WO2023008500A1 - 複合繊維束および繊維製品 - Google Patents
複合繊維束および繊維製品 Download PDFInfo
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- WO2023008500A1 WO2023008500A1 PCT/JP2022/029025 JP2022029025W WO2023008500A1 WO 2023008500 A1 WO2023008500 A1 WO 2023008500A1 JP 2022029025 W JP2022029025 W JP 2022029025W WO 2023008500 A1 WO2023008500 A1 WO 2023008500A1
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Images
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
-
- D—TEXTILES; PAPER
- 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
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/34—Core-skin structure; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/10—Physical properties porous
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/03—Shape features
- D10B2403/033—Three dimensional fabric, e.g. forming or comprising cavities in or protrusions from the basic planar configuration, or deviations from the cylindrical shape as generally imposed by the fabric forming process
- D10B2403/0331—Three dimensional fabric, e.g. forming or comprising cavities in or protrusions from the basic planar configuration, or deviations from the cylindrical shape as generally imposed by the fabric forming process with one or more convex or concave portions of limited extension, e.g. domes or pouches
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2509/00—Medical; Hygiene
Definitions
- the present invention relates to a composite fiber bundle suitable for clothing textiles and a fiber product containing the composite fiber bundle.
- Synthetic fibers such as polyester and polyamide have excellent mechanical properties and dimensional stability, so they are widely used for both clothing and non-clothing applications.
- Synthetic fibers such as polyester and polyamide have excellent mechanical properties and dimensional stability, so they are widely used for both clothing and non-clothing applications.
- fibers with higher tactile sensations and functions.
- This side-by-side type conjugate fiber is intended to give a texture such as a moderate feeling of resilience and swelling by expressing crimps due to the difference in heat shrinkage between polymers.
- all the composite fibers express the same crimped form, so that the crimp phases are aligned, and there are cases where the texture lacks a feeling of swelling and is flat. rice field.
- the composite fibers that make up the composite fiber bundle are devised one by one.
- Various techniques have been proposed to make the tactile feel and texture of natural materials more complex and bring them closer to the unique tactile feel and texture found in natural materials.
- Patent Document 1 in a conjugate fiber bundle composed of conjugate fibers in which polyethylene terephthalate (PET) having different viscosities are conjugated side-by-side, the conjugate ratio is changed between the conjugate fibers to reduce the variation in the curvature of the polymer interface. It is disclosed that the crimps are formed independently without meshing due to the difference in crimp shape between the conjugate fibers depending on the conjugate ratio.
- PET polyethylene terephthalate
- a conjugate fiber bundle composed of such conjugate fibers expresses voids between the conjugate fibers according to the difference in crimp configuration, so when the conjugate fiber bundle is used as a textile, it has a bulging texture.
- Patent Document 2 a conjugated fiber in which polyethylene terephthalate (PET) having different viscosities is conjugated in a side-by-side type is used as a modified cross section, and three or more types of conjugates having different states of the conjugated bonding surfaces, which are the bonding surfaces between the conjugated components, are used. It discloses that by forming a conjugate fiber bundle composed of fiber groups, each conjugate fiber group has a different flexural rigidity, and conjugate fiber groups with different crimp development properties can be obtained.
- PET polyethylene terephthalate
- the change in the conjugate ratio which can be used as a means for changing the crimp configuration of each conjugate fiber, is substantially in the range of 40:60 to 60:40 in order to maintain spinning stability.
- the difference in crimp shape change obtained here is small, and naturally the texture obtained is sometimes monotonous.
- each composite fiber group has a different bending rigidity, and crimp development is achieved. may be different composite fiber groups.
- the conjugate fiber described in Patent Document 2 has a substantially multilobed cross section, and the distance between the polymer centers of gravity required for crimp development is naturally short, so the crimp development force is low. In some cases, the bulge and resilience required for comfortable clothing were insufficient.
- the object of the present invention is to solve the above-described problems of the prior art, and to control the crimped form of each conjugate fiber that constitutes the conjugate fiber bundle, so that in addition to a smooth touch, an appropriate resilience is obtained.
- a conjugate fiber bundle composed of conjugate fibers composed of at least two kinds of polymers having different melting points, wherein the variation coefficient CV of the value of (distance between polymer centers of gravity/fiber diameter) between the conjugate fibers is 5 to 30.
- the conjugate fiber bundle according to (1) wherein the difference between the maximum and minimum flatness values of the conjugate fibers is less than 0.5; (3) The conjugate fiber bundle according to (1) or (2), characterized in that the average value of flatness between the conjugate fibers is 1.2 to 3.0; (4) The conjugate fiber bundle according to any one of (1) to (3), wherein the surface layer of the conjugate fiber is covered with one type of polymer; (5) A textile product partially containing the composite fiber bundle according to any one of (1) to (4) above, is.
- the conjugate fiber bundle of the present invention has the features described above, so that the crimped form of each conjugate fiber constituting the conjugate fiber bundle is precisely controlled. Therefore, by using the conjugate fiber bundle of the present invention, it is possible to obtain a textile for clothing that is excellent in wearing comfort and has a moderate resilience and a puffy texture in addition to a dry feel.
- FIG. 1 are schematic diagrams showing an example of the cross-sectional structure of the composite fibers that constitute the composite fiber bundle of the present embodiment.
- FIGS. 2(a) and 2(b) are schematic diagrams showing an example of the cross-sectional structure of the conjugate fibers forming the conjugate fiber bundle of the present embodiment.
- FIG. 3 is a schematic diagram showing an example of a cross-sectional structure of conjugate fibers forming a conventional conjugate fiber bundle.
- FIG. 4 is a schematic diagram showing an example of the cross-sectional structure of each composite fiber that constitutes the composite fiber bundle of the present embodiment.
- FIG. 5 is a diagram for understanding the coefficient of variation CV of the value of (distance between center of gravity of polymer/fiber diameter) between conjugate fibers constituting the conjugate fiber bundle of the present embodiment. means the top, bottom, left, and right sides of .
- FIG. 6 is a schematic diagram showing an example of the crimped form of the conjugate fibers that constitute the conjugate fiber bundle of the present embodiment.
- FIG. 7 is a cross-sectional view for explaining the manufacturing method of the conjugate fibers forming the conjugate fiber bundle of the present embodiment.
- the present inventors have made intensive studies to realize complex voids and irregularities like natural materials with synthetic fibers, and have found that in a conjugate fiber bundle composed of conjugate fibers composed of at least two types of polymers having different melting points, the conjugate By controlling the distance between the polymer centers of gravity of each fiber and aligning the crimp phase appropriately, we discovered that it was possible to form complex voids and irregularities that were difficult to obtain with conventional synthetic fibers.
- the conjugate fiber bundle when all the conjugate fibers constituting the conjugate fiber bundle express the same crimped form, the conjugate fiber bundle is converged with the same crimp phase, and the gap between the conjugate fibers becomes smaller.
- the texture when used as a textile may be flat without a feeling of swelling.
- the conjugate fibers constituting the conjugate fiber bundle express different crimped forms, gaps tend to be formed between the conjugate fibers due to the shift in the crimp phase of the conjugate fibers.
- the morphology of the conjugate fiber bundle does not change, and the size of the voids formed between the conjugate fibers becomes uniform, so that when the conjugate fiber bundle is used as a textile, the appearance and texture may be monotonous. .
- the crimp expression of the composite fibers constituting the composite fiber bundle is changed, if the crimp phase of the composite fibers is controlled to be partially aligned, when the composite fiber bundle is used as a textile Furthermore, in addition to the fine voids inherent in the conjugate fiber bundle, there are areas where the crimp phases are aligned and those where the crimp phases are not aligned between adjacent conjugate fibers. As a result, complex voids are created between the composite fibers, and complex irregularities not found in conventional composite fiber bundles are created. can be expressed.
- the present invention is constructed based on this idea, and specifically, a conjugate fiber bundle composed of conjugate fibers composed of at least two kinds of polymers having different melting points, and the distance between the centers of gravity of the polymers (distance between the centers of gravity of the polymers /fiber diameter) is 5 to 30%.
- the conjugate fiber bundle in the present embodiment is a conjugate fiber bundle in which, for example, 20 or more conjugate fibers made of at least two types of polymers are bundled. say.
- thermoplastic polymer is preferable as the polymer used for the conjugate fibers constituting the conjugate fiber bundle of the present embodiment because of its excellent workability.
- Preferred thermoplastic polymers are, for example, polyester-based, polyethylene-based, polypropylene-based, polystyrene-based, polyamide-based, polycarbonate-based, polymethyl methacrylate-based, polyphenylene sulfide-based polymers, and copolymers thereof. From the viewpoint that a particularly high interfacial affinity can be imparted and a fiber having no abnormalities in the composite cross section can be obtained, all the thermoplastic polymers used in the composite fiber are preferably the same polymer group and copolymers thereof.
