U.S. patent application number 11/489607 was filed with the patent office on 2006-11-16 for method for melt-spinning polymer alloy fiber.
Invention is credited to Akira Kishiro, Takaaki Mihara, Shuichi Nonaka, Takashi Ochi, Norio Suzuki.
Application Number | 20060255499 11/489607 |
Document ID | / |
Family ID | 31497634 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060255499 |
Kind Code |
A1 |
Ochi; Takashi ; et
al. |
November 16, 2006 |
Method for melt-spinning polymer alloy fiber
Abstract
The present invention provides a nanoporous fiber being
substantially free from coarse pores and having homogeneously
dispersed nanopores, unlike conventional porous fibers. A porous
fiber has pores each having a diameter of 100 nm or less, in which
the area ratio of pores each having a diameter of 200 nm or more to
the total cross section of the fiber is 1.5% or less, and the pores
are unconnected pores, or a porous fiber has pores each having a
diameter of 100 nm or less, in which the area ratio of pores each
having a diameter of 200 nm or more to the total cross section of
the fiber is 1.5% or less, the pores are connected pores, and the
fiber has a strength of 1.0 cN/dtex or more.
Inventors: |
Ochi; Takashi; (Mishima-shi,
JP) ; Kishiro; Akira; (Mishima-shi, JP) ;
Nonaka; Shuichi; (Otsu-shi, JP) ; Mihara;
Takaaki; (Mishima-shi, JP) ; Suzuki; Norio;
(Sunto-gun, JP) |
Correspondence
Address: |
KUBOVCIK & KUBOVCIK
SUITE 710
900 17TH STREET NW
WASHINGTON
DC
20006
US
|
Family ID: |
31497634 |
Appl. No.: |
11/489607 |
Filed: |
July 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10523416 |
Mar 21, 2005 |
7097904 |
|
|
PCT/JP03/09532 |
Jul 28, 2003 |
|
|
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11489607 |
Jul 20, 2006 |
|
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Current U.S.
Class: |
264/211.22 ;
264/211.23 |
Current CPC
Class: |
D01F 6/06 20130101; D01F
8/12 20130101; Y10T 442/444 20150401; D01F 6/76 20130101; Y10T
442/3146 20150401; B29C 48/362 20190201; D01F 6/00 20130101; B29C
48/40 20190201; Y10T 428/2913 20150115; Y10T 442/3065 20150401;
D01F 6/84 20130101; Y10T 428/2935 20150115; Y10T 442/609 20150401;
D01F 6/62 20130101; D01F 6/04 20130101; Y10T 442/3089 20150401;
Y10T 442/637 20150401; Y10T 442/64 20150401; Y10T 428/2975
20150115; D01F 6/16 20130101; Y10T 442/431 20150401; D01F 6/60
20130101; Y10T 428/2973 20150115; D01D 5/247 20130101; Y10T
428/2967 20150115; Y10T 428/2931 20150115; Y10T 428/2924 20150115;
Y10T 442/3163 20150401; Y10T 428/2929 20150115 |
Class at
Publication: |
264/211.22 ;
264/211.23 |
International
Class: |
B29C 47/60 20060101
B29C047/60 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 5, 2002 |
JP |
2002-227619 |
Mar 10, 2003 |
JP |
2003-62910 |
Claims
1. A method for melt-spinning a polymer alloy fiber, comprising the
steps of weighing and feeding a lower soluble polymer and a higher
soluble polymer independently to a twin-screw extrusion-kneader,
melting and blending the polymers in the twin-screw
extrusion-kneader to form a polymer alloy, and melt-spinning the
polymer alloy, wherein the spinning is carried out so as to satisfy
the following conditions (1) to (3): (1) the content of the higher
soluble polymer in the polymer alloy is 5 to 60% by weight; (2) the
ratio in melt viscosity of the lower soluble polymer to the higher
soluble polymer is 0.1 to 2; and (3) the length of a kneading
section of the twin-screw extrusion-kneader is 20 to 40% of the
effective length of screws.
2. The method for melt-spinning a polymer alloy fiber according to
claim 1, wherein the content of the higher soluble polymer in the
resulting blend is 10 to 30% by weight.
3. The method for melt-spinning a polymer alloy fiber according to
claim 1, wherein the content of the higher soluble polymer in the
resulting blend is 15 to 25% by weight.
4. The method for melt-spinning a polymer alloy fiber according to
claim 1, further comprising a polyamide containing terminal amino
groups in an amount of 5.5.times.10.sup.-5 molar equivalent or less
per gram as the lower soluble polymer.
5. The method for melt-spinning a polymer alloy fiber according to
claim 1, further comprising carrying out the spinning at
temperatures of 300.degree. C. or less.
6. A method for melt-spinning a polymer alloy fiber, comprising the
steps of weighing and feeding a lower soluble polymer and a higher
soluble polymer independently to a static mixer having a number of
splits of 100.times.10.sup.4 or more, melting and blending the
polymers in the static mixer to form a polymer alloy, and
melt-spinning the polymer alloy, wherein the spinning is carried
out so as to satisfy the following conditions (4) and (5): (4) the
content of the higher soluble polymer in the polymer alloy is 5 to
60% by weight; and (5) the ratio in melt viscosity of the lower
soluble polymer to the higher soluble polymer is 0.1 to 2.
7. The method for melt-spinning a polymer alloy fiber according to
claim 6, wherein the content of the higher soluble polymer in the
resulting blend is 10 to 30% by weight.
8. The method for melt-spinning a polymer alloy fiber according to
claim 6, wherein the content of the higher soluble polymer in the
resulting blend is 15 to 25% by weight.
9. The method for melt-spinning a polymer alloy fiber according to
claim 6, further comprising a polyamide containing terminal amino
groups in an amount of 5.5.times.10.sup.-5 molar equivalent or less
per gram as the lower soluble polymer.
10. The method for melt-spinning a polymer alloy fiber according to
claim 6, further comprising carrying out the spinning at
temperatures of 300.degree. C. or less.
11. A method for melt-spinning a polymer alloy fiber comprising a
lower soluble polymer and a higher soluble polymer, comprising
storing and dry-blending two or more different pellets in a
blending tank before melting of the pellets, feeding the
dry-blended pellets to a melting section, and blending and
melt-spinning the dry-blended pellets, wherein the spinning is
carried out so as to satisfy the following conditions (6) to (8):
(6) the content of the higher soluble polymer in the fiber is 5 to
60% by weight; (7) the ratio in melt viscosity of the lower soluble
polymer to the higher soluble polymer is 0.1 to 2; and (8) the
blending tank can contain 5 to 20 kg of pellets.
