CN1109782C - 卷曲聚酯纤维及包含其的混合纤维结构 - Google Patents
卷曲聚酯纤维及包含其的混合纤维结构 Download PDFInfo
- Publication number
- CN1109782C CN1109782C CN00804766A CN00804766A CN1109782C CN 1109782 C CN1109782 C CN 1109782C CN 00804766 A CN00804766 A CN 00804766A CN 00804766 A CN00804766 A CN 00804766A CN 1109782 C CN1109782 C CN 1109782C
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- Prior art keywords
- polyester
- fiber
- fibre
- texturized
- thermoadhesive
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 229960005137 succinic acid Drugs 0.000 description 2
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- VSVVZZQIUJXYQA-UHFFFAOYSA-N [3-(3-dodecylsulfanylpropanoyloxy)-2,2-bis(3-dodecylsulfanylpropanoyloxymethyl)propyl] 3-dodecylsulfanylpropanoate Chemical compound CCCCCCCCCCCCSCCC(=O)OCC(COC(=O)CCSCCCCCCCCCCCC)(COC(=O)CCSCCCCCCCCCCCC)COC(=O)CCSCCCCCCCCCCCC VSVVZZQIUJXYQA-UHFFFAOYSA-N 0.000 description 1
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- YHWCPXVTRSHPNY-UHFFFAOYSA-N butan-1-olate;titanium(4+) Chemical compound [Ti+4].CCCC[O-].CCCC[O-].CCCC[O-].CCCC[O-] YHWCPXVTRSHPNY-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
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- 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
- D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/435—Polyesters
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
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- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43832—Composite fibres side-by-side
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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Abstract