- additives such as inorganic substances such as titanium oxide, silica, and barium oxide, carbon black, colorants such as dyes and pigments, flame retardants, fluorescent brighteners, antioxidants, and ultraviolet absorbers are included in the polymer. You can stay.
- titanium oxide in the polymer it is preferable to include titanium oxide in the polymer.
- the titanium oxide on the surface of the composite fiber diffusely reflects light, which only improves the appearance quality, such as suppressing the appearance unevenness (glare) caused by the increase or decrease in reflection depending on the angle of incidence of light.
- the titanium oxide inside the composite fiber also provides functionality such as anti-see-through and UV shielding.
- the content of titanium oxide in the polymer is preferably 1.0 wt % or more in order to sufficiently obtain the above effects.
- the content of titanium oxide is preferably 10.0 wt % or less, because an increase in diffuse reflection of light by titanium oxide may lead to a decrease in color developability.
- the conjugate fibers constituting the conjugate fiber bundle of the present embodiment need to be made of at least two types of polymers with different melting points in order to control the crimped form.
- the conjugated fiber is greatly curved toward the low-melting polymer side where the shrinkage is high after the heat treatment. Shortened forms can be expressed. Furthermore, by controlling the distance between the centers of gravity of the polymers, it is possible to express any crimped form, thereby achieving the control of the crimp phase, which is the object of the present invention.
- Polymers with different melting points in the present embodiment include a group of melt-moldable thermoplastic polymers such as polyesters, polyethylenes, polypropylenes, polystyrenes, polyamides, polycarbonates, polymethyl methacrylates, and polyphenylene sulfides, and their A combination of polymers having different melting points of 10°C or more among copolymers.
- melt-moldable thermoplastic polymers such as polyesters, polyethylenes, polypropylenes, polystyrenes, polyamides, polycarbonates, polymethyl methacrylates, and polyphenylene sulfides, and their A combination of polymers having different melting points of 10°C or more among copolymers.
- the purpose is to express a crimped form by the difference in shrinkage of polymers with different melting points.
- a combination of polymers such as ester-bonded polyesters and amide-bonded polyamides existing in the main chain It is more preferable to select from among the same group of polymers in which the bonds that bind are identical.
- Combinations of low-melting polymers and high-melting polymers in the same polymer group include, for example, polyester-based copolymer polyethylene terephthalate/polyethylene terephthalate, polypropylene terephthalate/polyethylene terephthalate, polybutylene terephthalate/polyethylene terephthalate, and thermoplastic polyurethane.
- polyethylene terephthalate polyester elastomer/polyethylene terephthalate, polyester elastomer/polybutylene terephthalate, nylon 66/nylon 610, nylon 6-nylon 66 copolymer/nylon 6 or 610, PEG copolymer nylon 6/nylon 6 as polyamide or 610, thermoplastic polyurethane/nylon 6 or 610, polyolefins such as ethylene-propylene rubber finely dispersed polypropylene/polypropylene, and propylene- ⁇ -olefin copolymer/polypropylene.
- polymers with different melting points are used together from the viewpoint that when the conjugate fiber bundle is made into textiles, a moderate resilience can be obtained from high bending recovery and good color development can be obtained when dyed.
- a polymerized polyethylene terephthalate/polyethylene terephthalate combination is particularly preferred.
- copolymerization components in copolymerized polyethylene terephthalate include succinic acid, adipic acid, azelaic acid, sebacic acid, 1,4-cyclohexanedicarboxylic acid, maleic acid, phthalic acid, isophthalic acid, 5-sodium sulfoisophthalic acid, and the like. is mentioned. Among these, it is preferable to use polyethylene terephthalate copolymerized with 5 to 15 mol % of isophthalic acid from the viewpoint of maximizing the difference in shrinkage from polyethylene terephthalate.
- recycled polyethylene terephthalate is preferably used as the polymer used in the present embodiment from the viewpoint of obtaining an appropriate resilience from high bending recovery and obtaining good color development when dyed. can be used.
- the cross section of the composite fiber of the present embodiment is preferably a composite section in which polymers with different melting points are arranged so that their centers of gravity are different.
- Examples of such a composite cross section include a side-by-side type as shown in FIG. 1(a) and an eccentric core-sheath type as shown in FIG. 1(b). be done.
- the surface layer of the composite fiber is preferably covered with one type of polymer. Since the surface layer of the conjugate fiber is covered with one type of polymer, even if a polymer with low heat resistance and abrasion resistance is used as one component of the conjugate fiber, the fiber does not peel off at the interface due to friction or impact. Good properties can be retained.
- the conjugate fiber bundle of the present embodiment when the conjugate fiber bundle of the present embodiment is produced, if melts of polymers with a large melting point difference are spun from the die as a composite flow, the high melting point polymer curves toward the low melting point polymer side due to the cooling difference after ejection. Yarn bending occurs, which causes yarn breakage by contacting the spinneret or interfering with the composite flow spun from another location.
- the cooling difference can be alleviated and yarn bending can be suppressed. Become.
- Examples of one type of polymer covering the surface layer of the conjugate fiber include polyethylene terephthalate, copolymerized polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate as polyesters, nylon 6, nylon 66 and nylon 610 as polyamides, and polypropylene as polyolefins. is mentioned.
- polyethylene terephthalate or copolymerized polyethylene terephthalate is preferably used to cover the surface layer of the conjugate fiber from the viewpoint of excellent heat resistance and color development.
- the thickness of one type of polymer covering the surface layer of the conjugate fiber can be adjusted as appropriate. is preferably 0.01 to 0.1. Within this range, even if the composite fiber or textile is subjected to friction or impact, whitening or fluffing does not occur, and the yarn processing stability and textile quality can be maintained. Furthermore, when the S/D is 0.02 to 0.08, the center of gravity of the high-melting polymer and the low-melting polymer are separated, and the crimp due to the difference in shrinkage can be maximized, so it is mentioned as a more preferable range. .
- the ratio S/D between the minimum thickness S of the polymer covering the surface layer of the conjugate fiber and the fiber diameter D in the present embodiment is obtained by embedding the conjugate fiber bundle in an embedding agent such as an epoxy resin, and then It is obtained by taking an image with a transmission electron microscope (TEM) at a magnification that allows observation of 10 or more composite fibers, and observing the cross section of the composite. At this time, by applying metal dyeing, a difference in dyeing between polymers can be obtained, so that the contrast of the joints of the composite cross section can be clarified.
- TEM transmission electron microscope
- the composite cross section of the photographed image is an eccentric core-sheath type cross section as shown in FIG.
- a value obtained by dividing the value of the obtained minimum thickness S by the value of the fiber diameter D obtained by measuring the area of each conjugate fiber and measuring the diameter obtained in terms of a perfect circle in units of ⁇ m to the first decimal place. is calculated, and the average value is rounded to the third decimal place to obtain the ratio S/D between the minimum thickness S of the polymer covering the surface layer of the composite fiber and the fiber diameter D.
- the area ratio of the low-melting polymer and the high-melting polymer in the composite cross-section of the composite fiber constituting the composite fiber bundle of the present embodiment is 70/30 to 30/70. A range is preferred, and 60/40 to 40/60 is more preferred. Within this range, the crimped form due to the difference in shrinkage of the polymer can be sufficiently developed without being affected by the hardening of the texture that occurs when the low-melting-point polymer undergoes high shrinkage due to heat treatment.
- the portions where the crimp phases are aligned and the portions where the crimp phases are not aligned are Since there is a difference in voids, unevenness can be formed on the surface when the composite fiber bundle is used as a textile.
- the coefficient of variation CV of the value of (distance between the center of gravity of the polymer / fiber diameter) between the conjugate fibers is 5 ⁇ 30% is important.
- the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) referred to in this embodiment can be calculated by the following method.
- the cross section of the textile perpendicular to the thickness direction of the textile and the fiber axis direction of the conjugate fiber is measured using a scanning electron microscope (SEM) as a magnification that allows observation of 20 or more conjugate fibers.
- SEM scanning electron microscope
- the area of the composite fiber is measured, and the diameter obtained by converting to a perfect circle is measured in ⁇ m to the first decimal place. do.
- the obtained value is defined as the fiber diameter ( ⁇ m) of the composite fiber.
- the length of a straight line connecting the respective centers of gravity (Gx, Gy) of the low melting point polymer x and the high melting point polymer y in the cross section of the conjugate fiber as shown in FIG. Measure to the first decimal place in units of ⁇ m. The obtained value is taken as the polymer center-to-center distance ( ⁇ m).
- This evaluation is performed on 20 composite fibers ((1) to (20) in FIG. 5) randomly extracted from the same image as above, and the standard deviation and average value are obtained. Calculate the value by dividing by and multiplying by 100, and round off to the nearest whole number. The obtained value is defined as the coefficient of variation CV (%) of the value of (distance between polymer centers of gravity/fiber diameter).
- the crimp form can be controlled by the distance between the polymer centers of gravity and the fiber diameter.