12. The method for melt-spinning a polymer alloy fiber according to
claim 11, wherein the content of the higher soluble polymer in the
resulting blend is 10 to 30% by weight.
13. The method for melt-spinning a polymer alloy fiber according to
claim 11, wherein the content of the higher soluble polymer in the
resulting blend is 15 to 25% by weight.
14. The method for melt-spinning a polymer alloy fiber according to
claim 11, further comprising a polyamide containing terminal amino
groups in an amount of 5.5.times.10.sup.-5 molar equivalent or less
per gram as the lower soluble polymer.
15. The method for melt-spinning a polymer alloy fiber according to
claim 11, further comprising carrying out the spinning at
temperatures of 300.degree. C. or less.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/523,416 which is a 371 of international application
PCT/JP2003/009532 filed Jul. 28, 2003, which claims priority based
on Japanese Patent Application Nos. 2002-227619 and 2003-62910
filed Aug. 5, 2002, and Mar. 10, 2003, respectively, which are
incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a porous fiber which has a
multitude of fine and even-sized nanopores and is substantially
free from coarse pores that reflect visible radiation. It also
relates to a polymer alloy fiber serving as a precursor of the
porous fiber in the production thereof, and to a method for
producing the polymer alloy fiber.
[0003] In the following descriptions relating to the present
invention, the term "nanopores" means fine pores each having a
diameter of 100 nm or less.
[0004] The term "nanoporous fiber" used in the present invention
refers to a fiber containing one or more pores having a diameter of
100 nm or less per square micrometer at cross section of a fiber
perpendicular to the axial direction thereof.
[0005] The fiber relating to the present invention has such a
multitude of fine pores and thereby exhibits dramatically increased
liquid adsorptivity and/or gas adsorptivity.
[0006] To achieve these properties satisfactorily, key factors are
that the resulting fiber is substantially free from not-fine, i.e.,
coarse pores and that the fiber contains a multitude of fine pores
in even-sized and homogeneously distributed at cross section of a
fiber.
[0007] The present invention relates to a porous fiber standing at
such a higher level than conventional porous fibers. This fiber not
only exhibits dramatically increased liquid adsorptivity and/or gas
adsorptivity as described above, but is also capable of having a
variety of functions by applying the nanoporous structure of the
fiber.
[0008] Namely, the fiber can be applied not only to the fiber
industry but also to a variety of industries and is very
revolutionary and useful.
BACKGROUND ART
[0009] Fibers of polyamides typified by nylon 6 (hereinafter may be
referred to as "N6") and nylon 66 (hereinafter may be referred to
as "N66") and fibers of polyesters typified by a polyethylene
terephthalate (hereinafter may be referred to as "PET") and a
polybutylene terephthalate (hereinafter may be referred to as
"PBT") exhibit excellent mechanical properties and/or dimensional
stability and are widely used not only for clothing but also for
interior decoration, vehicular interior decoration and industrial
use.
[0010] Fibers of polyolefins typified by a polyethylene
(hereinafter may be referred to as "PE") and a polypropylene
(hereinafter may be referred to as "PP") are light-weighted and are
widely utilized for industrial use.
[0011] However, in any kind of fibers, fibers each comprising a
single polymer have some limitations in the properties thereof.
Attempts have therefore been made to modify such polymers typically
by copolymerization or polymer blending or to compound functions
typically by multi-component fiber spinning or combined-filament
spinning.
[0012] Among them, polymer blending has been actively investigated,
since this technique does not require new designing of polymers and
such a polymer blend can be produced by using a mono-component
spinning machine.
[0013] Separately, hollow fibers and porous fibers have been
investigated in order to reduce the weight of fibers or to impart
water-adsorptivity thereto.
[0014] Attempts have been made to provide hollow fibers having high
hollowness, but such hollow portions may be crushed, for example,
as a result of false twisting. To avoid this, multi-islands hollow
fibers, wherein a multitude of islands parts constitutes a hollow
portion, using a conjugated fiber with a water-soluble polymer have
been developed. In such fibers, the hollow portion generally has a
diameter of 1 .mu.m or more, the interface between the polymer and
the air in the hollow portion significantly reflects visible
radiation, and the resulting fiber cannot satisfactorily develop a
color.
[0015] Porous fibers each having a multitude of pores on the order
of sub-micrometers have been investigated. Such porous fibers have
generally been produced not by multi-component fiber spinning but
by polymer blend spinning.
[0016] Japanese Unexamined Patent Publication (Kokai) No. 2-175965,
for example, describes a technique of blending a nylon with a PET
copolymerized with a hydrophilic group, forming a fiber from the
blend, and dissolving off the copolymerized PET from the fiber to
thereby obtain a porous nylon fiber. The fiber of the invention has
surface depressions and protrusions and/or pores on the order of
submicrometers and has pearly luster. However, this fiber shows
significantly deteriorated color property. This is because the
fiber has a multitude of pores having a size on the order of
wavelengths of visible radiation and thereby invites significant
scattering of visible radiation even as compared with the
multi-islands hollow fiber.
[0017] Japanese Unexamined Patent Publication (Kokai) No. 56-107069
(pages 1-3) describes a fiber having pores with a size smaller than
visible radiation. In actual fact, however, the resulting fiber
also shows significantly deteriorated color property, since the
blend fiber contains coarsely aggregated PET particles, and the
aggregated particles are dissolved off to form coarse pores each
having a size on the order of submicrometers to one micrometer. In
fact, above-mentioned Japanese Unexamined Patent Publication
(Kokai) No. 56-107069 describes "most of the polyester component
exists as lines with a diameter of 0.01 to 0.1 micron and there
remain hollows substantially having the above-mentioned size in the
polyamide" in line 7, in the left upper column of page 2,
suggesting the presence of aggregated PET particles.
[0018] In addition, certain porous fibers using a nylon/PET blend
fiber are described in Japanese Unexamined Patent Publication
(Kokai) Nos. 8-158251 and 8-296123. These fibers, however, show a
large variation in size of dispersed particles of PET in the nylon,
for example, about 0.1 to 1 .mu.m and cannot improve decreased
color property caused by coarse pores. In addition, when the
distribution of pore size is large as in the conventional
techniques, coarse pores play an extremely increased role in the
pores and, in contrast, nanopores do not play such a role. Thus,
the porous fiber does not sufficiently exhibits advantages of the
pores.
[0019] Demands have therefore been made to provide porous fibers
substantially free from such coarse pores.
[0020] Separately, a variety of polymer alloy fibers serving as
precursors for porous fibers and ultrafine yarns have been
investigated.
