U.S. patent application number 10/535205 was filed with the patent office on 2006-03-09 for high shrinkage side by side type composite filament and a method for manufactruing the same.
This patent application is currently assigned to KOLON INDUSTRIES, INC.. Invention is credited to Sung-Kwan Lee, Young-Hwan Lee, Joon-Young Yoon.
Application Number | 20060051575 10/535205 |
Document ID | / |
Family ID | 36113871 |
Filed Date | 2006-03-09 |
United States Patent
Application |
20060051575 |
Kind Code |
A1 |
Yoon; Joon-Young ; et
al. |
March 9, 2006 |
High shrinkage side by side type composite filament and a method
for manufactruing the same
Abstract
The present invention relates to a high shrinkage side-by-side
type composite filament, wherein two kinds of thermoplastic
polymers are arranged side by side type and a boiling water
shrinkage (Sr.sub.2) measured by the method (initial load=notified
denier.times.1/10 g, static load=notified denier.times.20/10 g) of
clause 5.10 of JIS L 1090 is 20 to 75% of a boiling water shrinkage
(Sr.sub.1) measured by the method (initial load=notified
denier.times.1/30 g, static load=notified denier.times.40/30 g) of
clause 7.15 of JIS L 1013. The side-by-side type composite filament
is made of two kinds of thermoplastic polymers having a number
average molecular weight difference (iMn) of 5,000 to 15,000 upon
spinning and the composite filament is drawn and heat-treated so as
to satisfy the following physical properties: Temperature area
exhibiting 95% of maximum thermal stress (Tmax, 95%): 120 to
230.degree. C. Range of maximum thermal stress per denier: 0.1 to
0.4 g/denier
Inventors: |
Yoon; Joon-Young;
(KYUNGSANGBUK-DO, KR) ; Lee; Young-Hwan;
(Kyungsangbuk-do, KR) ; Lee; Sung-Kwan;
(Kyungsangbuk-do, KR) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Assignee: |
KOLON INDUSTRIES, INC.
KOLON TOWER, 1-23, BYULYANG-DONG, KWACHEON-CITY
KYUNGKI-DO
KR
427-040
|
Family ID: |
36113871 |
Appl. No.: |
10/535205 |
Filed: |
November 21, 2003 |
PCT Filed: |
November 21, 2003 |
PCT NO: |
PCT/KR03/02522 |
371 Date: |
May 17, 2005 |
Current U.S.
Class: |
428/364 ;
264/172.14 |
Current CPC
Class: |
Y10T 428/2913 20150115;
D01F 6/78 20130101 |
Class at
Publication: |
428/364 ;
264/172.14 |
International
Class: |
D01D 5/32 20060101
D01D005/32 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 26, 2002 |
KR |
10-2002-0073701 |
Claims
1. A high shrinkage side-by-side type composite filament, wherein
two kinds of thermoplastic polymers are arranged side by side type
and a boiling water shrinkage (Sr.sub.2) measured by the method
(initial load=notified denier.times.1/10 g, static load=notified
denier.times.20/10 g) of clause 5.10 of JIS L 1090 is 20 to 75% of
a boiling water shrinkage (Sr.sub.1) measured by the method
(initial load=notified denier.times.1/30 g, static load=notified
denier.times.40/30 g) of clause 7.15 of JIS L 1013.
2. A method for manufacturing a high shrinkage side-by-side type
composite filament consisting two kinds of thermoplastic polymers
which are arranged side-by-side type, wherein the two kinds of
thermoplastic polymers having a number average molecular weight
difference (.DELTA.Mn) of 5,000 to 15,000 are used upon spinning
and the composite filament is drawn and heat-treated so as to
satisfy the following physical properties: Temperature area
exhibiting 95% of maximum thermal stress (Tmax, 95%): 120 to
230.degree. C. Range of maximum thermal stress per denier: 0.1 to
0.4 g/denier
3. The method of claim 2, wherein the composite filament is drawn
and heat-treated so that the temperature distribution range (Tmax)
of the maximum the thermal stress of the composite filament is 140
to 200.degree. C.
4. The method of claim 2, wherein the thermoplastic polymers are
polyethylene terephthalate.
5. A woven or knitted fabric containing the side-by-side type
composite filament of claim 1.
Description
TECHNICAL FIELD
[0001] The present invention relates to a side-by-side type
composite (conjugate) filament which has a high elastic property
(shrinkage) even in a filament state, and to a method for
manufacturing the same.