- a shortened form can be expressed. That is, the crimp development force is represented by (distance between polymer centers of gravity/fiber diameter). It is possible to control the formation of voids and irregularities on the textile surface.
- the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) between conjugate fibers constituting the conjugate fiber bundle is 5% or more.
- the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) is more preferably in the range of 10 to 20%, more preferably in the range of 15 to 20%.
- the coefficient of variation CV is within the above range, when the composite fiber bundle is used as a textile, the pitch of the irregularities on the surface of the textile becomes finer, and the dry feel is conspicuous.
- the voids between the conjugate fibers increase, when the conjugate fiber bundle is used as a textile, the apparent density is lowered, and an effect of improving swelling is also added.
- the coefficient of variation CV is 30% or less.
- the conjugate fibers constituting the conjugate fiber bundle of the present embodiment as a method of controlling (distance between polymer centers of gravity/fiber diameter), a method of changing the cross-sectional shape and conjugate ratio of the conjugate fibers for each conjugate fiber is conceivable.
- the cross-sectional shape of the composite fibers constituting the composite fiber bundle is flattened, and the difference between the maximum value and the minimum value of the flatness between the composite fibers is set to 0.5.
- a method of less than 5 is preferred.
- the term "flat” means an elongated shape in a plan view, and specifically, the "flatness" of the cross section of the conjugate fiber described later is 1.1 or more.
- the cross-sectional shape of the conjugate fiber is flat (flat cross section), when polymers with different melting points are joined in the longitudinal direction of the flat cross section as shown in FIG. In the case of bonding in the direction of the minor axis of the flat cross section as shown in FIG. 2B, the distance between the polymer centers of gravity is minimized. In this way, by making the cross-sectional shape of the conjugate fiber flat, it is possible to control the value of (distance between polymer centers of gravity/fiber diameter) by changing the direction of the joint surface of the conjugate fiber.
- the difference between the maximum flatness value and the minimum value of the flatness between the conjugate fibers is less than 0.5. is more preferable.
- the conjugate fibers have the above structure, the crimp phase between the conjugate fibers becomes easier to partially align, and the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) can be easily set within the desired range.
- the difference between the maximum and minimum values of is less than 0.2.
- the average value of the flatness between the conjugate fibers is preferably 1.2 or more, more preferably 1.4 or more, and further preferably 1.6 or more. preferable.
- the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) can be brought closer to the optimum range.
- voids are formed between the conjugate fibers due to steric hindrance when the conjugate fibers having a flat cross section are crimped, and swelling is obtained when the conjugate fiber bundle is used as a textile.
- the average value of flatness in the present embodiment is preferably 3.0 or less, more preferably 2.5 or less, and even more preferably 2.0 or less.
- the average flatness value and the difference between the maximum and minimum values of the flatness between the conjugate fibers are obtained by the following method.
- a composite fiber bundle is embedded in an embedding agent such as an epoxy resin, and an image of the cross section of the fiber in the direction perpendicular to the fiber axis is observed with a scanning electron microscope (SEM) at a magnification of 10 or more composite fibers. to shoot.
- SEM scanning electron microscope
- a straight line connecting two points (a1, a2) separated by a distance is taken as the major axis, and a straight line passing through the midpoint of the long axis and perpendicular to the long axis and the intersection point (b1, b2) of the outer circumference of the fiber is taken as the short straight line.
- the value obtained by dividing the length of the long axis by the length of the short axis is calculated, and the obtained value is defined as the flatness.
- a simple numerical average of the results obtained by performing the same procedure on 10 conjugate fibers randomly extracted from the same image is calculated, and the value rounded to the second decimal place is used as the average flatness value.
- the value obtained by subtracting the smallest value from the largest value is obtained, and the value is rounded off to the second decimal place as the difference between the maximum flatness value and the minimum flatness value.
- the cross-sectional shape of the conjugate fibers constituting the conjugate fiber bundle of the present embodiment is flat as shown in FIG. 1(a), multilobed as shown in FIG. shape, gear shape, petal shape, star shape, and the like.
- conjugate fibers having a cross-sectional shape with three or more protrusions on the conjugate fiber surface.
- conjugate fibers having a cross-sectional shape with three or more protrusions on the surface of the conjugate fiber, it is possible to suppress appearance unevenness (glare) due to diffuse reflection of light and improve water absorption due to fine voids between the conjugate fibers.
- the number of protrusions is more preferably 5 or more, and even more preferably 8 or more. However, if the number of protrusions becomes too large, the effect will gradually decrease, so the practical upper limit of the number of protrusions is 20, and 12 or less is more preferable.
- the conjugate fibers constituting the conjugate fiber bundle of the present embodiment preferably have a crimped form with a number of crimp crests of 5 crimps/cm or more.
- the number of crimp crests is obtained by the following method.
- the conjugate fiber is pulled out from the textile so as not to be plastically deformed, one end of the conjugate fiber is fixed, and a load of 1 mg / dtex is applied to the other end for 30 seconds or more. Mark any point where the distance between two points is 1 cm.
- the sample was fixed on a slide glass after adjustment so that the distance between the markings made in advance was 1 cm so as not to plastically deform the composite fiber, and the 1 cm marking of this sample could be observed with a digital microscope. Take an image at magnification. In the photographed image, when the composite fiber CF has a crimped form as shown in FIG.
- the crimped form has a crimp number of crimps of 5 crests/cm or more, complex voids between the conjugate fibers and irregularities on the textile surface are formed by aligning the crimp phase between the conjugate fibers. be able to. More preferably, the number of crimp crests is 10 crests/cm or more. When the number of crimp crests is 10 crests/cm or more, not only is it possible to obtain the effect of improving swelling due to the increase in voids between conjugate fibers due to the excluded volume effect between conjugate fibers, but also the crimp form is fine. Stretchability is also given by becoming a spiral structure.
- the number of crimp crests in this embodiment is preferably 50 crests/cm or less, more preferably 40 crests/cm or less, and even more preferably 30 crests/cm or less.
- the conjugate fibers constituting the conjugate fiber bundle of the present embodiment have a fiber diameter of 20 ⁇ m or less. Within this range, the diffused reflection of light from the conjugate fiber is increased, and not only is it possible to suppress the appearance unevenness (glare) when made into a textile, but it is also possible to obtain a sufficient sense of repulsion. As a result, it is suitable for use in clothing such as pants and shirts that require a firm texture.
- the fiber diameter is set to 15 ⁇ m or less.
- the flexibility of the composite fiber bundle is increased, and it can be suitably used for apparel such as innerwear and blouses that come in contact with the skin. More preferably, the fiber diameter is 12 ⁇ m or less.
- the fiber diameter is preferably 5 ⁇ m or more, more preferably 8 ⁇ m or more.
- conjugate fiber bundle of the present embodiment since there is a difference in gaps between adjacent conjugate fibers where the crimp phase is aligned and where the crimp phase is not aligned, complex voids and unevenness are created between the conjugate fibers. is formed.
- the complex voids between the conjugate fibers provide an appropriate sense of resilience and swelling.
- a textile having a certain texture and excellent wearing comfort can be obtained.
- Composite fiber bundles of the present embodiment can be used for general clothing such as jackets, skirts, pants, and underwear, as well as sports clothing and clothing materials. It can be suitably used for a wide variety of textile products such as interior goods, cosmetics, cosmetic masks, and health products.
- the method for spinning the composite fiber bundle of the present embodiment includes a melt spinning method for the purpose of producing multifilament and spun yarn, a solution spinning method such as a wet and dry-wet method, and a method suitable for obtaining a sheet-like fiber structure. It can be produced by a melt blow method, a spunbond method, or the like. Among these, from the viewpoint of obtaining a composite fiber bundle that can be applied to textiles with high productivity, it is preferable to use the melt spinning method to form a multifilament or a spun yarn.
- the spinning temperature at that time is the temperature at which the high melting point polymer and the high viscosity polymer mainly show fluidity among the polymer types used. It is preferable to Although the temperature at which this fluidity is exhibited varies depending on the molecular weight, if it is set between the melting point of the polymer and +60° C., stable production can be achieved.
- the spinning speed is preferably about 500 to 6000 m/min, but it can be changed as appropriate depending on the physical properties of the polymer and the intended use of the composite fiber bundle. In particular, from the viewpoint of achieving high orientation and improving mechanical properties, it is more preferable to set the spinning speed to 500 to 4000 m/min and then draw. By setting the spinning speed to 500 to 4000 m/min, the uniaxial orientation of the conjugate fiber can be promoted.
- the preheating temperature When stretching, it is preferable to appropriately set the preheating temperature, using the softening temperature such as the glass transition temperature of the polymer as a guideline.
- the upper limit of the preheating temperature is preferably a temperature at which the conjugate fiber bundle is spontaneously stretched during the preheating process so that the yarn path is not disturbed. For example, in the case of PET having a glass transition temperature of around 70.degree.