[0021] U.S. Pat. No. 4,686,074 (page 28), for example, describes
that an ultrafine PET fiber having a size of 9.4.times.10.sup.-5
deniers is obtained using a static mixer according to calculations
and discloses a polymer alloy fiber having an islands-in-sea
structure and comprising a polystyrene (hereinafter may be referred
to as "PS") as a sea part and PET as islands parts.
[0022] This document, however, mentions that an actually measured
mono-filament fineness of the ultrafine PET fiber varies from
1.times.10.sup.-4 deniers to 1.times.10.sup.-2 deniers, showing
that the resulting polymer alloy fiber includes dispersed particles
of the islands parts PET with a diameter of 100 to 1000 nm and thus
contains many coarse islands.
[0023] Japanese Unexamined Patent Publication (Kokai) No. 8-113829
(pages 1-12) discloses a very special polymer alloy fiber
comprising a copolyester blended with 30% by weight of a polyether
imide (hereinafter may be referred to as "PEI"), which copolyester
comprises PET copolymerized with 10% by mole of an ethylene
naphthalate component. In this fiber, PEI is dispersed as particles
with a size on the order of 2 to 80 nm. The fiber, however, invites
unstable spinning to thereby obtain yarns with large unevenness and
lacks practical utility, because PEI is dispersed as particles in
the fiber.
[0024] According to the invention disclosed in above-mentioned
Japanese Unexamined Patent Publication (Kokai) No. 8-113829,
spinning is carried out at a temperature of 320.degree. C. in
accordance with the melting point of PEI, which is excessively high
for the copolyester, to thereby cause remarkable thermal
decomposition. In an experiment for corroboration, the resulting
polymer alloy fiber has a strength less than 1.5 cN/dtex and is not
usable in practice. The invention disclosed in Japanese Unexamined
Patent Publication (Kokai) No. 8-113829 also provides a spongy
fiber having pores connected with each other by treating the
polymer alloy fiber with a base in a 6% NaOH solution at 90.degree.
C. for 2 hours. The resulting yarn, however, has a strength less
than 0.5 cN/dtex and is not practically usable from this viewpoint
of strength, because both PEI and the copolyester have been
hydrolyzed in the fiber.
DISCLOSURE OF INVENTION
[0025] Under these circumstances, a first object of the present
invention is to provide a nanoporous fiber having a multitude of
nanopores which are very homogeneously dispersed and are
substantially free from coarse pores, in contrast to conventionally
investigated porous fibers.
[0026] To achieve the first object, the present invention provides,
in an aspect, a porous fiber containing pores each having a
diameter of 100 nm or less, in which the area ratio of pores each
having a diameter of 200 nm or more to the total cross section of
the fiber is 1.5% or less, and the pores are unconnected pores.
[0027] Alternatively, the present invention provides, in another
aspect to achieve the first object, a porous fiber containing pores
each having a diameter of 100 nm or less, in which the area ratio
of pores each having a diameter of 200 nm or more to the total
cross section of the fiber is 1.5% or less, the pores are connected
pores, and the fiber has a strength of 1.0 cN/dtex or more.
[0028] A second object of the present invention is to provide a
yarn, cut fiber, felt, package, woven fabric, knitted fabric or
nonwoven fabric using the nanoporous fiber having a multitude of
nanopores which are very homogeneously dispersed and are
substantially free from coarse pores, in contrast to conventionally
investigated porous fibers as mentioned above, or to provide
various applied products using these, such as clothing, clothing
materials, products for interior, products for vehicle interior,
livingwares, industrial materials and medical devices (hereinafter
these are generically referred to as "fibrous articles").
[0029] To achieve the second object, the present invention
provides, in an aspect, a fibrous article containing the porous
fiber in the first aspect of the present invention which has pores
each having a diameter of 100 nm or less, in which the area ratio
of pores each having a diameter of 200 nm or more to the total
cross section of the fiber is 1.5% or less and the pores are
unconnected pores, alone or in combination with one or more other
fibers.
[0030] Alternatively, the present invention provides, in another
aspect to achieve the second object, a fibrous article containing
the porous fiber in the second aspect of the present invention
which has pores each having a diameter of 100 nm or less, in which
the area ratio of pores each having a diameter of 200 nm or more to
the total cross section of the fiber is 1.5% or less, the pores are
connected pores and the fiber has a strength of 1.0 cN/dtex or
more, alone or in combination with one or more other fibers.
[0031] The porous fibers according to the present invention are
substantially free from coarse pores that cannot be avoided in
conventional porous fibers. In other words, the porous fibers of
the present invention are nanoporous fibers having very
homogeneously dispersed nanopores. These nanoporous fibers serve to
significantly improve color property as compared with conventional
porous fibers to thereby obtain high-value added fibrous articles
utilizing excellent moisture adsorption and adsorption
properties.
[0032] A third object of the present invention is to provide a
novel polymer alloy fiber which serves as a material fiber for the
production of the porous fibers of the present invention.
[0033] To achieve the third object, the present invention provides
a polymer alloy fiber having an islands-in-sea structure and
comprising a lower soluble polymer as a sea part, and a higher
soluble polymer as islands parts, the islands constituting a lined
structure, in which the area ratio of islands each having a
diameter of 200 nm or more to the total islands is 3% or less.
[0034] A fourth object of the present invention is to provide
pellets that is suitably used for the production of the novel
polymer alloy fiber which is, in turn, used for the production of
the porous fibers of the present invention.
[0035] To achieve the fourth object, the present invention provides
pellets of a polymer alloy comprising a polyamide and a polyester,
in which a dispersed polymer component is dispersed in an average
diameter of 1 to 50 nm.
[0036] Alternatively, the present invention provides, in another
aspect to achieve the fourth object, pellets of a polymer alloy
comprising a polyamide and a polyester, containing 30 to 90% by
weight of a polyester copolymerized with 1.5 to 15% by mole of a
sulfonate and having an average weight per pellet of 2 to 15
mg.
[0037] In addition, the present invention provides, yet another
aspect to achieve the fourth object, pellets of a polymer alloy,
comprising a polymer selected from polyamides, polyesters and
polyolefins; and a polyetherester being soluble in hot water, in
which the content of the polyetherester is 10 to 30% by weight, and
the pellets have a b* value as an indicator of coloring of 10 or
less.
[0038] A fifth object of the present invention is to provide a
method for melt-spinning the novel polymer alloy fiber that serves
as a material fiber for the production of the porous fibers of the
present invention.
[0039] To achieve the fifth object, the present invention provides,
in an aspect, a method for melt-spinning a polymer alloy fiber,
comprising the steps of weighing and feeding a lower soluble
polymer and a higher soluble polymer independently to a twin-screw
extrusion-kneader, melting and blending the polymers in the
twin-screw extrusion-kneader to form a polymer alloy, and
melt-spinning the polymer alloy, in which the spinning is carried
out so as to satisfy the following conditions (1) to (3):
[0040] (1) the content of the higher soluble polymer in the polymer
alloy is 5 to 6.0% by weight;
[0041] (2) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2; and
[0042] (3) the length of a kneading section of the twin-screw
extrusion-kneader is 20 to 40% of the effective length of
screws.
