによる皮膜を形成したことにより、実施例1の嵩高糸と比較して、触感が滑らかになり、嵩高糸の嵩高性と相まって心地よいヌメリ感を有したものであった。この嵩高糸の繊維間静摩擦係数は0.1であり、実施例1と比較して更に低下したものであることが分かった。シリコーン処理したことによる嵩高糸の形態に対する影響を調べたところ、実施例1の形態特性と概ね一致しており、その他機能は維持されていた。解舒性及び風合いも優れたものであった。
本発明の嵩高加工の効果を検証するため、圧縮空気の噴射角度を90°に変更したノズルを用い、セラミックガイドによる旋回点を設けないこと以外は全て実施例1と同様に実施した。ただし、比較例1においては、実施例1と同様の圧縮空気流量では、芯糸と鞘糸の絡み合いが過剰で、ノズル詰まりにより、安定した糸加工が困難であったため、気流速度を実施例1の半分の200m/sに低下させたところ、糸の走行が可能となったため、得られた加工糸を採取し、特性を評価することとした(比較例1)。
比較例1の加工糸を用いて、実施例2で行った処理と同様にシリコーン処理を行い、加工糸を得た。
本発明の嵩高加工の効果を検証するため、圧縮空気の噴射角度を60°に変更したノズルを用い、ノズルの吐出孔直後に糸が排出できるようにセラミックガイドを配置したこと以外は全て比較例3にしたがい実施した。
供給速度を、実施例3では芯糸50m/min、鞘糸500m/min、実施例4では芯糸20m/min、鞘糸1000m/minと変更したこと以外は全て実施例2と同様に実施した。
実施例4では、実施例2と比較してループのサイズが59mmと大きくなったものの、ループのたるみはほとんどないものであった。風合いに関しては、柔軟性を有した優れた嵩高性を有したものであるものの、鞘糸の切断や、たるみも抑制された構造であったため、解舒性も良好なものであった。結果を表3に示す。
用いる紡糸口金を6ホールに変更して、中空率20%になるように製糸し、単糸繊度及び中空率を変更した延伸糸を採取した(繊度78dtex、フィラメント数6(単糸繊度13dtex)、中空率20%)。該延伸糸を鞘糸として使用したこと以外は全て実施例1にと同様に実施した。
幅0.1mmのスリットが4つ同心円状に配置された中空断面用吐出孔が24ホール穿設された紡糸口金に変更して製糸し、単糸繊度及び中空率を変更した延伸糸を採取した(繊度78dtex、フィラメント数24(単糸繊度3.3dtex)、中空率40%)。該延伸糸を鞘糸として使用したこと以外は全て実施例1にと同様に実施した。
一般的な丸断面繊維となるように用いる丸孔が12ホール穿設された紡糸口金に変更し、実施例1と同様に20℃の冷却風で片側から過剰に冷却して紡糸し、その他の条件は同様にして延伸糸を採取した。採取した延伸糸の熱処理後の捲縮形態は実施例1と比較して緩やかな形態となり、捲縮の曲率半径は28mmであった。該延伸糸を鞘糸として使用したこと以外は全て実施例2にしたがい実施した。
実施例7においては、鞘糸の捲縮形態が緩やかになったことにより、鞘糸のループが房状の形態となり、適度な反発性を有した優れた風合いを奏でるものであった。結果を表4に示す。
実施例7で用いた丸断面繊維を鞘糸に加えて芯糸にも用いたこと以外は全て実施例7にしたがって実施した。
芯糸及び鞘糸の3次元的な捲縮形態の効果を検証するため、実施例2の条件から、芯糸及び鞘糸を変更して、糸加工を実施した。
まず、芯糸においては、実施例7で使用した一般的な丸断面繊維用の紡糸口金とし、鞘糸においては、実施例1で使用した幅0.1mmのスリットが3つ同心円状に配置された中空断面用吐出孔を具備した紡糸口金とし、冷却風の速度は20m/minに変更した。それ以外の条件は実施例1と同様にして延伸糸を採取した。芯糸用及び鞘糸用の延伸糸は、繊度78dtex、フィラメント数12であり、いずれも熱処理後にも本発明で言う3次元的な捲縮形態を発現しないものであった。これらの延伸糸を利用したこと以外は、全て実施例1にしたがい、加工糸を採取した。
比較例5では、鞘糸が3次元的な捲縮を発現しないにもかかわらず、ループを形成していることもあって、実施例1と比べると鞘糸同士の絡み合いが起こりやすく、解舒の際には糸の引っ掛かりが多数見られるものであった。また、ドラムから解除した加工糸は、圧縮変形を受けたことで、ループがヘタリ、且つ横にスライド移動されたまま、固定されたことで嵩高性は低下したものであった。結果を表4に示す。
IV=0.51dl/gの低粘度PETとIV=1.20dl/gのポリトリメチレンテレフタレート(3GT)を準備し、280℃で溶融後、低粘度PET/3GT=50/50に複合されるように計量し、貼り合せ型複合口金が組み込まれた紡糸パックに流入さて、複合ポリマー流を吐出した。その後、糸条に20℃の冷却風を20m/min吹き付けて、冷却固化し、油剤を付与した後に紡糸速度1500m/minで未延伸糸を巻き取った。引き続き、巻き取った未延伸糸を90℃と130℃に加熱したローラ間で延伸速度800m/minで3.0倍延伸し、繊度78dtex、フィラメント数12、サイドバイサイド複合繊維の延伸糸を採取した。該延伸糸を鞘糸、比較例5で用いた丸断面繊維を芯糸として用いたこと以外はいずれも比較例1にしたがって加工糸を採取した。
2 芯糸
3 加工糸中心線
4 糸ガイド
5 加工糸中心線からループ頂点までの距離
6 3次元的な捲縮
7 供給ローラ
8 合成繊維
9 サクションノズル
10 旋回点
11 加工糸
12 引取ローラ
13 ヒータ
14 デリバリーローラ
15 ワインダ
16 圧空の噴射角度
17 スリット状吐出孔
Claims (7)
- 3次元的な捲縮構造を有する鞘糸、
および該鞘糸との交錯で鞘糸を固定している芯糸からなり、
前記鞘糸が、実質的に破断しておらず、連続的にループを形成している、
合成繊維からなる嵩高糸。 - 芯糸と鞘糸の単糸繊度比(鞘/芯)が0.5から2.0の範囲であり、
芯糸と鞘糸との交錯点が嵩高糸の繊維軸方向に1個/mmから30個/mm存在し、
鞘糸の捲縮構造が2mmから30mmの曲率半径をもつ、請求項1に記載の嵩高糸。 - 嵩高糸を構成する繊維の単糸繊度が3.0dtex以上であり、