[0002] More particularly, the present invention relates to a
side-by-side type composite filament, which can omit a
false-twisting process and can attain a fine denier filament since
it has a superior crimp even in a filament state where no
false-twisting treatment has been carried out, and to a method for
manufacturing the same.
BACKGROUND ART
[0003] Synthetic fibers have reached the level not inferior to
natural fibers in some properties owing to repeated technical
development in spite of their short history. But, the crimp
property is a property which is not easy for synthetic fibers to
exhibit and is being considered as an intrinsic property of natural
fibers such as wool.
[0004] As prior art methods providing synthetic fibers with crimp
properties are (i) a method for manufacturing a different shrinkage
composite false twisted yarn by doubling, false-twisting and
heat-setting two kinds of synthetic fibers (yarns) having a big
difference in shrinkage properties, (ii) a method for mixing a
polyurethane fiber with an excellent crimp property in a
longitudinal direction and other synthetic fiber upon manufacturing
woven or knitted fabrics, and (iii) a method for manufacturing a
composite fiber by conjugated-spinning two kinds of polymers.
[0005] Of these methods, the method for manufacturing a different
shrinkage composite false twisted yarn is a method that provides a
potential shrinkage difference by mixing, false-twisting and
heat-setting two kinds of yarns having a big difference in
shrinkage properties. That is to say, this method makes the best of
a difference between a strain in false twist areas and a residual
strain after untwisting, in which a core yarn is deformed
relatively larger than a effect yarn to be mixed and crosslinked
with the effect yarn.
[0006] The different shrinkage composite false twisted yarn
exhibits a good elastic property due to a difference in elongation
between core yarns and effect yarns. But, the above method was
disadvantageous in that, since the appearance of crimps is uneven
and the binding force of core yarns and effect yarns is relatively
small because it is dependent upon air texturing and the like, one
component yarn is released or removed by a physical force applied
during a after-process or the crimping property is decreased.
[0007] In addition, the above method for manufacturing a different
shrinkage composite false twisted yarn was problematic in that it
is difficult to provide a fine fineness because two or more kinds
of yarns have to be mixed, and the process becomes complicated and
the manufacturing cost is increased because the two or more kinds
of yarns pre-produced have to be rewound and combined again.
[0008] On the other hand, the method for mixing a polyurethane
fiber and other synthetic fiber upon manufacturing woven or knitted
fabrics was disadvantageous in that it is difficult to process
because the synthetic fiber is different from the polyurethane
fiber in physical and chemical properties. For instance, the
polyester fiber is dyed using a disperse dye while a polyurethane
fiber has to be dyed with an acid dye or a metal-containing
dye.
[0009] Therefore, in a case that the polyester fiber and the
polyurethane fiber are mixed upon manufacturing woven or knitted
fabrics, there are many problems that, for example, it is necessary
to use a chlorobenzene or methyl naphthalene carrier for dyeing,
and the final product is weak to a chlorine bleaching agent and
easily hydrolysable by NaOH.
[0010] Meanwhile, a synthetic fiber manufactured by a polybutylene
terephthalate (PBT) resin has a problem that they have to undergo a
false twisting process for improving elastic property because of
their lack of shrinkage in a filament state.
[0011] Accordingly, it is an object of the present invention to
provide a side-by-side type composite filament which has a superior
crimp property even in a filament state and thus requires no
false-twisting process.
DISCLOSURE OF THE INVENTION
[0012] The present invention provides a side-by-side type composite
filament which has a excellent shrinkage even in a filament state
which is not passed false-twisting process. Additionally, the
present invention provides a method for manufacturing a high
elastic side-by-side type composite filament which has a simple
process and can attain a fine denier filament since a
false-twisting process can be omitted.
[0013] To achieve the above objects, there is provided a high crimp
(shrinkage) side-by-side type composite filament according to the
present invention, wherein two kinds of thermoplastic polymers are
arranged in side by side type and a boiling water shrinkage
(Sr.sub.2) measured by the method (initial load=notified
denier.times.1/10 g, static load=notified denier.times.20/10 g) of
clause 5.10 of JIS L 1090 is 20 to 75% of a boiling water shrinkage
(Sr.sub.1) measured by the method (initial load=notified
denier.times.1/30 g, static load=notified denier.times.40/30 g) of
clause 7.15 of JIS L 1013.