[0043] Alternatively, the present invention provides, in another
aspect to achieve the fifth object, a method for melt-spinning a
polymer alloy fiber, comprising the steps of weighing and feeding a
lower soluble polymer and a higher soluble polymer independently to
a static mixer having a number of splits of 100.times.10.sup.4 or
more, melting and blending the polymers in the static mixer to form
a polymer alloy, and melt-spinning the polymer alloy, wherein the
spinning is carried out so as to satisfy the following conditions
(4) and (5):
[0044] (4) the content of the higher soluble polymer in the polymer
alloy is 5 to 60% by weight; and
[0045] (5) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2.
[0046] In addition, the present invention provides, in yet another
aspect to achieve the fifth object, a method for melt-spinning a
polymer alloy fiber, comprising storing and dry-blending two or
more different pellets comprising a lower soluble polymer and a
higher soluble polymer, respectively, in a blending tank before
melting of the pellets, feeding the dry-blended pellets to a
melting section, and blending and melt-spinning the dry-blended
pellets, wherein the spinning is carried out so as to satisfy the
following conditions (6) to (8):
[0047] (6) the content of the higher soluble polymer in the fiber
is 5 to 60% by weight;
[0048] (7) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2; and
[0049] (8) the blending tank can contain 5 to 20 kg of pellets.
[0050] The attached drawings will be described below.
[0051] FIG. 1 is a transmission electron micrograph showing a cross
section of a nanoporous fiber according to after-mentioned Example
1 of the present invention.
[0052] FIG. 2 is a transmission electron micrograph showing a
longitudinal section of the nanoporous fiber according to
after-mentioned Example 1 of the present invention.
[0053] FIG. 3 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 1 of the present invention.
[0054] FIG. 4 is a transmission electron micrograph showing an
example of a longitudinal section of the polymer alloy fiber
according to after-mentioned Example 1 of the present
invention.
[0055] FIG. 5 is a transmission electron micrograph showing an
example of a cross section of pellets of a polymer alloy according
to after-mentioned Example 1 of the present invention.
[0056] FIG. 6 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 4 of the present invention.
[0057] FIG. 7 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 4 of the present invention.
[0058] FIG. 8 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 8 of the present invention.
[0059] FIG. 9 is a transmission electron micrograph showing an
example of a cross section of the polymer alloy fiber according to
after-mentioned Example 8 of the present invention.
[0060] FIG. 10 is a transmission electron micrograph showing an
example of a longitudinal section of the polymer alloy fiber
according to after-mentioned Example 8 of the present
invention.
[0061] FIG. 11 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 8 of the present invention.
[0062] FIG. 12 is a transmission electron micrograph showing an
example of a longitudinal section of the nanoporous fiber according
to after-mentioned Example 8 of the present invention.
[0063] FIG. 13 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 9 of the present invention.
[0064] FIG. 14 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 9 of the present invention.
[0065] FIG. 15 is a transmission electron micrograph showing an
example of a longitudinal section of the nanoporous fiber according
to after-mentioned Example 9 of the present invention.
[0066] FIG. 16 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 10 of the present invention.
[0067] FIG. 17 is a transmission electron micrograph showing an
example of a longitudinal section of the polymer alloy fiber
according to after-mentioned Example 10 of the present
invention.
[0068] FIG. 18 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 10 of the present invention.
[0069] FIG. 19 is a transmission electron micrograph showing an
example of a longitudinal section of the nanoporous fiber according
to after-mentioned Example 10 of the present invention.
[0070] FIG. 20 is a transmission electron micrograph showing an
example of a cross section of polymer alloy pellets according to
after-mentioned Comparative Example 2 in the present invention.
[0071] FIG. 21 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 15 of the present invention.
[0072] FIG. 22 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 15 of the present invention.
[0073] FIG. 23 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 16 of the present invention.
[0074] FIG. 24 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 16 of the present invention.
[0075] FIG. 25 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 19 of the present invention.
[0076] FIG. 26 is a transmission electron micrograph showing an
example of a cross section of a nanoporous fiber according to
after-mentioned Example 19 of the present invention.
[0077] FIG. 27 is a transmission electron micrograph showing an
example of a cross section of a polymer alloy fiber according to
after-mentioned Example 35 of the present invention.
[0078] FIG. 28 is a diagram showing an example of a spinning
machine.
[0079] FIG. 29 is a diagram showing an example of a false-twist
texturing machine.
[0080] FIG. 30 is a diagram showing an example of a spinneret.
[0081] FIG. 31 is a diagram showing an example of a spinning
machine.
[0082] FIG. 32 is a diagram showing an example of a drawing
machine.
[0083] FIG. 33 is a diagram showing an example of a spinning
machine.
[0084] FIG. 34 is a diagram showing an example of a draw
false-twist texturing machine.
REFERENCE NUMERALS
[0085] 1: hopper [0086] 2: melting section [0087] 3: spinning pack
[0088] 4: spinneret [0089] 5: cooling equipment [0090] 6: line of
thread [0091] 7: thread-collecting finishing guide [0092] 8: first
take-up roller [0093] 9: second take-up roller [0094] 10: wound
yarn [0095] 11: undrawn yarn [0096] 12: feed roller [0097] 13:
heater [0098] 14: cooling plate [0099] 15: twister [0100] 16:
delivery roller [0101] 17: false-twisted yarn [0102] 18: weighing
section [0103] 19: orifice length [0104] 20: orifice diameter
[0105] 21: static mixer [0106] 22: undrawn yarn [0107] 23: feed
roller [0108] 24: first hot roller [0109] 25: second hot roller
[0110] 26: delivery roller (room temperature) [0111] 27: drawn yarn
[0112] 28: metering device [0113] 29: blending tank [0114] 30:
extrusion-kneader [0115] 31: first hot roller [0116] 32: second hot
roller
BEST MODE FOR CARRYING OUT THE INVENTION
[0117] The nanoporous fibers according to the present invention
will be described below.
[0118] Examples of polymers for constituting the nanoporous fibers
of the present invention are thermoplastic polymers such as
polyesters, polyamides and polyolefins; thermosetting polymers such
as phenol resins; polymers with poor thermoplasticity, such as
polyvinyl alcohols and polyacrylonitriles; and biopolymers, of
which thermoplastic polymers are preferred for their satisfactory
moldability.