繊維間静摩擦係数が0.3以下である、請求項1または2に記載の嵩高糸。 - 芯糸が3次元的な捲縮を有している、請求項1から3のいずれか1項に記載の嵩高糸。
- 芯糸および鞘糸の両方または一方が中空率20%以上の中空断面繊維である、請求項1から4のいずれか1項に記載の嵩高糸。
- 芯糸および鞘糸が同種の単成分繊維である、請求項1から5のいずれか1項に記載の嵩高糸。
- 請求項1から6に記載される嵩高糸を少なくとも一部に含む繊維製品。
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JP3197328U (ja) * | 2014-11-28 | 2015-05-14 | 株式会社ヒラカワコーポレーション | 羽毛状綿素材 |
JP6103157B1 (ja) * | 2015-07-22 | 2017-03-29 | 東レ株式会社 | 嵩高糸 |
JP6696288B2 (ja) * | 2016-04-26 | 2020-05-20 | 東レ株式会社 | 嵩高構造糸 |
EP3514276A4 (en) * | 2016-09-14 | 2020-07-29 | Toray Industries, Inc. | FIBER FILLED MATERIAL AND FIBER PRODUCT THEREFOR |
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- 2016-07-20 JP JP2016556917A patent/JP6103157B1/ja active Active
- 2016-07-20 EP EP16827801.8A patent/EP3327188B1/en active Active
- 2016-07-20 US US15/745,559 patent/US20180216261A1/en not_active Abandoned
- 2016-07-20 CN CN201680041511.5A patent/CN107849755A/zh active Pending
- 2016-07-20 WO PCT/JP2016/071299 patent/WO2017014241A1/ja active Application Filing
- 2016-07-20 KR KR1020187001290A patent/KR102611708B1/ko active IP Right Grant
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2017
- 2017-02-22 JP JP2017030969A patent/JP6776938B2/ja active Active
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2020
- 2020-06-29 US US16/915,309 patent/US20200325601A1/en not_active Abandoned
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JP2000144541A (ja) * | 1998-11-05 | 2000-05-26 | Toray Ind Inc | ポリエステル混繊糸 |
WO2012026424A1 (ja) * | 2010-08-23 | 2012-03-01 | 倉敷紡績株式会社 | 詰め物体 |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2017122304A (ja) * | 2015-07-22 | 2017-07-13 | 東レ株式会社 | 嵩高糸の製造方法 |
WO2017188104A1 (ja) * | 2016-04-26 | 2017-11-02 | 東レ株式会社 | 嵩高糸 |
JP2017197858A (ja) * | 2016-04-26 | 2017-11-02 | 東レ株式会社 | 嵩高構造糸 |
WO2018051983A1 (ja) * | 2016-09-14 | 2018-03-22 | 東レ株式会社 | 繊維詰め物体およびそれを用いた繊維製品 |
JP2018193642A (ja) * | 2017-05-18 | 2018-12-06 | 東レ株式会社 | 嵩高糸 |
JP2021085121A (ja) * | 2019-11-28 | 2021-06-03 | 東レ株式会社 | 嵩高糸 |
JP7427934B2 (ja) | 2019-11-28 | 2024-02-06 | 東レ株式会社 | 嵩高糸 |
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US20180216261A1 (en) | 2018-08-02 |
JP6103157B1 (ja) | 2017-03-29 |
KR102611708B1 (ko) | 2023-12-08 |
TWI756178B (zh) | 2022-03-01 |
EP3327188A4 (en) | 2019-07-17 |
JPWO2017014241A1 (ja) | 2017-07-27 |
EP3327188B1 (en) | 2023-10-04 |
EP3327188A1 (en) | 2018-05-30 |
US20200325601A1 (en) | 2020-10-15 |
JP6776938B2 (ja) | 2020-10-28 |
CN107849755A (zh) | 2018-03-27 |
TW201712175A (zh) | 2017-04-01 |
KR20180033171A (ko) | 2018-04-02 |
JP2017122304A (ja) | 2017-07-13 |
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