- the ejection amount per single hole in the spinneret for manufacturing the composite fiber bundle of the present embodiment is preferably 0.1 to 10 g/min/hole.
- the discharge amount is preferably 0.1 to 10 g/min/hole.
- the melt viscosity ratio of the conjugated polymer is less than 5.0.
- the melt viscosity ratio is set within such a range, excessive crimping is suppressed, and the formation of complex voids and unevenness on the textile surface, which is the object of the present invention, is controlled by aligning the crimp phase between the conjugate fibers. becomes easier.
- the melt viscosity ratio of the composite polymer is preferably less than 5.0.
- the difference in the solubility parameter value is less than 2.0, because it is possible to stably form a composite polymer flow and obtain a composite fiber having a favorable composite cross section.
- the spinneret used when manufacturing the composite fiber bundle of the present embodiment for example, the composite spinneret described in Japanese Patent Application Laid-Open No. 2011-208313 is suitably used.
- the composite spinneret shown in FIG. 7 is incorporated into a spinning pack in a state in which roughly three types of members, namely a weighing plate 1, a distribution plate 2 and a discharge plate 3, are layered from the top, and used for spinning.
- FIG. 7 is an example using three types of polymers, A polymer, B polymer, and C polymer. Since it is difficult to combine three or more types of polymers with a conventional composite spinneret, a composite spinneret using fine flow channels as shown in FIG. It is preferable to use
- the metering plate 1 measures and flows the amount of polymer per each discharge hole and each distribution hole, and the distribution plate 2 controls the cross section of each conjugate fiber and its cross-sectional shape.
- 3 has the role of compressing and discharging the composite polymer stream formed by the distribution plate 2 .
- the flow of the composite polymer may be controlled such that the direction of the bonding surface of the polymer differs for each ejection hole in the distribution plate 2 while the ejection holes of the ejection plate 3 are flat. From the viewpoint of being able to control an arbitrary composite cross section for each discharge hole in this way, it is preferable to use a composite spinneret using fine flow channels as illustrated in FIG. 7 in this embodiment.
- the members stacked above the weighing plate 1 are formed with flow paths in accordance with the spinning machine and the spinning pack. Just do it.
- the metering plate 1 By designing the metering plate 1 according to the existing channel member, the existing spinning pack and its members can be used as they are. Therefore, it is not necessary to dedicate a spinning machine specifically for the spinneret.
- the composite polymer stream discharged from the discharge plate 3 is cooled and solidified in accordance with the above-described manufacturing method, then applied with an oil solution and taken up by a roller having a specified peripheral speed. After that, it is drawn with a heating roller and post-processed as necessary to form a conjugate fiber bundle in which desired conjugate fibers are bundled.
- the post-processing referred to here is applied when producing a spun yarn composed of short fibers, and after drawing, crimping is applied using a crimper or the like, and then the fiber length is 20. It may be cut into short fibers of ⁇ 120 mm and then subjected to known spinning processing techniques.
- known yarn processing techniques such as false twisting and non-uniform drawing processing may be applied at the same time as drawing.
- non-uniform drawing processing is performed and the composite fiber is drawn at a draw ratio within a range not exceeding the natural draw ratio of the composite fiber.
- the non-uniform stretching process creates a difference in dyeability between the stretched and unstretched sections, which emphasizes the shade of the color, and when used as a textile, it can express the heathered tone of natural materials. .
- the stretching ratio is within the range of the lower limit of the natural stretching ratio x 1.2 times to the upper limit. Magnification may be determined according to the key.
- the number of false twists T (unit: times/m), which is the number of twists of the yarn bundle in the twisting region, is determined according to the total fineness Df (unit: dtex) of the yarn bundle after false twisting. It is preferable to set the false twisting conditions such as the rotation speed of the twisting mechanism and the processing speed so as to satisfy the following conditions. 20000/ Df0.5 ⁇ T ⁇ 40000 / Df0.5
- the false twist number T is measured by the following method. That is, the yarn bundle running in the twisting area of the false twisting step is collected with a length of 50 cm or more so as not to untwist just before the twister.
- the false twist number T is obtained by attaching the collected yarn sample to a twist tester and measuring the number of twists by the method described in JIS L1013 (2010) 8.13.
- the obtained yarn bundle can control a coarse crimp diameter of 300 ⁇ m or more, and can suppress deterioration of the textile surface quality such as grains and streaks.
- the draw ratio referred to here is calculated as Vd/V0 using the peripheral speed V0 of the roller that supplies the yarn to the twisting region and the peripheral speed Vd of the roller installed immediately after the twisting mechanism. It is preferable to determine according to the characteristics of the yarn to be used.
- Vd/V0 When drawn yarn is used as the supply yarn, Vd/V0 may be 0.9 to 1.4 times, and when undrawn yarn is used as the supply yarn, Vd/V0 is 1.2 to 1.2. At 2.0 times, drawing may be performed at the same time as false twisting. By setting the draw ratio within such a range, uniform crimping can be imparted to the entire conjugate fibers forming the conjugate fiber bundle without causing excessive tension in the twisting region or slackening of the yarn bundle.
- the false twisting temperature in the range of Tg + 50 to Tg + 150 ° C based on the Tg of the polymer on the high Tg side in the composite polymer.
- the false twist temperature here means the temperature of the heater installed in the twisting area. By setting the false-twisting temperature within this range, it is possible to sufficiently fix the structure of the polymer that has been greatly twisted and deformed within the cross section of the conjugate fiber. Good quality textiles can be obtained. In order to fix the crimps obtained in the twisting step and not to impair the crimp development force obtained by polymer compositing, it is preferable to use a one-heater method in which a heater is arranged only in the twisting region.
- melt Viscosity of Polymer Chip-shaped polymer was adjusted to a moisture content of 200 ppm or less by a vacuum dryer, and the melt viscosity was measured by changing the strain rate stepwise by Toyo Seiki Capillograph. The measurement temperature was the same as the spinning temperature, the sample was placed in the heating furnace under a nitrogen atmosphere and the measurement was started in 5 minutes.
- a chip-shaped polymer is made to have a moisture content of 200 ppm or less by a vacuum dryer, and about 5 mg is weighed and heated from 0 ° C. to 300 ° C. using a differential scanning calorimeter (DSC) Q2000 manufactured by TA Instruments. After the temperature was raised at a temperature rate of 16°C/min, the DSC measurement was performed after holding at 300°C for 5 minutes. The melting point was calculated from the melting peak observed during the heating process. The measurement was performed three times for each sample, and the average value was taken as the melting point. When multiple melting peaks were observed, the melting peak top on the highest temperature side was taken as the melting point.
- DSC differential scanning calorimeter
- the conjugate fiber bundle is embedded in an embedding agent such as epoxy resin, and the cross section of the fiber in the direction perpendicular to the fiber axis is observed with a scanning electron microscope (SEM) manufactured by HITACHI as a magnification at which 10 or more conjugate fibers can be observed.
- SEM scanning electron microscope
- One composite fiber randomly extracted from the photographed image is analyzed using image analysis software, and as shown in FIG. A straight line connecting two distant points (a1, a2) is taken as the long axis, and a straight line passing through the midpoint of the long axis and perpendicular to the long axis is taken as the short axis, and a straight line joining the intersection points (b1, b2) of the outer circumference of the fiber is taken.
- the value obtained by dividing the length of the long axis by the length of the short axis was calculated, and the obtained value was taken as the flatness.
- a simple numerical average of the results of 10 conjugate fibers randomly extracted from the same image was obtained, and the value rounded to the second decimal place was used as the average flatness value.
- the value obtained by subtracting the smallest value from the largest value was obtained, and the value was rounded off to the second decimal place as the difference between the maximum flatness value and the minimum flatness value.
- Fiber diameter A composite fiber bundle is embedded in an embedding agent such as epoxy resin, and the cross section of the fiber in the direction perpendicular to the fiber axis is observed with a scanning electron microscope (SEM) as a magnification at which 10 or more composite fibers can be observed. I took a picture. The area of one conjugate fiber randomly extracted from the photographed image was measured, and the diameter obtained in terms of a perfect circle was measured in ⁇ m to the first decimal place. A simple number average of the results obtained in the same manner for 10 conjugate fibers randomly extracted from the same image as above was obtained, and the value rounded to the first decimal place was taken as the fiber diameter ( ⁇ m).
- SEM scanning electron microscope
- the length of a straight line connecting the respective centers of gravity (Gx, Gy) of the low melting point polymer x and the high melting point polymer y in the cross section of the conjugate fiber as shown in FIG. It was measured in units of ⁇ m to the first decimal place. The obtained value was defined as the distance between polymer centers of gravity ( ⁇ m).
- the conjugate fiber is extracted from the textile so as not to be plastically deformed, one end of the conjugate fiber is fixed, and a load of 1 mg / dtex is applied to the other end for 30 seconds or more. Marking was performed at an arbitrary point where the distance between two points in the fiber axis direction of the fiber was 1 cm. After that, the sample was fixed on a slide glass after adjustment so that the distance between the markings made in advance was 1 cm so as not to plastically deform the composite fiber, and the 1 cm marking of this sample could be observed with a digital microscope. Images were taken at magnification. When the composite fiber had a crimped form as shown in FIG.