由聚对苯二甲酸丙二酯聚酯生产的，具有卷曲数为9～30个/25mm，卷曲率为20～50%的三维卷曲的，且卷曲弹性模量为80%或以上的卷曲聚酯纤维，以及，上述卷曲聚酯纤维的短纤维与热粘合性复合短纤维的重量比为30∶70至95∶5且两短纤维的接触点和/或热粘合性复合短纤维彼此间的接触点的至少一部分形成了热粘合的纤维结构。
Description
技术领域
本发明涉及具有三维卷曲的聚酯纤维及使用此纤维的纤维结构。更详言之，涉及梳理性能良好、能提供富具膨松性和压缩耐久性良好的制品如非织造织物、纤维填料等的卷曲聚酯纤维，及包含该卷曲聚酯纤维和热粘合复合短纤维的纤维结构。
发明背景
聚酯纤维，特别是聚对苯二甲酸乙二酯纤维，为机械强度、耐药品性、耐热性等优良的纤维，且被广泛使用于衣料用途和产业用途等。但是，聚对苯二甲酸乙二酯纤维本身平直且缺乏膨松性。故在诸如需要具有膨松感的非织造织物或絮棉等用途中，已有许多尝试通过使聚对苯二甲酸乙二酯纤维卷曲而使膨松性提高。
卷曲聚对苯二甲酸乙二酯纤维所制造的上述纤维制品，虽于刚刚使用后具有高膨松性，但若长时间使用则具有易发生压缩耐久性消失的问题。
与此相反，于特开平11-189938号(1999)(下文中，特开平指日本未审专利公布)中提出具有规定的拉伸弹性恢复率、弯曲恢复率等的卷曲聚对苯二甲酸丙二酯短纤维，此类短纤维的压缩耐久性，与包含聚对苯二甲酸乙二酯的卷曲纤维的压缩耐久性相比，有所改善。但是，该短纤维为将聚对苯二甲酸丙二酯纤维予以热处理后，施以填塞箱式卷曲机卷曲，并将卷曲纤维切割成短纤维的方法制造而成，所存在的问题是：短纤维仅仅是平面的，所谓二维的卷曲，由该纤维所得的纤维制品膨松性不足。此外，USP 3,681,188提出，通过不对称骤冷而在丝的径向赋予对于聚对苯二甲酸丙二酯的挤出长丝不对称双折射并且形成三维卷曲，而制造的纤维。但是，根据此先前技术方法所得的卷曲纤维为卷曲数极低，或者卷曲率过高，存在的问题是：由此类卷曲纤维仅可制得膨松性和压缩耐久性不足的纤维制品，另外，当于梳理步骤中在纤网于滚筒或辊上卷绕时，会产生下脚纤维、纤网破损等。
另一方面，以往，聚酯短纤维，尤其是聚对苯二甲酸乙二酯(以下，简称为PET)系短纤维已被广泛用作寝具、家具和衣料等的纤维填料材料。尤其是，将此类聚酯短纤维和热粘合性复合纤维混纤并且热处理所得混合纤维所制得的纤维结构，作为聚氨酯替代材料，被用于诸如垫材和蒲团(futon)衬垫、汽车片材、床垫等各种应用。使用如上述热粘合性复合纤维所得的纤维结构已于根据专利合作条约发表的国际申请WO 91/19032号，特开平4-240219号(1992)等中被提出。但是，对于这些纤维结构，期望进一步改善压缩耐久性。
发明内容
作为为了解上述问题而进行的深入研究工作的结果，发现，在使用包含聚对苯二甲酸丙二酯的、具有适度三维卷曲的且卷曲弹性模量高的卷曲聚酯纤维时，不仅可改善梳理性能，而且所得纤维制品的膨松性和压缩耐久性也显著改善，因而完成了本发明。而且，在将上述卷曲聚酯纤维与热粘合性复合纤维结合并制成纤维结构时，所得纤维结构的膨松性和压缩耐久性，均较常规提出的纤维结构的这些性能有明显的改善。
因此，根据本发明，提出了卷曲聚酯纤维，其特征在于：包含聚对苯二甲酸丙二酯基聚酯，具有卷曲数为9～30个/25mm、卷曲率为20～50％和卷曲弹性模量为80％或以上的三维卷曲；及一种纤维结构，其特征在于：包含上述的卷曲聚酯纤维的短纤维和热粘合性复合短纤维，该卷曲聚酯纤维的短纤维和该热粘合性复合短纤维的重量比为30∶70至95∶5，和具有由所述卷曲聚酯纤维的短纤维与所述热粘合性复合短纤维的接触点和/或热粘合性复合短纤维彼此同的接触点的至少一部分所形成的热粘合点。
实施发明的最佳方式
本发明叙述的聚对苯二甲酸丙二酯基聚酯，为以对苯二甲酸丙二酯单元为主要重复单元的聚酯，在不妨碍本发明目的的范围内，也可以是例如，以酸成分为基准，共聚有15摩尔％或以下、优选为5摩尔％或以下第三成分的聚酯。