[0119] Among them, most of polyesters and polyamides have a high
melting point and are more preferred. The melting point of the
material polymer is preferably 165.degree. C. or higher for
satisfactory thermal stability. In general, for example, a
polylactic acid (hereinafter may be referred to as "PLA"), PET and
N6 have melting points of around 170.degree. C., around 255.degree.
C. and around 220.degree. C., respectively, and are preferred.
[0120] The polymer may further comprise additives such as
particles, flame retardants and antistatics. In addition, the
polymer may further comprise other copolymerized components within
ranges not deteriorating the properties of the polymers. For
retaining inherent thermal stability and mechanical properties of
the polymers, the degree of copolymerization is preferably 5% by
mole or less, or 5% by weight or less.
[0121] For use in, for example, clothing, interior decoration and
vehicle interior decoration, polyesters and polyamides are
preferred for their melting points, mechanical properties and
hands. Among them, nylon 6 and nylon 66 each having a degree of
copolymerization of 5% by mole or less or 5% by weight or less and
having a relative viscosity of 2 or more; PETs, polytrimethylene
terephthalates and polybutylene terephthalates each having an
intrinsic viscosity of 0.50 or more; and PLAs each having a
weight-average molecular weight of 7.times.10.sup.4 or more are
specifically preferred. The content of these polymers in the porous
fiber is preferably 80% by weight or more.
[0122] An essential feature of the porous fibers of the present
invention is that the porous fibers have pores each having a
diameter of 100 nm or less.
[0123] As is mentioned at the outset, the term "porous fiber" used
in the present invention means a fiber containing pores each having
a diameter of 100 nm or less in a number of one or more per square
micrometer at cross section of a fiber and is referred to as
"nanoporous fiber" in the present invention. Such a fiber having
nanopores as in the present invention can have dramatically
increased liquid adsorptivity and/or gas adsorptivity.
[0124] Another essential feature is that the area ratio of pores
each having a diameter of 200 nm or more to the total cross section
of the fiber is 1.5% or less. The visible radiation has a
wavelength of about 400 to 800 nm. Thus, by substantially
eliminating coarse pores each having a diameter of 200 nm or more,
the nanoporous fiber is prevented from decreasing in color
property. The diameters and areas of the pores can be estimated by
cutting the nanoporous fiber into ultrathin peaces and observing
the ultrathin peaces under a transmission electron microscope
(TEM). These parameters are determined in this manner in the
present invention.
[0125] The pores may have irregular profiles such as oval profiles
and do not always have perfect circular profiles. The diameters of
the pores herein are therefore determined from the areas of the
pores, assuming that the pores have perfect circular profiles.
[0126] The phrase "total cross section of the fiber" refers to the
area of a cross section of a mono-filament and means a total area
of polymer sections and pore sections. Such areas can be relatively
easily determined by using an image processing software such as
WINROOF. The area ratio of pores each having a diameter of 50 nm or
more to the total cross section of the fiber is preferably 1.5% or
less, and more preferably 0.1% or less in the porous fibers of the
present invention.
[0127] The pores preferably have an average diameter of 0.1 to 50
nm. This substantially prevents the visible radiation from
scattering, and the resulting fiber is optically transparent to the
visible radiation but exhibits a new function of blocking harmful
ultraviolet rays, since the pores each have a diameter near to the
wavelengths of ultraviolet rays. In addition, the resulting fiber
has a dramatically increased surface area and thereby exhibits high
hygroscopicity and/or adsorptivity unexpectable in conventional
porous fibers.
[0128] Such a multitude of fine pores serve to dramatically improve
the capability of adsorbing various liquids (fluids) such as
organic solvents in addition to water. However, an excessively
small average diameter of the pores may cause filling of the pores
as a result of, for example, heat treatment. Thus, the present
inventors have found that the pores more preferably have an average
diameter of 5 to 30 nm.
[0129] An example of the nanoporous fibers of the present invention
is shown in FIG. 1 as a transmission electron micrograph of a cross
section of a nanoporous N6 fiber. The figure shows minute shades of
gray by metal staining, in which dark regions are regions at high
density of N6, and bright regions are regions at low density of N6.
The bright regions are considered to correspond to pores. The pores
may be connected pores being connected with each other or
unconnected pores substantially without being connected with each
other.
[0130] In the present invention, the term "connected pores" refers
to pores which are connected with each other and substantially
extend from a surface top layer to an inner layer of the fiber. The
term "unconnected pores" refers to pores which are not
substantially connected with each other, in which pores in a
surface layer of the fiber are substantially isolated from pores in
an inner layer thereof.
[0131] These pores are capable of taking various molecules therein,
as mentioned later. For satisfactory washing resistance and
sustained releasability of such molecules, the pores are preferably
unconnected pores, since such unconnected pores can trap or
encapsulate the taken molecules to some extent.
[0132] When the fiber has connected pores, the polymer constituting
the fiber has reduced continuity and may often have a decreased
strength. The porous fiber according to the present invention
should essentially have a strength of 1.0 cN/dtex or more when the
fiber has connected pores.
[0133] Whether the nanopores in the present invention are formed as
unconnected pores or as connected pores can be controlled by
appropriately selecting blending and dissolving-off conditions of
the islands-part polymer in the polymer alloy fiber serving as a
raw yarn.
[0134] The porous fiber having connected pores can have a strength
of 1.0 cN/dtex or more by controlling the average diameter of the
pores to 50 nm or less.
[0135] As is described above, the nanoporous fibers according to
the present invention have myriad nanopores and thereby have
increased specific surface areas to show excellent hygroscopicity
and/or adsorptivity.
[0136] The present inventors have had the following findings.
Specifically, the ratio of moisture adsorption (.DELTA.MR) of the
nanoporous fibers is preferably 4% or more. The ratio of moisture
adsorption (.DELTA.MR) may be controlled to 4% or more according
to, but not limited to, a procedure of forming the nanoporous
fibers according to the present invention using a hydrophilic
polymer inherently having some hygroscopicity. Examples of the
hydrophilic polymer are polyamides such as N6 and N66. Even when
the nanoporous fibers comprise a not-hydrophilic polymer such as a
polyester, they can have a ratio of moisture adsorption (.DELTA.MR)
of 4% or more by incorporating a hygroscopic material into the
nanopores. Examples of the hygroscopic material are polyalkylene
oxides and modified products thereof. Such deodorant fibers
preferably have an ammonia adsorbing rate, for example, of 50% or
more, and the porous fibers of the present invention satisfy this
requirement. The nanoporous fibers according to the present
invention can have an ammonia adsorbing rate of 50% or more
according to any suitable procedure, such as by using a polymer
inherently having some odor adsorbing capability to constitute the
nanoporous fibers. Needless to say, any of deodorizers may be
incorporated into the nanopores.