- the resulting woven fabric was subjected to scouring, wet heat treatment, alkali treatment and heat setting in this order, and then evaluated for two functions of water absorption and quick drying and stretchability using the following methods.
- the scouring, relaxation treatment, and heat setting were performed under the same conditions as in the textile feel evaluation, and the alkali treatment was performed under the following conditions.
- the stretchability was evaluated in three stages based on the following criteria. S: Excellent stretchability (20 ⁇ elongation rate) A: Good stretchability (5 ⁇ elongation rate ⁇ 20) C: Poor stretchability (elongation ratio ⁇ 5).
- the obtained woven fabric was subjected to scouring, relaxation treatment, and heat setting under the same conditions as those used for textile texture evaluation.
- an automatic variable angle photometer (GONIOPHOTOMETER GP-200 type) manufactured by Murakami Color Research Laboratory, light was incident on each sample at an incident angle of 60 °, and the light receiving angle was 0 ° to 90 ° for every 0.1 °. was determined by two-dimensional reflected light distribution measurement, and a value was calculated by dividing the maximum light intensity (specular reflection) near the light receiving angle of 60° by the minimum light intensity (diffuse reflection) near the light receiving angle of 0°.
- GONIOPHOTOMETER GP-200 type manufactured by Murakami Color Research Laboratory
- This operation was performed 3 times per location, and a simple numerical average of the results of performing this operation for a total of 10 locations was obtained, and the value rounded to the second decimal place was taken as the degree of glare.
- the appearance quality of the textile was evaluated in four stages based on the following criteria. S: excellent appearance quality (glare degree ⁇ 2.0) A: Good appearance quality (2.0 ⁇ glare degree ⁇ 2.5) B: Good appearance quality (2.5 ⁇ glare degree ⁇ 3.0) C: Inferior in appearance quality (3.0 ⁇ glare degree).
- a disc on which the fabric moistened with distilled water is attached is brought into horizontal contact with the fabric fixed on a horizontal plate so that the center of the disc draws a circle with a diameter of 10 cm, with a load of 420 g and a speed of 50 rpm.
- the disc was circularly moved for 10 minutes to rub the two fabrics.
- the degree of discoloration of the fabric attached to the disk was evaluated using a discoloration gray scale, grades 1 to 5 in increments of 0.5 grade. Based on the results of the grade judgment obtained, the wear resistance was judged in four grades based on the following criteria.
- Example 1 Polyethylene terephthalate (IPA copolymer PET, melt viscosity: 140 Pa s, melting point: 232° C.) obtained by copolymerizing 7 mol % of isophthalic acid as polymer 1, and polyethylene terephthalate (PET, melt viscosity: 130 Pa s, melting point: 254° C.) as polymer 2. °C) was prepared.
- IPA copolymer PET melt viscosity: 140 Pa s, melting point: 232° C.
- PET melt viscosity: 130 Pa s, melting point: 254° C.
- polymer 1/polymer 2 was weighed so that the area ratio in the composite cross section was 50/50.
- the above polymer is flowed into a spinning pack incorporating a composite spinneret shown in FIG.
- the inflow polymer was discharged from the discharge hole so that the cross section and the joint surface direction of each composite fiber changed (6 types in FIG. 4 are examples of the composite cross section).
- an oil agent is applied, wound at a spinning speed of 1500 m / min, and drawn between rollers heated to 90 ° C. and 130 ° C. to obtain 84 dtex-36 filament (fiber diameter 15 ⁇ m ) was spun into a composite fiber bundle. At this time, the number of yarn breakages was 1.5 times/10 million m, indicating good spinning stability.
- All of the conjugate fibers constituting the obtained conjugate fiber bundle had a flattened cross-sectional shape, the average flatness value among the conjugate fibers was 1.8, and the difference between the maximum and minimum flatness values was was 0.1. Also, the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) between conjugate fibers was 18%, confirming that the conjugate fiber bundle of the present embodiment was obtained.
- the obtained conjugate fiber bundle is woven, subjected to scouring treatment at 80°C and wet heat treatment at 130°C, and then heat setting at 180°C, whereby the number of crimp crests of the conjugate fiber is 18 crests/cm.
- a woven fabric composed of composite fiber bundles having a crimped form of .
- the woven fabric made of the conjugate fiber bundle has a dry feel (friction fluctuation : 1.3 ⁇ 10 ⁇ 2 ). Furthermore, in the fabric composed of the composite fiber bundle, complex voids are generated between the composite fibers, and a moderate rebound feeling (bending recovery 2HB: 1.1 ⁇ 10 -2 gf cm / cm) and swelling (apparent density: 0 .8 g/cm 3 ), it has excellent stretchability (elongation rate: 18%) and water absorption and quick drying due to the voids formed between the composite fibers (moisture diffusion time: 25 minutes). was Therefore, the woven fabric composed of the conjugate fiber bundle was a woven fabric excellent in wearing comfort, having both a texture and functions directly related to wearing comfort of the wearer.
- the composite fiber is made of polyethylene terephthalate and its copolymer, it has good wear resistance (4th grade) that does not cause discoloration due to fibrillation caused by the polymer, and has properties suitable for clothing textiles. I also found out that Table 1 shows the above results.
- Comparative Example 1 the coefficient of variation CV of the value of (distance between polymer centers of gravity/fiber diameter) was 0%, so that all the conjugate fibers constituting the conjugate fiber bundle exhibited the same crimped form. A phase-aligned composite fiber bundle was obtained. As a result, the texture of the textile surface is small, lacking a dry feel, and the voids between the conjugate fibers are also small, resulting in a lack of a bulging feel. Table 1 shows the results.
- Comparative Example 2 Polymer 1 was changed to the same PET as polymer 2, and after stretching, the processing speed was 250 m / min, and the stretching ratio was 1.05 times between rollers, while heating with a heater set to 180 ° C., using a friction disk. , was carried out according to Comparative Example 1 except that false twisting was performed at a number of revolutions such that the number of false twists was 3000 T/m.
- an oil agent is applied, wound at a spinning speed of 1500 m / min, and drawn between rollers heated to 90 ° C. and 130 ° C. to obtain 84 dtex-36 filament (fiber diameter 14 ⁇ m (minimum value: 11 ⁇ m (18 filaments), maximum value: 17 ⁇ m (18 filaments))).
- the fiber diameter of the composite fiber bundle here was calculated by (minimum value+maximum value)/2.
- the resulting conjugate fiber bundle was woven, subjected to scouring treatment at 80°C and wet heat treatment at 130°C, and then heat-set at 180°C to obtain a fabric composed of the conjugate fiber bundle. .
- Example 2 Everything was carried out according to Example 1 except that the surface layer of the composite fiber was covered with PET and the composite cross section was changed as shown in FIG. 1(b).
- the ratio S/D between the minimum thickness S of PET and the fiber diameter D determined by the method described above was 0.03.
- Example 2 since the copolymer PET is not exposed on the surface layer of the conjugate fiber, not only the wear resistance is improved, but also the difference in cooling between the PET and the copolymer PET is alleviated, so that after ejection from the nozzle Yarn bending could be suppressed, and the spinning stability was also excellent. Table 1 shows the results.
- Example 3 Everything was carried out according to Example 1, except that the cross-sectional shape of the conjugate fiber was changed to a flat multi-lobed shape having eight protrusions on the surface as shown in FIG. 1(c).
- Example 3 unevenness in the appearance of the textile (glittering) was suppressed due to irregular reflection of light by forming unevenness on the surface of the composite fiber, and the quality of the appearance was improved. Furthermore, by combining conjugate fibers having an uneven surface, fine inter-fiber voids are formed in the conjugate fiber bundle, and dry feeling and water absorption and quick-drying properties are improved. Table 1 shows the results.
- Example 4 Everything was carried out according to Example 1, except that the average value of the flatness between the conjugate fibers was changed to 1.3.
- Example 4 As the average value of flatness of the conjugate fibers decreased, the crimped shape developed by the heat treatment became finer and closer to a coil shape. As a result, not only is the stretchability increased, but also the flattened edges are reduced to reduce friction and improve wear resistance. Table 2 shows the results.
- Example 5 Everything was carried out according to Example 1 except that polymer 2 was changed to PET having a melt viscosity of 30 Pa ⁇ s.
- Example 5 the crimped form was more strongly expressed, and not only the resulting woven fabric had an increased feeling of fullness, but also the stretchability was improved. Table 2 shows the results.
- Example 6 Everything was carried out according to Example 1 except that the discharge amount was changed so that the fiber diameter of the composite fiber was 10 ⁇ m (Example 6) and 20 ⁇ m (Example 7).