可以用作优选使用的第三成分的各种成分是，例如间苯二甲酸、琥珀酸、己二酸、2，6-萘二羧酸或金属磺基间苯二甲酸等的酸成分、和例如1，4-丁二醇、1，6-己二醇、环已烷二醇或环己烷二甲醇等的二元醇成分等各种成分，并且通过考虑纺丝性能等可适当使用。
另外，视需要可添加各种添加剂例如消光剂、热稳定剂、消泡剂、正色剂、阻燃剂、抗氧化剂、紫外线吸收剂、红外线吸收剂、萤光增白剂或着色颜料等。
于本发明中，重要的不仅是本发明的卷曲聚酯纤维为包含上述的聚对苯二甲酸丙二酯基聚酯的卷曲纤维，而且是该纤维具有满足下述的卷曲数、卷曲率和同时满足后述条件的卷曲弹性模量的三维卷曲。因此，可获得梳理性能良好，且，膨松性、压缩耐久性优良的纤维制品。
即，本发明的卷曲聚酯纤维的卷曲数必须为9～30个/25mm，且优选为11～20个/25mm。若卷曲数低于9个/25mm，则由该纤维所得的纤维制品的膨松性不足。另一方面，卷曲数若超过30个/25mm，则纤维间的缠合性过高，因此梳理性能变差。
另外，该聚酯纤维的卷曲率必须为20～50％，且以30～40％为更优选。该卷曲率低于20％则纤维彼此间的缠合性低，且梳理性能恶化并且无法取得充分的膨松性。另一方面，卷曲率若超过50％，则不仅缠合性过高，导致缠结使梳理通过性降低，且所得的纤网不均匀。
再者，该聚酯纤维的卷曲弹性模量必须为80％或以上，且以85％或以上为更优选。卷曲弹性模量低于80％时，因为卷曲的压缩耐久性消失较大，故梳理性能极差，纤维易于在滚筒和辊上卷绕，产生大量下脚纤维，并且发生纤网破损等。结果，生产率极低，所得纤维制品的膨松性亦不足。同时亦令该纤维制品的压缩耐久性显著降低。因为聚对苯二甲酸丙二酯基聚酯纤维，比聚对苯二甲酸乙二酯纤维的模量低且结晶度低，故易引起卷曲的压缩耐久性消失。所以重要的是令卷曲弹性模量为如上述。
于本发明中，通过使卷曲聚酯纤维同时满足如所述的百分率卷曲、卷曲率、及卷曲弹性模量的要求，上述效果协同作用，令梳理性能良好，且可提高纤维制品的膨松性和压缩耐久性。
并且，此类效果在赋予该聚酯纤维的卷曲为三维卷曲时更为显著。因此，该卷曲若为以诸如填塞箱卷曲机等卷曲方法所赋予的平面卷曲，则无法取得充分的效果。
本发明的卷曲聚酯纤维包括：通过将粘度不同的聚对苯二甲酸丙二酯聚合物成形为并列型或偏心皮芯型复合纤维，并将所得复合纤维热处理和产生卷曲而制得的纤维，或者，通过于纺丝步骤中施以不对称骤冷，对所得纤维进行热处理和产生卷曲而制得的纤维，等等。在本发明中，特别以后者的通过不对称骤冷产生卷曲的纤维为优选。上述的卷曲，与卷曲机等填塞箱卷曲所赋予的机械卷曲不同，即使在将纤维加以压缩压力包装成包状长期放置时，其卷曲的压缩耐久性消失得亦非常少，且以后在将纤维供于梳理步骤时加工性能亦极佳，且纤维不会卷绕滚筒或辊，并且不会产生下脚纤维、纤网破损等。
本发明的卷曲聚酯纤维的单丝截面形状并无特别限定，可以配合用途目的适当选择圆形、三角形、扁平形、六角形等。于本发明中，考虑到纺丝步骤中在径向上易赋予不对称双折射率，且易于产生三维卷曲，上述纤维较优选为中空率5～80％的中空纤维。
以上说明的本发明的卷曲聚酯纤维可按照例如下述方法制造：
即，将聚对苯二甲酸丙二酯聚合物熔融，并对刚从抽丝板表面抽出的长丝，从其一侧吹送具有1.0m/s或以上流速的骤冷空气流，吹送气流与长丝行进方向的垂直方向成±20度范围内的角度，并以350～2500m/min牵引形成的长丝。以此取得沿长丝径向具有以双折射率表示的高度不对称双折射的未拉伸纱。其次，将该未拉伸纱在50～95℃的热水中，拉伸1.2～3.5倍，更优选进行二段拉伸，未进行定长热处理而切断为短纤维，并在100～150℃进行松驰热处理。此时，可令骤冷空气流流速为1.0m/s或以上，借此则可赋予高度的沿长丝径向的不对称双折射，并且易于和利于产生卷曲数为9或以上的三维卷曲。另外，特别优选调节骤冷气流从长丝一侧的吹送方向与长丝行进方向的垂直方向成±20度，这样可令纺丝性能改善，且可易赋予沿长丝径向的不对称双折射。如上所述，在将本发明的卷曲聚酯纤维切成短纤维时，切断长度以10～100mm的范围为优选，且特别以15～90mm的范围为优选。所得的卷曲短纤维可以进行梳理加工以及相应制品所需要的加工，以提供膨松性、压缩耐久性良好的非织造织物、纤维填料和垫材等。