[0137] The ammonia adsorbing rate can be determined by the
following method. Specifically, 1 g of a fabric comprising 100% of
the nanoporous fiber is placed in a 5-liter Tedlar bag, and 3
liters of a gas containing ammonia is introduced into the bag to
adjust the initial concentration (C.sub.0) to 40 ppm. The gas is
sampled from the Tedlar bag 2 hours later, and the ammonia
concentration (C.sub.1) is determined. Separately, a blank test
without using a fabric sample is carried out, and the ammonia
concentration (C.sub.B) is determined 2 hours later. The ammonia
adsorbing rate is determined by calculation according to the
following equation. Ammonia adsorbing rate
(%)={(C.sub.B-C.sub.1)/C.sub.B}.times.100(%)
[0138] The porous fibers according to the present invention can
adsorb not only gases but also liquids, may exhibit water retention
capability equivalent to cotton to have a percentage of water
retention of 60% or more. The nanoporous fibers according to the
present invention can have a percentage of water retention of 60%
or more according to any suitable procedure, for example, by using
a polymer inherently having some water retention capability to
constitute the nanoporous fibers. Examples of the polymer
inherently having some water retention capability are polyamides
such as N6 and N66. As a matter of course, a water-absorbing
material such as a polyalkylene oxide may be incorporated into the
nanopores.
[0139] The percentage of water retention can be determined in the
following manner. Initially, a fabric comprising 100% of the
nanoporous fiber is allowed to adsorb water sufficiently by
immersing in water for one hour, is hanged on a hanger for one
minute, is dewatered in a domestic washing machine (manufacturer:
SANYO, Model: SW150P (A)) for 3 minutes to remove excess water on
the surface of the fiber or in cavities between fibers.
[0140] In this procedure, the weight of the fabric sample (W.sub.1)
is determined, and, after drying at 60.degree. C. for one hour, the
dry weight (W.sub.0) of the sample fabric is determined. Based on
these parameters, the percentage of water retention is determined
by calculation according to the following equation. In this
connection, regular nylons have a percentage of water retention of
about 20 to 30%. Percentage of water retention
(%)={(W.sub.1-W.sub.0)/W.sub.0}.times.100(%)
[0141] Some of the nanoporous fibers of the present invention
exhibit reversible liquid-swelling property in a longitudinal
direction of the yarn as wool and can exhibit functions as in
naturally-occurring fibers, although they are synthetic fibers. The
phrase "exhibit reversible liquid-swelling property" means that,
when immersed therein, the nanoporous fiber adsorbs a liquid and
swells or elongates in a longitudinal direction of the yarn, and,
when the liquid is removed typically by drying, the nanoporous
fiber shrinks in the longitudinal direction of the yarn to have the
original length, and this behavior of the fiber is reversibly
repeatable. The degree of reversible liquid swelling in a
longitudinal direction of the yarn is preferably 6% or more.
[0142] Such nanoporous fibers having reversible liquid-swelling
property in a longitudinal direction of the yarn can be produced
according to any suitable procedure, such as by dispersing
nanopores homogeneously in an total cross section of the fiber. The
degree of reversible liquid swelling in a longitudinal direction of
the yarn can be controlled to 6% or more by rendering the nanopores
to have an average diameter of 30 nm or less.
[0143] The features and advantages mentioned above are essential
features and advantages of the nanoporous fibers according to the
present invention.
[0144] In addition, the fibers can have functions more easily than
conventional fibers, since the nanopores easily take a variety of
functional materials therein.
[0145] If a fabric made from a regular polyester fiber, for
example, is mixed with a moisture absorbent containing a
polyethylene glycol (hereinafter may be referred to as "PEG")
having a molecular weight of 1000 or more in order to impart
hygroscopicity thereto, the fiber cannot significantly take the
moisture absorbent therein. In contrast, a nanoporous fiber of the
present invention comprising PET can take a large quantity of the
moisture absorbent therein, if imparted.
[0146] Squalanes are natural-occurring oil components extracted
from shark liver and receive attentions as a substance having
skin-care functions by the action of moisturizing. If a fabric made
from a regular polyester fiber is mixed with such a squalane, the
fiber cannot significantly take the squalane therein. In contrast,
a fabric comprising the nanoporous fiber of the present invention
can take a large quantity of a squalane therein and shows
significantly improved washing resistance. This is surprising for
those familiar with regular polyester fibers.
[0147] Examples of functional agents to be taken in are, in
addition to such moisture absorbents and humectants, flame
retardants, water repellents, cold insulators, heat insulators and
lubricating agents. Such agents can have any shape in addition to
such a fine-particle shape. The agents also include health-beauty
promoting agents such as polyphenols, amino acids, proteins,
capsaicin and vitamins; agents for dermatoses such as
dermatophytosis; and medicaments such as antiseptics,
anti-inflammatory agents and analgesics. In addition, agents for
adsorbing and/or decomposing harmful substances, such as polyamines
and photocatalytic nanoparticles, can also be used. If desired, it
is also possible to allow the fiber to take one or more monomers
capable of forming an organic or inorganic polymer therein and to
allow them to be polymerized to form a hybrid material. The fiber
can also have selective adsorptivity and/or catalytic activity by
activating walls of the pores by chemical processing utilizing
their large specific surface area. It is also surprising that the
fiber can have any optional function with any optional effect.
[0148] The strength of the nanoporous fibers of the present
invention is preferably 1.5 cN/dtex or more for higher tear
strength and/or durability of the resulting fibrous article, and is
more preferably 2 cN/dtex or more, and further preferably 2.5
cN/dtex or more.
[0149] The elongation percentage is preferably 20% or more for
higher durability of the fibrous article.
[0150] To control the strength to 1.5 cN/dtex or more and the
elongation percentage to 20% or more, the nanoporous fiber is
preferably formed by using a polymer that can satisfy these
requirements even if the polymer alone is made into yarns. For
further improving the strength, it is important to use a polymer
such as a polyamide or polyester which can yield a high strength
when the polymer alone is made into yarns, or to reduce the area
ratio of coarse pores and to reduce the average diameter of pores.
The selection of a higher soluble polymer for use in the polymer
alloy fiber serving as a precursor is also important. The higher
soluble polymer preferably does not comprise such a substance as to
inhibit the developing of a fiber structure, such as a
pseudocrosslinking component.
[0151] The nanoporous fibers of the present invention may have a
variety of profiles (cross sections) such as a trefoil, cross or
hollow profile. Such nanoporous fibers having a modified profile
can be prepared by using a conventional spinneret for fibers having
an irregular profile.