[0014] Additionally, there is provided a method for manufacturing a
high shrinkage side-by-side type composite filament according to
the present invention consisting two kinds of thermoplastic
polymers which are arranged in side by side type, wherein two kinds
of thermoplastic polymers having a number average molecular weight
difference (.DELTA.Mn) of 5,000 to 15,000 are used upon spinning
and the composite filament is drawn and heat-treated so as to
satisfy the following physical properties:
[0015] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 120 to 230.degree. C.
[0016] Range of maximum thermal stress per denier: 0.1 to 0.4
g/denier
[0017] Hereinafter, the present invention will be described in
detail.
[0018] Firstly, in the present invention, a side-by-side type
composite filament is manufactured by conjugated-spinning two kinds
of thermoplastic polymers in side by side type and then drawing and
heat-treating the composite filament spun by a continuous or
discontinuous process.
[0019] Specifically, in the present invention, a side-by-side type
composite filament can be manufactured by a spin-direct draw method
which carries out spinning, drawing and heat-treating in one
process as shown in FIG. 1, or a side-by-side type composite
filament can be manufactured by conjugated-spinning two kinds of
thermoplastic polymers in side by side type to prepare an undrawn
or half-drawn composite filament and then drawing and heat-treating
the undrawn or half-drawn composite filament by a discontinuous
process as shown in FIG. 2.
[0020] The present invention is characterized in that two kinds of
thermoplastic polymers having a number average molecular weight
difference (.DELTA.Mn) of 5,000 to 15,000 are used upon conjugated
spinning. The thermoplastic polymers include polyethylene
terephthalate, etc.
[0021] The polyethylene terephthalate is produced by an ester
interchange between ethylene glycol and terephthalic acid dimethyl,
or by polymerization between ethylene glycol and terephthalic acid.
At this time, if the polymerization time is adjusted, a number (n)
of chains of polyethylene terephthalte can be adjusted, and a
polyethylene terephthalte with desired molecular weight can be
obtained.
[0022] The number average molecular weight is a value measured by
Gel Permeation Chromatograpy (GPC).
[0023] If the number average molecular weight difference
(.DELTA.Mn) between the polymers is smaller than 5,000, the
difference in degree of orientation between the polymers is
insufficient and thus the shrinkage ratio of the final product
becomes lower. If greater than 15,000, the shrinkage ratio is
superior but a serious yarn swelling phenomenon occurs upon
spinning due to an excessive difference in number average molecular
weight and the yarn strength becomes lower to thereby make it
difficult to set a stable spinning condition.
[0024] The side-by-side type composite filament has such a shape
that two kinds of thermoplastic polymers are bonded each other to
form an interface dividing the filament into halves and its cross
section is a circular type, a rectangular type, a cocoon type,
etc.
[0025] The shape of the cross section is freely changeable
according to a cross section shape of a spinneret hole and a
bonding method of polymers, and the interface has a linear shape or
a bow-like curved shape according to a difference in melt viscosity
between polymers. Generally, a polymer having a low melt viscosity
surrounds a polymer having a high viscosity to form an interface of
a bow-like curved shape.
[0026] Meanwhile, the present invention is characterized in that
the finally manufactured composite filament is drawn and
heat-treated so as to satisfy the following physical
properties:
[0027] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 120 to 230.degree. C.
[0028] Range of maximum thermal stress per denier: 0.1 to
0.4g/denier
[0029] Preferably, the composite filament is drawn and heat-treated
so that the temperature distribution range of maximum thermal
stress of the finally manufactured composite filament is 140 to
200.degree. C. If the temperature distribution range of maximum
thermal stress is deviated from the above range, the processibility
may be deteriorated or the quality of woven or knitted fabrics may
be degraded.
[0030] Further, if the range of maximum thermal stress per denier
is smaller than 0.1 g/denier, the appearance of crimps is degraded,
or if greater than 0.4 g/denier, it becomes hard to control the
shrinkage.
[0031] Further, if the temperature distribution range of maximum
thermal stress is smaller than 140.degree. C. or the temperature
area (Tmax, 95%) exhibiting 95% of maximum thermal stress is
smaller than 120.degree. C., the shrinkage becomes too large and
thus the appearance of crimps is degraded. On the contrary, if the
temperature distribution range of maximum thermal stress is greater
than 200.degree. C. or the temperature area (Tmax, 95%) exhibiting
95% of maximum thermal stress is greater than 230.degree. C., the
drawing stability is degraded.