例如，能够制造包含本发明的卷曲聚酯纤维的短纤维和下述热粘合性复合纤维，其重量比为30∶70～95∶5，优选为40∶60～90∶10，且具有该卷曲聚酯纤维的短纤维和该热粘合性复合短纤维的接触点和/或热粘合性复合短纤维彼此间的接触点的至少一部分形成的热粘合点的纤维结构，借此可生产膨松性、压缩耐久性为格外提高的纤维填料、垫材等。形成上述纤维结构骨架的纤维为上述的卷曲聚酯纤维，借此生产的纤维结构，与包含单独的热粘合性短纤维的或者包含热粘合性短纤维和聚对苯二甲酸乙二酯基聚酯短纤维的惯用纤维结构相比，前者的压缩耐久性得到更显著的改善。
优选上述的热粘合性复合短纤维为聚酯基复合纤维，其制法包括：将热塑性聚酯基弹性体(E)和比该弹性体熔点高10℃或以上的聚酯(P)，以在纤维横截面中的E与P面积比＝20∶80至80∶20进行配置，以使该弹性体(E)的至少一部分露出在纤维表面。将此类纤维和本发明的卷曲聚酯纤维的组合，可提供更好的弹性，且改进压缩耐久性。
此外，上述的热塑性聚酯基弹性体(E)优选为以聚酯做为硬链段，且以聚环氧烷二元醇做为软链段的聚醚酯基嵌段共聚物。上述硬链段可例示包括由至少一种二羧酸与至少一种二醇形成的聚酯，所述二羧酸选自芳香族二羧酸如对苯二甲酸、间苯二甲酸、萘-2，6-二羧酸、萘-2，7-二羧酸、联苯-4，4′-二羧酸、二苯氧基乙烷二羧酸或5-钠磺基间苯二甲酸，脂环族二羧酸等如1，4-环己烷二羧酸，脂族二羧酸等如琥珀酸、草酸、己二酸、癸二酸、十二烷酸或二聚酸；二元醇组分选自脂族二醇如乙二醇、二甘醇、丙二醇、丁二醇、戊二醇、已二醇、新戊二醇、癸66二醇，或脂环族二醇等如1，1-环已烷二甲醇或三环癸烷二甲醇。另外，软链段可列举平均分子量为400～5000左右的诸如聚乙二醇、聚(1，2-环氧丙烷)二醇、聚(环氧丁烷)二醇、聚(环氧丙烷)二醇、环氧乙烷和环氧丙烷的共聚物或环氧乙烷和四氢呋喃的共聚物等的聚环氧烷二醇。
特别优选的热塑性聚酯基弹性体(E)是，硬链段成分为包含主要酸成分为40～100摩尔％的对苯二甲酸和0～50摩尔％的间苯二甲酸，且主要二元醇成分为1，4-丁二醇的聚酯，且主要软链段成分为平均分子量400～5000的聚环氧烷二醇，并且该硬链段成分和该软链段成分的共聚比例(重量比)为95∶5至20∶80重量％的聚醚酯基嵌段共聚物。
另外，上述的热塑性聚酯基弹性体(E)为熔点为100～210℃，更优选为130～180℃。熔点为此范围内时，制造该热粘合性复合纤维时的纤维彼此间的熔合和接触粘合的发生进一步被抑制，并且令制造纤维结构时的粘合不匀亦更被抑制。更且，上述弹性体(E)的特性粘度就纺丝性能等方面而言以0.6～1.7为优选。
另一方面，聚酯(P)可为聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚对苯二甲酸己二酯、聚对苯二甲酸丙二酯、聚对苯二甲酸环己烷二甲醇酯、聚新戊内酯、或其共聚物等的任一者，然而由所得纤维结构的弹性恢复性观点而言，以聚对苯二甲酸丙二酯基聚酯、聚对苯二甲酸丁二酯基聚酯或聚对苯二甲酸环己烷二甲醇酯基聚酯为优选。
上述聚酯(P)为比前述聚酯基弹性体(E)的熔点高10℃或以上为优选。若满足此技术条件，则可将前述聚醚酯基嵌段共聚物中构成硬链段成分的聚酯相同的各种共聚成分进行共聚。