[0152] The nanoporous region may spread overall at cross section of
the fiber or may be unevenly located, for example, in a surface
layer or an inner layer of the fiber or be located
eccentrically.
[0153] The "nanoporous region" herein refers to a region containing
pores each having a diameter of 100 nm or less in a number of one
or more per square micrometer.
[0154] When the inner layer part of the fiber comprises a
nanoporous region and the surface layer part of the fiber comprises
a regular polymer, the resulting fiber has improved wear
resistance, dimensional stability and/or strength.
[0155] In contrast, when the surface layer part of the fiber
comprises a nanoporous region and the inner layer part of the fiber
comprises a regular polymer, the fiber has improved dimensional
stability and/or strength.
[0156] When the nanoporous region is eccentrically unevenly
located, the fiber adsorbs water, swells in a longitudinal
direction of the yarn and is further highly crimped.
[0157] When the nanoporous region is located in an outer area of
crimps and the fiber swells as a result of water adsorption, the
fiber is further highly crimped to thereby improve stretchability
and/or bulkiness.
[0158] In contrast, when the nanoporous region is located in an
inner area of crimps, the crimps elongate as a result of water
adsorption, and the yarn elongates as wool. Thus, the entanglement
of the fabric structure is loosened, and/or the stitches or weaves
are enlarged to thereby improve air permeability.
[0159] When the nanoporous region is eccentrically located at cross
section of a fiber as in the above examples, a fabric capable of
breathing as a result of water adsorption can be provided. When the
nanoporous region is unevenly located as described above, the area
ratio of the nanoporous region is preferably 5 to 95%, more
preferably 30 to 80%, and further preferably 40 to 60% of the total
cross section of the fiber, for yielding satisfactory advantages of
the nanoporous region and those of the other region. Such a
nanoporous fiber having a located nanoporous region can be prepared
by stopping dissolving off the higher soluble component from the
polymer alloy fiber in the midway to thereby allow the higher
soluble component to remain in the fiber, or by subjecting a
polymer alloy and a regular polymer to multi-component fiber
spinning to form a conjugated fiber and dissolving off the higher
soluble component from the conjugated fiber.
[0160] Some of the nanoporous fibers of the present invention may
be easily fibrillated by physical napping, such as buffing or water
punching and are useful as fibrillated fibers or fibrous articles
derived therefrom.
[0161] The diameter of the fibril can be controlled within a range
of 0.001 to 5 .mu.m, by selecting, for example, the combination of
polymers in the polymer alloy fiber serving as a precursor,
physical properties of the polymer alloy fiber, shape or
configuration of pores in the nanoporous fiber, or napping
conditions. Among them, the configuration of the pores are
important, and the fiber is increasingly fibrillated with a
reducing size of pores and an increasing number of the pores. This
is also affected by the size and proportion of the higher soluble
polymer blended in the polymer alloy fiber serving as a precursor.
Such a fibrillated fiber has not been achieved in fibers having an
excessively high wear resistance, such as polyamides, and is very
useful.
[0162] The nanoporous fibers of the present invention can be used
alone or in combination with one or more regular synthetic fibers,
regenerated fibers or naturally-occurring fibers, for example, by
mixing yarns, spinning of mixed cut fibers, mixing of cut fibers,
combined weaving or combined knitting. When used in combination
with a synthetic fiber having excellent dimensional stability
and/or durability, the resulting fabric can have improved
dimensional stability, durability and/or chemical resistance. When
used in combination with a regenerated fiber or a
naturally-occurring fiber, the fabric can have further improved
hygroscopicity, water adsorptivity and/or hands.
[0163] When the nanoporous fibers of the present invention are
yarns, they may be flat yarns without crimp, crimped yarns or yarns
having any other configuration. The nanoporous fibers are
preferably crimped yarns, since the resulting fabric can have
bulkiness and/or stretchability and can be used in a wider range of
applications. They can be formed into various fibrous articles such
as continuous fibers, staples, woven fabrics, knitted fabrics,
nonwoven fabrics, felts, synthetic leather and thermally molded
articles. The fibers are preferably formed into woven fabrics or
knitted fabrics for use as general clothing or products for
interior. Alternatively, the fibers are preferably formed into
nonwoven fabrics for use as functional products such as synthetic
leather or filters, adsorptive materials, wiping cloths and
abrasive cloths.
[0164] As is described above, the nanoporous fibers according to
the present invention can yield high-quality dyed fabrics that are
substantially free from decrease in color property and exhibit
excellent hygroscopicity and/or adsorptivity, as compared with
conventional porous fibers.
[0165] The nanoporous fibers can thereby provide comfortable
clothing such as panty hoses, tights, underwear, shirts, blousons,
pants or trousers, and coats. In addition, they can also be
advantageously used for clothing materials such as cups and pads;
for interior decoration that can control indoor environments, such
as curtains, carpets, mats and furniture; for livingwares such as
wiping cloths; for industrial materials such as filters and
abrasive cloths; and for vehicle interior such as car seats and
ceiling materials.
[0166] The nanoporous fibers, if adsorbing any functional molecule,
can also be used as most advanced materials typically in the fields
of environment, medical and information technology, such as
health-cosmetic-related goods, base fabrics for medicaments, and
electrodes of fuel cells.
[0167] The nanoporous fibers of the present invention can be
produced by any suitable method, such as the following method in
which a nanoporous fiber is produced by dissolving off a higher
soluble polymer from a polymer alloy fiber comprising a lower
soluble polymer and the higher soluble polymer. The method will be
described below.
[0168] In the following description, a polymer alloy fiber having
an islands-in-sea structure and comprising a lower soluble polymer
as a sea part and a higher soluble polymer as islands parts is
taken as an example. In this case, the abundance ratio of islands
each having a diameter of 200 nm or more, namely the abundance
ratio of coarsely aggregated polymer particles is 3% or less in
terms of area ratio of the total islands. This significantly avoid
decrease in color property in the resulting nanoporous fibers. The
islands may have somewhat deformed elliptic shapes and do not
always have perfect circular shapes. The diameters thereof are
determined from the areas of the islands in terms of circle. The
area of the total islands is a total area of all the islands
present at cross section of a fiber and can be estimated based on
the observation of the cross section of the fiber or the polymer
blending ratio. The area ratio of islands each having a diameter of
200 nm or more is preferably 1% or less. More preferably, the area
ratio of islands each having a diameter of 100 nm or more is 3% or
less. The area ratio of islands each having a diameter of 100 nm or
more is further preferably 1% or less.