[0032] In order for the drawn and heat-treated composite filament
to satisfy the physical properties, a temperature of heat treatment
in a second Godet roller (6) is adjusted in the spin-direct draw
method of FIG. 1, and a temperature of heat treatment in a hot
plate (12) is adjusted in the method of drawing and heat treatment
by a discontinuous process as shown in FIG. 2.
[0033] The side-by-side type composite filament manufactured by the
above-mentioned method according to the present invention has two
kinds of polymers arranged side by side type and tends to have a
different boiling water shrinkage from that of a typical composite
fiber filament.
[0034] Generally, a synthetic fiber filament and a textured
synthetic fiber yarn (false-twisted yarn) have a different
condition for measuring a boiling water shrinkage from each other
due to their difference in crimp property. Specifically, since the
synthetic fiber filament has almost no crimp, the possibility of an
error according to a change of the condition of measuring a boiling
water shrinkage is relatively low. On the contrary, since the
textured synthetic fiber yarn (false-twisted yarn) has relatively
many crimps, the possibility of an error according to a change of
the measuring condition is relatively high.
[0035] The boiling water shrinkage of the synthetic fiber filament
is mostly measured by the method (initial load=notified
denier.times.1/30 g, static load=notified denier.times.40/30 g) of
clause 7.15 of JIS L 1013 while the boiling water shrinkage of the
textured synthetic fiber yarn (false-twisted yarn) is mostly
measured by the method (initial load=notified denier.times.1/10 g,
static load=notified denier.times.20/10 g) of clause 5.10 of JIS L
1090.
[0036] In the side-by-side type composite filament of this
invention, the boiling water shrinkage (Sr.sub.2) measured by the
method of clause 5.10 of JIS L 1090 is 20 to 75% of the boiling
water shrinkage (Sr.sub.1) measured by the method of clause 7.15 of
JIS L 1013.
[0037] In other words, in case of the side-by-side type composite
filament of this invention, the boiling water shrinkage (Sr.sub.2)
measured under the condition of measuring the boiling water
shrinkage of a textured synthetic fiber yarn (false-twisted yarn)
is 20 to 75% of the boiling water shrinkage (Sr.sub.1) measured
under the condition of measuring the boiling water shrinkage of a
synthetic fiber filament.
[0038] On the contrary, in case of a general synthetic fiber
filament, the boiling water shrinkage (Sr.sub.2) measured under the
condition of measuring the boiling water shrinkage of a textured
synthetic fiber yarn (false-twisted yarn) is 90 to 99% of the
boiling water shrinkage (Sr.sub.1) measured under the condition of
measuring the boiling water shrinkage of a synthetic fiber
filament, which is almost not different from a boiling water
shrinkage measured regardless of a measuring method.
[0039] As described above, the side-by-side type composite filament
of this invention is similar to a textured yarn (false-twisted
yarn) in the boiling water shrinkage behavior in spite of its
filament form, and is much superior to the textured yarn in the
crimp performance.
[0040] In the present invention, various physical properties of the
composite filament and of a woven or knitted fabric are evaluated
as below.
[0041] Boiling Water Shrinkage (Sr.sub.1 and Sr.sub.2) and Crimp
Recovery Rate (CR)
[0042] The boiling water shrinkage (Sr.sub.1) was measured by the
method of clause 7.15 of JIS L 1013 and the boiling water shrinkage
(Sr.sub.2) was measured by the method of clause 5.10 of JIS L 1090.
Specifically, a hank was prepared by winding a composite filament
around a creel 10 or 20 times (20 times in the method of clause
7.15 of JIS L 1013 and 10 times in the method of clause 5.10 of JIS
L 1090). An initial load and a static load were applied to the
prepared hank to measure the length (L.sub.0). In the method of
clause 7.15 of JIS L 1013, the initial load equals to notified
denier.times.1/30 g and the static load equals to notified
denier.times.40/30 g). In the method of clause 5.10 of JIS L 1090,
the initial load equals to notified denier.times.1/10 g and the
static load equals to notified denier.times.20/10 g. The hank was
heat-treated for 30 minutes in a hot water of 100.degree.
C..+-.2.degree. C., taken out, dewatered with a moist absorbent
paper, and left indoors. Then, the initial load and the static load
corresponding to each of the methods were applied again to the hank
to measure the length (L.sub.1). Continuously, the hank with
initial load and static load was left in the water of 20.degree.