在本发明的热粘合性复合纤维中，如前所述，上述的热塑性聚酯基弹性体(E)优选和聚酯(P)复合以在纤维横截面中使E∶P面积比＝20∶80至80∶20。此时，E、P两成分的复合状态除了皮芯型以外，亦可为诸如偏心皮芯型、并列型、海岛型复合纺丝纤维或海岛型混合纺丝纤维或柑橘链段型排列(分割)纤维等公知的复合状态；但成分E和P的排列优选为该弹性体(E)的一部分露出纤维表面，且优选该弹性体占纤维截面中圆周的30％或以上。其中，在并列型、偏心皮芯型的情况，于成型纤维结构时的热处理时，可轻易赋予易于实现微细卷曲的潜在卷曲能力，所以特别优选并列型和偏心皮芯型，这是由于纤维彼此间的缠合增加且可提高粘合性。
本发明的热粘合性复合纤维的单纤维纤度优选为0.5～200dtex，且更优选为2～100dtex。优选使单根纤维纤度保持在上述的范围内，则可使在为作成纤维结构而进行的热接合处理时，该纤维结构中所形成的热粘合点的数目适当，可取得充分的强度，并且亦可极度抑制制造该热粘合性复合纤维时的胶着现象。
另外，纤维横截面的形状并非必要为正圆形，可采用多角形和附翼形、丸型等，但是，若考虑形成短纤维且通过梳理步骤的情况，则以正圆形为佳。也可具有1个或以上的中空部。
在制造本发明的热粘合性复合纤维时，可根据先前公知的方法进行制造。
将上述的热粘合性复合纤维切成短纤维时，切断长度优选为10～100mm，特别优选为15～95mm。于此范围则梳理性能和纤维结构的粘合性为特别良好。
另外，对于上述的热粘合性复合短纤维，可卷曲至在工程上不发生问题的程度。此时，卷曲数优选为8～20个/25mm、卷曲率优选为6～18％。
由上述说明的卷曲聚酯纤维的短纤维和热粘合性复合短纤维制造本发明的纤维结构可采用已知方法，只要在该纤维结构内部，于卷曲聚酯纤维的短纤维和热粘合性复合短纤维的接触点和/或热粘合性复合短纤维彼此间的接触点的至少一部分可形成热粘合点。可以优选采用的方法是：例如，将纤维在特定模具中吹塑成型后对所得模制纤维进行热处理的方法，和一边以热风等热处理纤维且一边形成纤维团并将其吹入特定模具中，再视需要再度予以热处理，从而模制出目的结构的方法等。
仅使得热塑性聚酯基弹性体(E)熔融的温度及时间可用作上述模制时的热处理条件。具体而言，热处理温度优选为约100～210℃，热处理时间优选为约10～30分钟。
以下，列举实施例等更加具体说明本发明的构成及效果，但本发明完全不受这些实施例所限定。实施例中的各数值依据下列方法求出：1)特性粘度
于邻氯苯酚溶液中，将聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丙二酯(PTT)以1.2g/dl溶解，聚对苯二甲酸丁二酯(PBT)以0.8g/dl溶解，且分别于35℃依常法测定特性粘度。2)纤度、纤维长度、卷曲数、卷曲率、卷曲弹性模量
依据JIS-L1015定义的方法测定。3)比容、压缩率和恢复率
所得的短纤维通过梳理机作成纤网，并且依据JIS-L1097定义的方法测定。4)梳理性能
纤维在落纱机的表面速度为35m/min，纺出纤网的单位面积重量为50g/m2的条件下进行梳理，评价运转1小时的梳理性能，其结果以良好、差和劣表示。纤维结构评价5)硬度(弹性)：
根据JIS-K6401(5.4)中定义的方法测定。数值130～200N为良好。6)重复压缩残留应变(耐久性)：
根据JIS-K6401(5.6)中定义的方法测定。数值10％或以下为良好。7)硬度不匀：
任意选出熟练者10名，以手触摸每个纤维结构的表面，并且根据下述判定基准，进行硬度不匀、柔软性的感官评价。
5：优良(极为均匀且未察见不匀)
4：相当好(几乎没有不匀且大部分均匀)
3：良好(虽有部分不匀但并不令人介意)
2：差(察见不匀)
1：劣(明显的许多不匀)
实施例1