- Example 6 by setting the fiber diameter of the conjugate fiber to 10 ⁇ m, the diffused reflection of light was increased, and the appearance quality was improved by suppressing the appearance unevenness (glare) when made into textiles. Flexibility improved as the bending stiffness of the book decreased. Table 2 shows the results.
- Example 7 by setting the fiber diameter to 20 ⁇ m, the crimped loops developed by the heat treatment became larger, and in addition to improving the dry feeling and the swelling feeling, the bending hardness was increased. Therefore, a characteristic elastic tactile sensation was obtained. Table 2 shows the results.
- Example 8 Everything was carried out according to Example 1, except that the polymer 2 was changed to polyethylene terephthalate (TiO 2 -containing PET) containing 5.0 wt% of titanium oxide.
- Example 8 the titanium oxide on the surface of the composite fiber diffusely reflects light, thereby suppressing the increase or decrease in reflection (glare) depending on the angle of incidence of light, thereby improving the appearance quality of the textile.
- the titanium oxide inside the conjugate fiber provided functionality such as anti-see-through and ultraviolet shielding. Table 2 shows the results.
- Example 9 Everything was carried out according to Example 1 except that the polymer 1 was changed to polypropylene terephthalate (PPT) (Example 9) and polybutylene terephthalate (PBT) (Example 10).
- PPT polypropylene terephthalate
- PBT polybutylene terephthalate
- Example 11 After winding at a spinning speed of 2500 m/min and storing for one month under standard conditions (temperature of 23°C, relative humidity of 65%), hot pin temperature of 70°C was applied at the same draw ratio as the upper limit of the natural draw ratio of the composite fiber bundle. Everything was carried out according to Example 1, except that non-uniform stretching was applied at a set temperature of 130°C. In Example 11, since a difference in dyeability occurs between the stretched portion and the unstretched portion of the conjugate fiber, when the conjugate fiber bundle is used as a textile, the shade of the color is more emphasized, and the heather tone like a natural material is obtained. was obtained. Table 2 shows the results.
- the portions where the crimp phases are aligned between adjacent conjugate fibers are aligned. Differences in the gaps are created where there are no gaps, and complex gaps and irregularities can be formed between the composite fibers, and a unique smooth feel can be expressed.
- the composite fiber bundle of the present invention it is possible to obtain a textile that is comfortable to wear and has a moderate resilience due to the complex voids between the composite fibers and a puffy texture. Therefore, in addition to general clothing such as jackets, skirts, pants, and underwear, sports clothing, clothing materials, interior products such as carpets and sofas, vehicle interiors such as car seats, It can be suitably used for a wide variety of textile products such as cosmetics, cosmetic masks, and health products.
- x Low-melting point polymer
- y High-melting point polymer
- a1 Two points b1, b2 farthest apart on the outer circumference of the fiber: Within a straight line connecting the two farthest points on the outer circumference of the fiber
- Intersection point Gx of a straight line perpendicular to the point and the circumference of the fiber Center of gravity Gy of low melting point polymer: Center of gravity CF of high melting point polymer:
- Composite fiber Cr Crimp crest 1: Weighing plate 2: Distributing plate 3: Discharge plate
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Abstract
Description
(1)少なくとも2種類の融点の異なるポリマーからなる複合繊維で構成された複合繊維束であり、前記複合繊維間での(ポリマー重心間距離/繊維径)の値の変動係数CVが5~30%であることを特徴とする複合繊維束、
(2)前記複合繊維間での扁平度の最大値と最小値の差が0.5未満であることを特徴とする前記(1)に記載の複合繊維束、
(3)前記複合繊維間での扁平度の平均値が1.2~3.0であることを特徴とする前記(1)または(2)に記載の複合繊維束、
(4)複合繊維の表層が1種類のポリマーで覆われていることを特徴とする前記(1)~(3)のいずれか1つに記載の複合繊維束、
(5)前記(1)~(4)のいずれか1つに記載の複合繊維束が一部に含まれる繊維製品、
である。
さらっとした触感やふくらみのある柔らかな風合いを有する天然素材として幅広く展開しているコットンを分析すると、繊維一本ごとに捲縮形態が異なるものである、この捲縮形態の異なる繊維を複数本束ねられることで、テキスタイルとした際に複雑な空隙や凹凸を形成することとなり、その特異的な触感や風合いが達成されていると考えられる。
まず、複合繊維束をエポキシ樹脂などの包埋剤にて包埋し、繊維軸に垂直方向の繊維横断面を走査型電子顕微鏡(SEM)で10本以上の複合繊維が観察できる倍率として画像を撮影する。次いで、撮影された画像から無作為に抽出した1本の複合繊維を、画像解析ソフトを用いて解析し、図1の(a)に示すように複合繊維の外周上の任意の点のうち最も距離が離れた2点(a1、a2)を結んだ直線を長軸とし、長軸の中点を通って長軸と直交する直線と繊維外周の交点(b1、b2)を結んだ直線を短軸として、長軸の長さを短軸の長さで割り返した値を算出し、得られた値を扁平度とする。これを同一画像内で無作為に抽出した複合繊維10本について同様に行った結果の単純な数平均を求め、小数点第2位で四捨五入した値を扁平度の平均値とする。また、扁平度を求めた複合繊維のうち、最も大きい値から最も小さい値を引いた値を求め、小数点第2位で四捨五入した値を扁平度の最大値と最小値の差とする。
ただし、凸部の数が多くなりすぎるとその効果は徐々に小さくなることから、凸部の実質的な上限は20個であり、12個以下がより好ましい。