C..+-.2.degree. C. and then the sample length (L.sub.2) was
measured. The static load was removed again and left and then the
sample length (L.sub.3) was measured. The measured values are
substituted into the following formula to calculate the boiling
water shrinkage and the crimp recovery rate. Boiling .times.
.times. water .times. .times. shrinkage .times. .times. ( Sr 1
.times. .times. and .times. .times. Sr 2 ) = L 0 - L 1 L 0 .times.
100 .times. ( % ) ##EQU1## Crimp .times. .times. recovery .times.
.times. rate .times. .times. ( CR ) = L 2 - L 3 L 2 .times. 100
.times. ( % ) ##EQU1.2##
[0043] Elastic Property of Fabric
[0044] It was evaluated by an organoleptic test using a panel
composed of 30 people. If 25 or more out of 30 people judges the
shrinkage of a fabric excellent, it is represented as
.circleincircle.. If 20 to 24 people judge it excellent, it is
represented as .largecircle.. If 10 to 19 people judge it
excellent, it is represented as .DELTA.. If 9 or less people judges
it excellent, it is represented as x.
[0045] Temperature (Tmax) Exhibiting Maximum Thermal Stress and
Maximum Thermal Stress Per Denier (g/denier)
[0046] They were measured by a Thermal Stress Tester of Kanebo
Engineering Co. Ltd. Specifically, a loop-shaped sample having a 10
cm length was suspended on upper and lower hooks and then a
predetermined tension [notified denier of composite
filament.times.2/30 g] was applied to the sample. In this state,
the temperature was raised at a predetermined speed (300.degree.
C./120 seconds). A stress change corresponding to a temperature
change was drawn on a chart as shown in FIG. 3 and then a
temperature area (Tmax, 95%) exhibiting more than 95% of maximum
the thermal stress was obtained with the maximum thermal stress as
a center. The maximum thermal stress per yarn denier was calculated
by obtaining maximum thermal stress on the chart and then
substituting it into the following formula. Maximum .times. .times.
Thermal .times. .times. Stress .times. .times. Per .times. .times.
Denier = Maximum .times. .times. Thermal .times. .times. Stress
Notified .times. .times. denier .times. .times. of .times. .times.
Composite .times. .times. Filamment .times. 2 ##EQU2##
[0047] Number Average Molecular Weight (Mn) and Weight Average
Molecular Weight (Mw)
[0048] They were measured using the gel permeation chromatograph
(GPC) method by the following formula: Mn = i = 1 n .times. .times.
Hi i = 1 n .times. .times. Hi / Mi ##EQU3## Mw = i = 1 n .times.
.times. Hi .times. Mi i = 1 n .times. .times. Hi ##EQU3.2##
[0049] Hi: length of signal of detector on baseline of retention
volume (Vi)
[0050] Mi: molecular weight of polymer fraction in retention volume
(Vi)
[0051] N: number of data
[0052] Wherein the retention volume (Vi) is the volume of solvent
consumed during the retention time of sample component molecules in
columns.
[0053] The retention time is the time taken until the sample
component molecules enter the columns and melt out.
[0054] Since the results measured by the above method are relative
values, a standard material is used in order to compensate these
values. As the standard material, mainly used is polystyrene, of
which the molecular weight and the breadth of the molecular weight
distribution are already known. Other kinds of standard materials
also may be used on a proper basis.
[0055] The breadth of the molecular weight distribution is the
width of the peak value of the molecular weight distribution and
represents the dispersity (Mw/Mn) of a target polymer material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] FIG. 1 is a schematic view of a process for manufacturing a
high crimp side-by-side type composite filament according to the
present invention by a spin-direct draw method;
[0057] FIG. 2 is schematic view of a process for manufacturing a
high crimp side-by-side type composite filament according to the
present invention by drawing and heat treatment an undrawn yarn or
a half-drawn yarn;
[0058] FIG. 3 is a thermal stress curve of the composite filament
of the present invention charted in a thermal stress tester;
[0059] FIG. 4 is a micrograph showing the cross sectional state of
the side-by-side type composite filament according to the present
invention;
[0060] FIG. 5 is a micrograph showing the state of the side-by-side
type composite filament before heat treatment according to the
present invention; and
[0061] FIG. 6 is a micrograph showing the state of the side-by-side
type composite filament after a hot water treatment (100.degree.