使用聚对苯二甲酸丙二酯(特性粘度0.85，熔点225℃)，并于260℃熔融，由公知的中空圆形截面喷丝板(150孔)以吐出量480克/min吐出长丝，于喷丝板面下1.5～15cm位置，将25℃的骤冷空气以1.5m/s的流速，由长丝的一侧以与长丝行进方向垂直的角度吹送，并以1200m/min的卷取速度取得未拉伸丝。然后，将所得的未拉伸丝作成50万dtex的丝束，接着以70℃×90℃的二段热水拉伸法拉伸2.46倍。将此拉伸丝以填塞型卷曲机赋予卷曲后，切断成64mm长的纤维，且于135℃施以松弛热收缩处理，取得具有中空率15％的螺旋状三维卷曲的卷曲纤维。所得的卷曲纤维通过梳理机作成纤网，成形为蒲团纤维填料，测定其性能。结果示于表1。实施例2至4及比较例1和2
除了通过调整骤冷空气的流速，将卷曲数及卷曲率如表1变更以外，同实施例1进行处理，作成蒲团纤维填料并且测定性能。结果示于表1。比较例3
使用聚对苯二甲酸乙二酯(特性粘度0.64，熔点256℃)，并于290℃熔融，由公知的中空圆形截面喷丝板(150孔)吐出长丝，于喷丝板面下1.5～15cm位置，将25℃的骤冷空气以1.5m/s的流速，由长丝的一侧以与长丝行进方向垂直的角度吹送，并以1200m/min的卷取速度取得未拉伸丝。将所得的未拉伸丝作成50万dtex的丝束后，以70℃×90℃的二段热水拉伸法拉伸2.40倍。将此拉伸丝以填塞型卷曲机赋予卷曲后，切断成64mm长的纤维，且于135℃施以松弛热收缩处理，取得具有中空率15％的螺旋状三维卷曲的卷曲纤维。所得的卷曲纤维通过梳理机作成纤网，成形为蒲团纤维填料，测定其性能。结果示于表1。比较例4
除了未进行不对称骤冷，将骤冷空气对长丝均匀吹送，实施纺丝，取得未拉伸丝以外，同实施例1进行处理，作成蒲团纤维填料。所得的蒲团纤维填料仅为通过填塞卷曲赋予的二维卷曲，而不具有实施例1中蒲团纤维填料的螺旋状三维卷曲。对于该蒲团纤维填料评价性能的结果示于表1。
表1
实施例5
| 实施例 | 比较例 | |||||||
| 1 | 2 | 3 | 4 | 1 | 2 | 3 | 4 | |
| 组成 | PTT | PTT | PTT | PTT | PTT | PTT | PET | PTT |
| 卷曲方法(卷曲形状) | 不对称骤冷(三维) | 不对称骤冷(三维) | 不对称骤冷(三维) | 不对称骤冷(三维) | 不对称骤冷(三维) | 不对称骤冷(三维) | 不对称骤冷(三维) | 仅填塞卷曲(二维) |
| 骤冷空气流速(m/s) | 1.5 | 2.0 | 3.0 | 4.0 | 0.5 | 5.0 | 1.5 | 1.5 |
| 纤度(dtex) | 12.5 | 12.2 | 12.0 | 11.8 | 12.0 | 12.2 | 12.2 | 12.0 |
| 卷曲数(个/25mm) | 9.2 | 11.5 | 13.3 | 18.5 | 5.2 | 30.5 | 9.4 | 6.3 |
| 卷曲率(％) | 30.5 | 31.3 | 34.5 | 39.4 | 14.8 | 52.0 | 31.2 | 12.4 |
| 卷曲弹性模量(％) | 92.3 | 87.5 | 89.1 | 92.4 | 85.6 | 93.0 | 82.4 | 84.1 |
| 比容(cm3/g) | 115 | 117 | 109 | 113 | 121 | - | 120 | 128 |
| 压缩率(％) | 52 | 50 | 57 | 56 | 61 | - | 68 | 66 |
| 恢复率(％) | 95 | 94 | 93 | 94 | 81 | - | 72 | 69 |
| 梳理性能 | 良好 | 良好 | 良好 | 良好 | 差 | 劣 | 良好 | 良好 |
将对苯二甲酸二甲酯75重量份、同苯二甲酸二甲酯25重量份、丁二醇59重量份、聚丁二醇(分子量1500)71重量份、催化剂四丁氧基钛酸酯0.2重量份装入具备蒸馏装置的反应容器中。且依常法于210℃进行酯交换反应，随后于240℃进行缩聚反应。且于缩聚反应终了前向所得产物中立即添加1重量份的Sumitomo Chemical Co.，ltd.制的Sumilizer GA-80、1重量份的Sumitomo Chemical Co.，ltd.制的Sumilizer TP-D做为抗氧化剂。在熔融搅拌所得产物后，依常法成形为切片，取得含有40重量％软链段的聚醚酯嵌段共聚物弹性体。此热塑性弹性体的熔点为130℃，特性粘度为1.15。