まず、テキスタイルから複合繊維を塑性変形させないように抜き出し、複合繊維の片方の末端を固定し、もう片方の末端へ1mg/dtexの荷重をかけて30秒間以上経過後に、複合繊維の繊維軸方向へ2点間の距離が1cmとなる任意の箇所にマーキングを施す。
その後、複合繊維を塑性変形させないように予めつけておいたマーキングの間が元の1cmとなるように調整してスライドガラス上に固定し、このサンプルをデジタルマイクロスコープにて1cmのマーキングが観察できる倍率で画像を撮影する。撮影した画像において図6のように複合繊維CFが捲縮形態を有していた場合には、マーキング間に存在する捲縮の山Crの数を求める。この動作を複合繊維10本について行った結果の単純な数平均を求め、小数点第1位で四捨五入した値を捲縮山数(山/cm)とする。
本実施形態の複合繊維束は、ジャケット、スカート、パンツ、下着などの一般衣料から、スポーツ衣料、衣料資材に加えて、その快適性を生かしてカーペット、ソファーなどのインテリア製品、カーシートなどの車輌内装品、化粧品、化粧品マスク、健康用品などの生活用途など多岐に渡る繊維製品に好適に用いることができる。
本実施形態の複合繊維束を製糸する方法としては、マルチフィラメントや紡績糸の製造を目的とした溶融紡糸法、湿式および乾湿式などの溶液紡糸法、シート状の繊維構造体を得るのに適したメルトブロー法およびスパンボンド法などによって製造できる。これらの中でも、高い生産性でテキスタイルに適用できる複合繊維束が得られるという観点から、溶融紡糸法にてマルチフィラメントや紡績糸とすることが好適である。
すなわち、加撚領域での糸束の撚数である仮撚数T(単位は回/m)が、仮撚加工後の糸束の総繊度Df(単位はdtex)に応じて決定される、以下の条件を満たすように、加撚機構の回転数や加工速度等の仮撚条件を設定することが好ましい。
20000/Df0.5≦T≦40000/Df0.5
実施例および比較例については下記の評価を行った。
チップ状のポリマーを真空乾燥機によって、水分率200ppm以下とし、東洋精機製キャピログラフによって、歪速度を段階的に変更して、溶融粘度を測定した。なお、測定温度は紡糸温度と同様にし、窒素雰囲気下で加熱炉にサンプルを投入してから測定開始までを5分とし、せん断速度1216s-1の値をポリマーの溶融粘度として評価した。
チップ状のポリマーを真空乾燥機によって、水分率200ppm以下とし、約5mgを秤量し、TAインスツルメント製示差走査熱量計(DSC)Q2000型を用いて、0℃から300℃まで昇温速度16℃/分で昇温後、300℃で5分間保持してDSC測定を行った。昇温過程中に観測された融解ピークより融点を算出した。測定は1試料につき3回行い、その平均値を融点とした。なお、融解ピークが複数観測された場合には、最も高温側の融解ピークトップを融点とした。
100mの複合繊維束の重量を測定し、その値を100倍した値を算出した。この動作を10回繰り返し、その平均値の小数点第2位を四捨五入した値を繊度(dtex)とした。
複合繊維束をエポキシ樹脂などの包埋剤にて包埋し、繊維軸に垂直方向の繊維横断面をHITACHI製走査型電子顕微鏡(SEM)で10本以上の複合繊維が観察できる倍率として画像を撮影した。撮影された画像から無作為に抽出した1本の複合繊維を、画像解析ソフトを用いて解析し、図1の(a)に示すように複合繊維の外周上の任意の点のうち最も距離が離れた2点(a1、a2)を結んだ直線を長軸とし、長軸の中点を通って長軸と直交する直線と繊維外周の交点(b1、b2)を結んだ直線を短軸として、長軸の長さを短軸の長さで割り返した値を算出し、得られた値を扁平度とした。これを同一画像内で無作為に抽出した複合繊維10本について同様に行った結果の単純な数平均を求め、小数点第2位で四捨五入した値を扁平度の平均値とした。また、扁平度を求めた複合繊維のうち、最も大きい値から最も小さい値を引いた値を求め、小数点第2位で四捨五入した値を扁平度の最大値と最小値の差とした。
複合繊維束をエポキシ樹脂などの包埋剤にて包埋し、繊維軸に垂直方向の繊維横断面を走査型電子顕微鏡(SEM)で10本以上の複合繊維が観察できる倍率として画像を撮影した。撮影された画像から無作為に抽出した1本の複合繊維の面積を測定し、真円換算で求められる直径をμm単位で小数点1桁目まで測定した。上記と同一画像内で無作為に抽出した10本の複合繊維について同様に行った結果の単純な数平均を求め、小数点第1位を四捨五入した値を繊維径(μm)とした。
複合繊維束からなるテキスタイルにおいて、テキスタイルの長さ方向に垂直かつ複合繊維の繊維軸方向に垂直なテキスタイル断面をHITACHI製走査型電子顕微鏡(SEM)で20本以上の複合繊維が観察できる倍率として画像を撮影した。撮影された画像から無作為に抽出した1本の複合繊維をコンピューターソフトウェアの三谷商事製WinROOFを用いて解析することで、複合繊維の面積を測定し、真円換算で求められる直径をμm単位で小数点1桁目まで測定した。得られた値を繊維径(μm)とした。
複合繊維束からなるテキスタイルにおいて、テキスタイルから複合繊維を塑性変形させないように抜き出し、複合繊維の片方の末端を固定し、もう片方の末端に1mg/dtexの荷重をかけて30秒間以上経過後に、複合繊維の繊維軸方向へ2点間の距離が1cmとなる任意の箇所にマーキングを施した。その後、複合繊維を塑性変形させないように予めつけておいたマーキングの間が元の1cmとなるように調整してスライドガラス上に固定し、このサンプルをデジタルマイクロスコープにて1cmのマーキングが観察できる倍率で画像を撮影した。撮影した画像において複合繊維が図6のような捲縮形態を有していた場合には、マーキング間に存在する捲縮の山数を求めた。この動作を複合繊維10本について行った結果の単純な数平均を求め、小数点第1位で四捨五入した値を捲縮山数(山/cm)とした。
各実施例および比較例についての製糸を行い、1千万m当たりの糸切れ回数(回/千万m)から製糸安定性をそれぞれ次の基準に基づき4段階判定した。
S:優れた製糸安定性(糸切れ回数<1.0)
A:良好な製糸安定性(1.0≦糸切れ回数<2.0)
B:製糸安定性がある(2.0≦糸切れ回数<3.0)
C:製糸安定性に劣る(3.0≦糸切れ回数)。
経糸方向のカバーファクター(CFA)が800、緯糸方向のカバーファクター(CFB)が1200となるように複合繊維の本数を調整し、3/1ツイル織物を作成した。
ただし、ここで言うCFAおよびCFBとは、織物の経密度および緯密度をJIS-L-1096:2010 8.6.1に準じて2.54cmの区間にて測定し、CFA=経密度×(経糸の繊度)1/2、CFB=緯密度×(緯糸の繊度)1/2の式より求めた値である。得られた織物について、以下の条件の精練、リラックス処理、熱セットをこの順で行った後、以下の手法を用いてふくらみ感、反発感、さらっと感の3つの風合いを評価した。
界面活性剤を含む80℃の温水中で10分間精練をおこなったのち、130℃の温水中で30分間のリラックス処理を行った。次いで、180℃、5分の条件にて、熱セットをおこなった。
テロテック製定圧厚さ測定器(PG-14J)を用いて、20cm×20cmの織物の厚み(cm)を一定圧力下(0.7kPa)で測定し、織物の体積を算出した。次いで、該織物の重量(g)を得られた体積で除した値を求め、小数点第2位を四捨五入した値を織物の見掛け密度(g/cm3)とした。得られた見掛け密度からふくらみ感をそれぞれ次の基準に基づき4段階判定した。
S:優れたふくらみ感(見掛け密度≦0.5)
A:良好なふくらみ感(0.5<見掛け密度≦0.8)
B:ふくらみ感がある(0.8<見掛け密度≦1.1)
C:ふくらみ感に劣る(1.1<見掛け密度)。
カトーテック製純曲げ試験機(KES-FB2)を用いて、20cm×20cmの織物を有効試料長20cm×1cmで把持し、緯糸方向に曲げたときの、曲率±1.0cm-1におけるヒステリシスの幅(gf・cm/cm)を算出した。この動作を1箇所あたり3回行い、これを合計10箇所について行った結果の単純な数平均を求め、小数点第4位を四捨五入した後に100で割った値を曲げ回復2HB×10-2(gf・cm/cm)とした。得られた曲げ回復2HB×10-2から反発感をそれぞれ次の基準に基づき4段階判定した。
S:優れた反発感(曲げ回復2HB×10-2≦0.8)
A:良好な反発感(0.8<曲げ回復2HB×10-2≦1.5)
B:反発感がある(1.5<曲げ回復2HB×10-2≦2.5)
C:反発感に劣る(2.5<曲げ回復2HB×10-2)。
カトーテック製自動化表面試験機(KES-FB4)を用いて、20cm×20cmの織物の10cm×10cmの範囲をピアノ線で巻かれた1cm×1cmの端子に50gの荷重をかけて、1.0mm/secの速さで滑らすことで平均摩擦係数の変動MMDを求めた。この動作を1箇所あたり3回行い、これを合計10箇所について行った結果について単純な数平均を求め、小数点第4位を四捨五入した値を摩擦変動(×10-2)とした。得られた摩擦変動からさらっと感を次の基準に基づき4段階判定した。
S:優れたさらっと感(1.5≦摩擦変動)
A:良好なさらっと感(1.2≦摩擦変動<1.5)
B:さらっと感がある(0.9≦摩擦変動<1.2)
C:さらっと感に劣る(摩擦変動<0.9)。
経糸方向のカバーファクター(CFA)が800、緯糸方向のカバーファクター(CFB)が1200となるように複合繊維の本数を調整し、3/1ツイル織物を作成した。ただし、ここで言うCFAおよびCFBとは、織物の経密度および緯密度をJIS-L-1096:2010 8.6.1に準じて2.54cmの区間にて測定し、CFA=経密度×(経糸の繊度)1/2、CFB=緯密度×(緯糸の繊度)1/2の式より求めた値である。得られた織物について、精練、湿熱処理、アルカリ処理、熱セットをこの順で行った後、以下の手法を用いて吸水速乾性、ストレッチ性の2つの機能を評価した。なお、精練、リラックス処理、熱セットは、テキスタイル風合い評価で行った条件と同様に行い、アルカリ処理は、以下の条件によって行った。
濃度0.5~2質量%の水酸化ナトリウム水溶液に、温度90℃、30分間浸漬させた。
吸水速乾性は、10cm×10cmの織物に水を0.1cc滴下後、温度20度で相対湿度65RH%の環境下で、5分ごとに織物の重量を測定し、残留水分率が1.0%以下となる時間(分)を求めた。この動作を合計3箇所について行った結果の単純な数平均を求め、小数点以下を四捨五入した値を水分拡散時間(分)とした。得られた水分拡散時間から吸水速乾性をそれぞれ次の基準に基づき3段階判定した。
S:優れた吸水速乾性(水分拡散時間≦15)
A:良好な吸水速乾性(15<水分拡散時間≦30)
C:吸水速乾性に劣る(30<水分拡散時間)。