C.) according to the present invention.
EXPLANATION OF REFERENCE NUMERALS FOR MAIN PARTS IN THE
DRAWINGS
[0062] 1,2: extruder 3: spinning block 4: quenching chamber 5:
first Godet roller [0063] 6: second Godet roller 7: conjugate
filament 8: draw winder [0064] 10: undrawn yarn or half-drawn yarn
drum 11: hot roller [0065] 12: hot plate 13: draw roller 14:
conjugate filament [0066] Tg: initial shrinkage start temperature
[0067] Tmax: temperature exhibiting maximum thermal stress [0068]
T.alpha.: lower limit value of temperature area exhibiting 95% of
maximum thermal stress [0069] T.beta.: upper limit value of
temperature area exhibiting 95% of maximum thermal stress
BEST MODE FOR CARRYING OUT THE INVENTION
[0070] The present invention is now understood more concretely by
comparison between examples of the present invention and
comparative examples. However, the present invention is not limited
to such examples.
EXAMPLE 1
[0071] A polyethylene terephthalate with a number average molecular
weight (Mn) of 15,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 25,000 are conjugated-spun
in side by side type at a speed of 3,000 m/min at a temperature of
285.degree. C. The resulting material is drawn and heat-treated at
a draw speed of 650 m/min and at a drawn ratio of 1.68 in a drawing
and heat treatment process as shown in FIG. 2, to prepare a
side-by-side type conjugate (composite) filament having 100
deniers/24 filaments. The drawing and heat-treatment temperature
(hot plate temperature) is set to 132.degree. C. so that the
composite filament can satisfy the following physical
properties.
[0072] Maximum thermal stress per denier: 0.21 g/denier
[0073] Temperature exhibiting maximum thermal stress (Tmax):
155.degree. C.
[0074] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 228.degree. C.
[0075] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a rapier
loom using the conjugate filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type conjugate filament and of the fabric made thereof are as shown
in Table 1.
EXAMPLE 2
[0076] A polyethylene terephthalate with a number average molecular
weight (Mn) of 12,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 25,000 are conjugated-spun
in side by side type at a speed of 3,000 m/min at a temperature of
285.degree. C. The resulting material is drawn and heat-treated at
a draw speed of 650 m/min and at a drawn ratio of 1.68 in a drawing
and heat treatment process as shown in FIG. 2, to prepare a
side-by-side type conjugate filament having 100 deniers/24
filaments. The drawing and heat-treatment temperature (hot plate
temperature) is set to 140.degree. C. so that the composite
filament can satisfy the following physical properties.
[0077] Maximum thermal stress per denier: 0.31 g/denier
[0078] Temperature exhibiting maximum thermal stress (Tmax):
165.degree. C.
[0079] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 228.degree. C.
[0080] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a rapier
loom using the conjugate filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type conjugate filament and of the fabric made thereof are as shown
in Table 1.
EXAMPLE 3
[0081] A polyethylene terephthalate with a number average molecular
weight (Mn) of 16,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 28,000 are conjugated-spun
in side by side type at a temperature of 290.degree. C. The
resulting material is drawn and heat-treated in a continuous
drawing and baking process as shown in FIG. 1, to prepare a
side-by-side type conjugate filament having 100 deniers/24
filaments. The temperature of a first Godet roller is set to
82.degree. C. and the speed thereof is set to 1,800 m/min. The
speed of a second Godet roller is set to 4,815 m/min, the speed of
a take-up roller is set to 4,800 m/min, and the temperature of the
second Godet roller is set to 163.degree. C., so that the conjugate
filament can satisfy the following physical properties.
[0082] Maximum thermal stress per denier: 0.16 g/denier
[0083] Temperature exhibiting maximum thermal stress (Tmax):
175.degree. C.
[0084] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 228.degree. C.
[0085] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a rapier
loom using the conjugate filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type conjugate filament and of the fabric made thereof are as shown
in Table 1.
COMPARATIVE EXAMPLE 1
[0086] A polyethylene terephthalate with a number average molecular
weight (Mn) of 21,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 25,000 are conjugated-spun
in side by side type at a speed of 3,000 m/min at a temperature of
285.degree. C. The resulting material is drawn and heat-treated at
a draw speed of 650 m/min and at a drawn ratio of 1.68 in a drawing
and heat treatment process as shown in FIG. 2, to prepare a
side-by-side type conjugate filament having 100 deniers/24
filaments. The drawing and heat-treatment temperature (hot plate
temperature) is set to 118.degree. C. so that the composite
filament can satisfy the following physical properties.