以所得的热塑性弹性体做为皮成分，且聚对苯二甲酸丁二酯(PBT；特性粘度0.85，熔点232℃)做为芯成分，令纤维截面积比为芯/皮＝60/40，使用公知的偏心皮芯复合纤维用喷丝板(260孔)，以吐出量720充/分钟纺丝，且以1100m/min卷绕取得未拉伸丝。其次，将所得的未拉伸丝作成50万dtex的丝束后，以70℃×90℃的二段热水拉伸法拉伸4.4倍。将此拉伸丝以填塞型卷曲机赋予卷曲后，于50℃施以松弛热收缩处理后，切断成51mm长的纤维，取得热粘合性复合短纤维。所得的纤维为单纤维纤度6dtex，卷曲数11个/25mm，卷曲率8％。
将上述的热粘合性复合短纤维和实施例1的聚对苯二甲酸丙二酯纤维以表2记载的比例混纤，且通过罗拉梳理机2回，取得混纤网。将此纤网以一定密度放入模具型腔中，且以循环式热风干燥机进行180℃×15分钟的热处理，取得密度0.04g/cm3，厚度5cm的纤维结构。所得的纤维结构柔软且触感良好。评价该纤维结构特性的结果示于表2。
实施例6和7
除了令热粘合性复合纤维中的成分E(皮)/成分P(芯)的截面积比率，或纤维结构中的热粘合性复合短纤维/聚对苯二甲酸丙二酯短纤维的混合率如表2所示变更以外，同实施例5进行处理，取得纤维结构。评价该纤维结构的结果示于表2。
实施例8
将热粘合性复合纤维的芯成分(P)，以聚对苯二甲酸乙二酯(PET；特性粘度0.64，熔点256℃)代替聚对苯二甲酸丁二酯，且根据实施例5同样的制造条件，取得热粘合性复合短纤维。该短纤维为单纤维纤度12dtex，卷曲数11个/25mm，卷曲率9％。
除了使用上述的热粘合性复合短纤维代替于实施例5中包含聚对苯二甲酸丁二酯做为芯成分(P)的热粘合性复合短纤维以外，同实施例5进行处理，取得纤维结构。所得的纤维结构柔软且触感良好。评价该纤维结构特性的结果示于表2。比较例5
除了使用比较例3的聚对苯二甲酸乙二酯短纤维代替于实施例5中的聚对苯二甲酸丙二酯短纤维以外，同实施例5进行处理，取得纤维结构。所得的纤维结构比实施例5的结构的触感稍硬。评价该纤维结构特性的结果示于表2。
表2
| 单位 | 实施例 | 比较例 | ||||||
| 5 | 6 | 7 | 8 | 5 | ||||
| 热粘合性纤维 | 成分(E) | TA | 摩尔％ | 75 | 75 | 75 | 75 | 75 |
| IA | 摩尔％ | 25 | 25 | 25 | 25 | 25 | ||
| TMG | 摩尔％ | 100 | 100 | 100 | 100 | 100 | ||
| PTMG分子量 | 摩尔％ | 1500 | 1500 | 1500 | 1500 | 1500 | ||
| PTMG共聚率 | 重量％ | 40 | 40 | 40 | 40 | 40 | ||
| 熔点 | ℃ | 1500 | 155 | 155 | 155 | 155 | ||
| 成分(P) | 聚合物 | PBT | PBT | PBT | PBT | PBT | ||
| 熔点 | ℃ | 232 | 232 | 232 | 256 | 236 | ||
| (E)/(P)截面积比 | 40/60 | 70/30 | 40/60 | 40/60 | 40/60 | |||
| 纺丝性能 | 良好 | 良好 | 良好 | 良好 | 良好 | |||
| 卷曲聚酯纤维 | PTT | PTT | PTT | PTT | PET | |||
| 卷曲聚酯纤维/热粘合性纤维重量比 | 70/30 | 70/30 | 50/50 | 70/30 | 70/30 | |||
| 纤维结构特性 | 硬度 | N | 161 | 153 | 160 | 174 | 209 | |