ストレッチ性は、JIS-L-1096:2010の第8.16.1項に記載の伸び率A法(定速伸長法)に準じて行った。なお、ストリップ法の17.6N(1.8kg)荷重時を採用し、試験条件は、サンプル幅5cm×長さ20cm、クランプ間隔10cm、引張速度20cm/分とした。また、初荷重は、JIS-L-1096:2010の方法に準じて、試料幅1m相当の重さを使用した。織物のヨコ方向に試験を3回行った結果の単純な数平均を求め、小数点以下を四捨五入した値を伸長率(%)とした。得られた伸長率からストレッチ性をそれぞれ次の基準に基づき3段階判定した。
S:優れたストレッチ性(20≦伸長率)
A:良好なストレッチ性(5≦伸長率<20)
C:ストレッチ性に劣る(伸長率<5)。
経糸方向のカバーファクター(CFA)が800、緯糸方向のカバーファクター(CFB)が1200となるように複合繊維の本数を調整し、3/1ツイル織物を作成した。ただし、ここで言うCFAおよびCFBとは、織物の経密度および緯密度をJIS-L-1096:2010 8.6.1に準じて2.54cmの区間にて測定し、CFA=経密度×(経糸の繊度)1/2、CFB=緯密度×(緯糸の繊度)1/2の式より求めた値である。
S:優れた外観品位(ギラツキ度<2.0)
A:良好な外観品位(2.0≦ギラツキ度<2.5)
B:外観品位がある(2.5≦ギラツキ度<3.0)
C:外観品位に劣る(3.0≦ギラツキ度)。
経糸方向のカバーファクター(CFA)が1100、緯糸方向のカバーファクター(CFB)が1100となるように複合繊維の本数を調整し、平織物を作成した。得られた平織物について、分散染料Sumikaron Black S-3B(10%owf)を用いて黒色に染色した。染色後の平織物を直径10cmの円形に切り出し、蒸留水で湿潤させて円盤に取り付けた。更に30cm角に切り出した平織物を乾いたまま水平の板の上に固定した。蒸留水で湿潤させた織物が取り付けられた円盤を水平な板の上に固定された織物に対して水平に接触させ、円盤の中心が直径10cmの円を描くように、荷重420g、速度50rpmで10分間円盤を円運動させ、2枚の織物を摩擦させた。摩擦終了後4時間放置してから、円盤に取り付けた織物の変褪色の程度を、変褪色用グレースケールを用い、0.5級刻みで1~5級の級判定を実施した。得られた級判定の結果から耐摩耗性を次の基準に基づき4段階判定した。
S:優れた耐摩耗性(級判定:4.5級以上)
A:良好な耐摩耗性(級判定:3.5級、4級)
B:良好な耐摩耗性(級判定:2.5級、3級)
C:耐摩耗性に劣る(級判定:2級以下)。
ポリマー1としてイソフタル酸を7mol%共重合したポリエチレンテレフタレート(IPA共重合PET、溶融粘度:140Pa・s、融点:232℃)、ポリマー2としてポリエチレンテレフタレート(PET、溶融粘度:130Pa・s、融点:254℃)を準備した。
複合繊維束を構成する全ての複合繊維において、複合繊維毎の接合面方向の変化をなしとした以外は全て実施例1に従い実施した。
ポリマー1をポリマー2と同じPETに変更し、延伸後に加工速度を250m/分、延伸倍率を1.05倍としたローラー間で、180℃に設定したヒーターにて加熱しながら、フリクションディスクを用い、仮撚数が3000T/mとなるような回転数にて仮撚加工を施した以外は全て比較例1に従い実施した。
ポリマー1としてイソフタル酸を7mol%共重合したポリエチレンテレフタレート(IPA共重合PET、溶融粘度:140Pa・s、融点:232℃)、ポリマー2としてポリエチレンテレフタレート(PET、溶融粘度:130Pa・s、融点:254℃)を準備した。
得られた複合繊維束を製織し、80℃での精練処理および130℃での湿熱処理を施した後、180℃で熱セットを加えることで、上記複合繊維束で構成される織物を得た。
また、繊維製造時には繊維径が異なる複合繊維を同時に巻き取ることから、冷却固化の挙動が異なることでの糸干渉が発生し、製糸安定性に劣るものであった。結果を表1に示す。
ポリマー1としてイソフタル酸を7mol%共重合したポリエチレンテレフタレート(IPA共重合PET、溶融粘度:140Pa・s、融点:232℃)、ポリマー2としてポリエチレンテレフタレート(PET、溶融粘度:130Pa・s、融点:254℃)を準備した。
得られた複合繊維束を製織し、80℃での精練処理および130℃での湿熱処理を施した後、180℃で熱セットを加えることで、上記複合繊維束で構成される織物を得た。
また、繊維製造時には扁平度が大きく異なる複合繊維を同時に巻き取ることから、冷却固化の挙動が異なることでの糸干渉が発生し、製糸安定性に劣るものであった。
複合繊維の表層をPETによって覆い、図1の(b)のような複合断面に変更する以外は全て実施例1に従い実施した。なお、上述した方法によって求められる、PETの最小厚みSと繊維径Dの比S/Dは、0.03であった。
複合繊維の断面形状を図1の(c)のような、表面に凸部を8個有する扁平多葉状に変更する以外は全て実施例1に従い実施した。
複合繊維間での扁平度の平均値が1.3となるように変更した以外は全て実施例1に従い実施した。
複合繊維の断面形状が図3のような丸断面となるように変更(複合繊維毎の接合面方向の変化はなし)した以外は全て実施例1に従い実施した。
ポリマー2を溶融粘度:30Pa・sのPETに変更する以外は全て実施例1に従い実施した。
複合繊維の繊維径を10μm(実施例6)、20μm(実施例7)となるように吐出量を変更する以外は全て実施例1に従い実施した。
ポリマー2を酸化チタンが5.0wt%含有されたポリエチレンテレフタレート(TiO2含有PET)に変更する以外は全て実施例1に従い実施した。
ポリマー1をポリプロピレンテレフタレート(PPT)(実施例9)、ポリブチレンテレフタレート(PBT)(実施例10)に変更する以外は全て実施例1に従い実施した。
紡糸速度を2500m/minで巻取り、標準状態(温度23℃、相対湿度65%)で一か月間保管した後、複合繊維束の自然延伸倍率の上限と同じ延伸倍率にてホットピン温度70℃、セット温度130℃で不均一延伸加工を施す以外は全て実施例1に従い実施した。
実施例11においては、複合繊維の延伸部と未延伸部でも染色性の差異が生じるために、複合繊維束をテキスタイルとした際に、色の濃淡がより強調され、天然素材のような杢調が得られるものであった。結果を表2に示す。
y: 高融点ポリマー
a1、a2: 繊維外周上にあり、最も距離が離れた2点
b1、b2: 繊維外周上にあり、最も距離が離れた2点を結んだ直線の中点を通って直交する直線と繊維外周の交点
Gx: 低融点ポリマーの重心
Gy: 高融点ポリマーの重心
CF: 複合繊維
Cr: 捲縮の山
1: 計量プレート
2: 分配プレート
3: 吐出プレート
Claims (5)
- 少なくとも2種類の融点の異なるポリマーからなる複合繊維で構成された複合繊維束であり、前記複合繊維間での(ポリマー重心間距離/繊維径)の値の変動係数CVが5~30%であることを特徴とする複合繊維束。
- 前記複合繊維間での扁平度の最大値と最小値の差が0.5未満であることを特徴とする請求項1に記載の複合繊維束。
- 前記複合繊維間での扁平度の平均値が1.2~3.0であることを特徴とする請求項1または2に記載の複合繊維束。
- 複合繊維の表層が1種類のポリマーで覆われていることを特徴とする請求項1~3のいずれか1項に記載の複合繊維束。
- 請求項1~4のいずれか1項に記載の複合繊維束が一部に含まれる繊維製品。
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Citations (7)
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JPS4968009A (ja) * | 1972-11-06 | 1974-07-02 | ||
JPS51116217A (en) * | 1973-03-26 | 1976-10-13 | Rhone Poulenc Textile | Crimped multifilament yarn and its manufacture |
JPS61116770U (ja) * | 1984-07-24 | 1986-07-23 | ||
JP2000212838A (ja) | 1999-01-20 | 2000-08-02 | Nippon Ester Co Ltd | ストレッチ性織編物用ポリエステル複合繊維マルチフィラメント |
JP2001355132A (ja) | 2000-06-15 | 2001-12-26 | Toray Ind Inc | ポリエステル複合繊維 |
JP2011208313A (ja) | 2010-03-30 | 2011-10-20 | Toray Ind Inc | 複合口金および複合繊維の製造方法 |
JP2021122063A (ja) | 2019-07-30 | 2021-08-26 | 昭和電工マテリアルズ株式会社 | 電子部品装置を製造する方法、及び電子部品装置 |
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Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS4968009A (ja) * | 1972-11-06 | 1974-07-02 | ||
JPS51116217A (en) * | 1973-03-26 | 1976-10-13 | Rhone Poulenc Textile | Crimped multifilament yarn and its manufacture |
JPS61116770U (ja) * | 1984-07-24 | 1986-07-23 | ||
JP2000212838A (ja) | 1999-01-20 | 2000-08-02 | Nippon Ester Co Ltd | ストレッチ性織編物用ポリエステル複合繊維マルチフィラメント |
JP2001355132A (ja) | 2000-06-15 | 2001-12-26 | Toray Ind Inc | ポリエステル複合繊維 |
JP2011208313A (ja) | 2010-03-30 | 2011-10-20 | Toray Ind Inc | 複合口金および複合繊維の製造方法 |
JP2021122063A (ja) | 2019-07-30 | 2021-08-26 | 昭和電工マテリアルズ株式会社 | 電子部品装置を製造する方法、及び電子部品装置 |
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