[0087] Maximum thermal stress per denier: 0.21 g/denier
[0088] Temperature exhibiting maximum thermal stress (Tmax):
135.degree. C.
[0089] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 228.degree. C.
[0090] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a rapier
loom using the composite filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type conjugate filament and of the fabric made thereof are as shown
in Table 1.
COMPARATIVE EXAMPLE 2
[0091] A polyethylene terephthalate with a number average molecular
weight (Mn) of 20,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 25,000 are conjugated-spun
in side by side type at a speed of 3,000 m/min at a temperature of
285.degree. C. The resulting material is drawn and heat-treated at
a draw speed of 650 m/min and at a drawn ratio of 1.68 in a drawing
and heat treatment process as shown in FIG. 2, to prepare a
side-by-side type conjugate filament having 100 deniers/24
filaments. The drawing and heat-treating temperature (hot plate
temperature) is set to 115.degree. C. so that the conjugate
filament can satisfy the following physical properties.
[0092] Maximum thermal stress per denier: 0.18 g/denier
[0093] Temperature exhibiting maximum thermal stress (Tmax):
130.degree. C.
[0094] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 235.degree. C.
[0095] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a rapier
loom using the composite filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type composite filament and of the fabric made thereof are as shown
in Table 1.
COMPARATIVE EXAMPLE 3
[0096] A polyethylene terephthalate with a number average molecular
weight (Mn) of 25,000 and a polyethylene terephthalate with a
number average molecular weight (Mn) of 25,000 are conjugated-spun
in side by side type at a speed of 3,000 m/min at a temperature of
285.degree. C. The resulting material is drawn and heat-treated at
a draw speed of 650 m/min and at a drawn ratio of 1.68 in a drawing
and heat treatment process as shown in FIG. 2, to prepare a
side-by-side type conjugate filament having 100 deniers/24
filaments. The temperature of a hot roll is set to 85.degree. C.
and the drawing and heat-treatment temperature (hot plate
temperature) is set to 130.degree. C. so that the conjugate
filament can satisfy the following physical properties.
[0097] Maximum thermal stress per denier: 0.18 g/denier
[0098] Temperature exhibiting maximum thermal stress (Tmax):
155.degree. C.
[0099] Temperature area exhibiting 95% of maximum thermal stress
(Tmax, 95%): 122 to 235.degree. C.
[0100] Next, a five-harness satin with a warp density of 190
yarns/inch and a weft density of 98 yarns/inch is woven in a repia
loom using the composite filament as a warp and a weft, then
scoured/contracted, then dyed in a rapid dyeing machine of
125.degree. C., and then after-processed under a typical
postprocessing condition, thereby making a fabric. The results of
measuring various physical properties of the prepared side-by-side
type conjugate filament and of the fabric made thereof are as shown
in Table 1. TABLE-US-00001 TABLE 1 Results of evaluating physical
properties of yarn and of fabric Physical Properties of Yarn
(Sr.sub.2/Sr.sub.1) .times. shrinkage Classification Sr.sub.1(%)
Sr.sub.2(%) 100(%) CR(%) of Fabric Example 1 15.40 6.89 44.7 37.7
.circleincircle. Example 2 10.80 7.04 65.2 39.9 .circleincircle.
Example 3 5.70 3.48 61.1 35.8 .circleincircle. Comparative 8.90
8.10 91.0 12.7 X Example 1 Comparative 7.17 5.80 80.1 26.3 .DELTA.
Example 2 Comparative 7.68 7.80 98.1 2.30 X Example 3
[0101] In the above table, Sr.sub.1 is a boiling water shrinkage of
the composite filament measured by the method of clause 7.15 of JIS
L 1013, and Sr.sub.2 is a boiling water shrinkage of the conjugate
filament measured by the method of clause 5.10 of JIS L 1090.
INDUSTRIAL APPLICABILITY
[0102] The side-by-side type conjugate filament of this invention
is superior in crimp property, exhibits the same properties as
natural fibers and is easy to carry out a dyeing process. Further,
the present invention reduces the manufacturing cost due to a
simple manufacturing process and enables the composite filament to
have a fine denier.
* * * * *