| 重复压缩残留应变 | ％ | 7.1 | 6.4 | 6.9 | 9.3 | 11.1 | ||
| 硬度不匀 | 级 | 5 | 5 | 5 | 5 | 4 | ||
工业上的可利用性
本发明的卷曲聚酯纤维包含聚对苯二甲酸丙二酯基聚酯，且具有卷曲数、卷曲率、卷曲弹性模量的平衡良好的三维卷曲。故通过这些协同效应，可改善梳理性能，且由该纤维所得的纤维制品的压缩耐久性、膨松性得到显著提高。因此，该聚酯纤维为特别适合使用于非织造织物、纤维填料或垫材的用途中。特别是，使用上述卷曲聚酯纤维的本发明的纤维结构可充分发挥该卷曲聚酯纤维的性能，且膨松性、压缩耐久性优良。故该纤维结构适合使用于寝具、家具、车辆材料(垫材、天花板材料、防护材料)、衣料、过滤材料、建筑/土木工程材料、农业用材料等，在工业上具有高的利用价值。
Claims (5)
1.一种卷曲聚酯纤维，其特征为包含聚对苯二甲酸丙二酯基聚酯，具有卷曲数为9～30个/25mm、卷曲率为20～50％的三维卷曲，且卷曲弹性模量为80％或以上。
2.按照权利要求1的卷曲聚酯纤维，其中卷曲聚酯纤维为中空率为5～80％的中空纤维。
3.一种混合纤维结构，其特征为包含卷曲聚酯纤维的短纤维和热粘合性复合短纤维，所述卷曲聚酯纤维包含聚对苯二甲酸丙二酯基聚酯，具有卷曲数为9～30个/25mm、卷曲率为20～50％的三维卷曲，且卷曲弹性模量为80％或以上，该卷曲聚酯纤维的短纤维和该热粘合性复合短纤维的重量比为30∶70至95∶5，且该卷曲聚酯纤维的短纤维和该热粘合性复合短纤维的接触点和/或热粘合性复合短纤维彼此间的接触点的至少一部分形成热粘合点。
4.按照权利要求3的混合纤维结构，其中热粘合性复合短纤维是由热塑性聚酯基弹性体(E)和比该弹性体熔点高10℃或以上的聚酯(P)配置而成的聚酯基复合纤维，在纤维横截面中E∶P的面积比＝20∶80至80∶20，该弹性体(E)的至少一部分在纤维表面露出。
5.按照权利要求4的混合纤维结构，其中热塑性聚酯基弹性体(E)为包含硬链段成分和软链段成分的、硬链段成分与软链段成分的共聚比例按重量计为95∶5至20∶80的聚醚酯基嵌段共聚物，该硬链段成分为包含主要的酸成分为40～100摩尔％的对苯二甲酸和0～50摩尔％的间苯二甲酸和主要的二元醇成分为1，4-丁二醇的聚酯，该软链段成分为平均分子量为400～5,000的聚环氧烷二元醇。
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| JP2000031813A JP4376408B2 (ja) | 2000-02-09 | 2000-02-09 | 繊維構造体 |
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| WO2001049909A1 (fr) | 2001-07-12 |
| KR20010102524A (ko) | 2001-11-15 |
| EP1160362B1 (en) | 2007-09-19 |
| EP1160362A1 (en) | 2001-12-05 |
| TW500846B (en) | 2002-09-01 |
| US6372343B1 (en) | 2002-04-16 |
| CN1343271A (zh) | 2002-04-03 |
| KR100698003B1 (ko) | 2007-03-23 |
| ID29973A (id) | 2001-10-25 |
| EP1160362A4 (en) | 2004-11-03 |
| DE60036462T2 (de) | 2008-06-19 |
| DE60036462D1 (de) | 2007-10-31 |
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