[0169] The islands preferably have an average diameter of 1 to 100
nm, since such a polymer alloy fiber can yield, by removing the
islands, a nanoporous fiber containing pores with smaller sizes
than conventional porous fibers. The resulting nanoporous fiber
containing pores with sizes on the order of nanometers is
substantially free from scattering of visible radiation, exhibits
markedly improved color property. In addition, it can scatter
harmful ultraviolet rays and thereby gains a novel function of
ultraviolet ray blocking. Furthermore, the fiber has a dramatically
increased surface area and can thereby exhibit excellent
hygroscopicity and/or adsorptivity unexpectable in conventional
porous fibers.
[0170] The less the average diameter of the islands is, the more
advantageous is from the viewpoints of color property and
adsorptivity. However, an excessively small average diameter may
cause excessively large interactions due to excessively large
interfaces between the polymers and may lead to unstable thinning
of the fiber in spinning. Accordingly, the average diameter of
islands is more preferably from 10 to 50 nm.
[0171] The islands preferably have a lined structure. Thus, the
islands-part polymer supports the polymer alloy upon thinning like
reinforcing reinforcing bars and thereby stabilizes the thinning in
spinning. The "lined structure" herein refers to a structure in
which the ratio of the length to the diameter of the islands in an
axial direction of the fiber is 4 or more. In general, the ratio of
the length to the diameter of the islands in an axial direction of
the fiber often stands at 10 or more, and such islands often become
out of a field of view of a TEM.
[0172] To obtain such a polymer alloy fiber which is substantially
free from coarse islands and contains the homogeneously dispersed
nano-sized islands-part polymer, a key factor is the selection of a
combination of polymers in consideration of affinity for each other
and/or of a kneading procedure so as to knead the polymers highly,
as mentioned later.
[0173] In another production method, an alloy fiber having the
following special layered structure can be used instead of the
polymer alloy having an islands-in-sea structure.
[0174] The "special layered structure" herein refers to a structure
in which the following condition is observed on TEM observation of
a cross section of the fiber.
[0175] Specifically, blended different polymers constitute layers
and are tangled with each other in the special layered structure
(FIG. 8, a transmission electron micrograph of a cross section of
the fiber). Thus, the interface between the different polymers is
markedly larger than that in the islands-in-sea structure (FIGS. 3
and 16, transmission electron micrographs of a cross section of the
fiber). This structure is a very unique structure in which the
compatibility is higher than that in the islands-in-sea structure
but is lower than that in a homogenous structure such as PET/PBT.
However, the layered structure is distinguished from a modulated
structure caused by "spinodal decomposition", since the structure
does not show a clear periodicity of layers. The samples for TEM
observation herein are dyed with a metal, and dark regions are the
lower soluble polymer, and bright regions are the higher soluble
polymer. The structure in question is a layered structure and is
structurally apparently distinguished from a "sea-and-sea
structure" in which islands parts are not clearly identified. The
sea-and-sea structure is a very unstable structure which is formed
at a blending ratio near to that where sea/islands are reversed in
a polymer blend, and the spinning cannot be significantly stably
carried out in this region. The average thickness of one layer of
the higher soluble component in a cross sectional direction of the
fiber should be preferably 1 to 100 nm. In the resulting fiber, the
different polymers are sufficiently homogeneously dispersed with
size on the order of nanometers and can satisfactorily exhibit
properties as a blended polymer even if a small amount of one
polymer is blended. The average thickness of one layer of the
higher soluble component is preferably 1 to 50 nm. The layer
observed at cross section of a fiber extends as a line in a
longitudinal direction of the fiber (FIG. 10, a transmission
electron micrograph of a longitudinal section of the fiber).
[0176] The polymer alloy fiber having the special layered structure
shown typically in the figures can be prepared by a combination of
specific polymers and spinning conditions. It can be prepared, for
example, by kneading a polyamide (70 to 85% by weight) and a
copolymerized PET (15 to 30% by weight) copolymerized with 4 to 6%
by mole of a sulfonate component in a static mixer (having a number
of splits of 100.times.10.sup.4 or more) arranged in a spinning
pack, and spinning the kneaded product.
[0177] As is described above, the nanoporous fibers of the present
invention can be prepared by removing a higher soluble polymer from
a polymer alloy fiber in which the higher soluble polymer is
homogenously dispersed with size on the order of nanometers in a
lower soluble polymer. According to conventional techniques, when a
polymer having a low melting point or low softening point is used
as the higher soluble polymer, the polymer is dispersed in large
diameter, and the resulting fiber cannot satisfactorily pass
through processes such as yarn treatment and fabric treatment, in
which a high-temperature treatment is carried out, such as crimping
and throwing. Thus, textured yarns or fabrics subjected to crimping
or throwing cannot be substantially obtained.
[0178] The polymer alloy fiber of the present invention comprises a
higher soluble polymer homogenously dispersed with size on the
order of nanometers. Thus, even if a polymer having a low melting
point or low softening point is used, the polymer alloy fiber can
satisfactorily pass through yarn processing and/or fabric
processing in which high-temperature treatment is carried out, and
the resulting product has higher quality.
[0179] The polymers in the polymer alloy fiber has only to be two
or more different polymers having different solubilities. Where
necessary, the number of types of the lower soluble polymer and/or
the higher soluble polymer can be increased, and one or more
compatibilizers can be used.
[0180] The higher soluble polymer in the polymer alloy fiber is
preferably a polymer easily soluble in an alkaline solution, since
an alkali treatment process generally used as an after-processing
process for regular fibers can be used for removing islands to
thereby form a porous fiber. This is a great advantage in
consideration that, for example, explosion-proof facilities are
required when a polymer soluble in an organic solvent, such as a
polystyrene, is used as the higher soluble polymer.
[0181] The higher soluble polymer is more preferably a polymer
soluble in hot water, since the islands can be removed in a scoring
or degumming process of the fiber. Examples of the polymer easily
soluble in an alkaline solution are polyesters and polycarbonates.
Examples of the polymer soluble in hot water are polyesters
copolymerized with a large quantity of hydrophilic groups; alkylene
oxides, polyvinyl alcohols, and modified products of these
polymers.
[0182] The reduction finish for removing the higher soluble polymer
is preferably carried out at a rate of 20% by weight or more per
hour. This prevents filling of pores upon reduction at high
temperatures and improves the productivity. The parameter herein is
a reduction speed (rate) of reduction finish, and a process time of
reduction finish less than one hour can be employed.
[0183] To allow the nanoporous fibers of the present invention to
satisfactorily exhibit functions of the nanopores while maintaining
the mechanical properties thereof, the content of the islands-part
polymer serving as a higher soluble polymer in the blend is
preferably 5 to 60% by weight, more preferably 10 to 30% by weight,
and further preferably 15 to 25% by weight.
[0184] The polymer alloy fiber does not contain coarsely aggregated
polymer particles and thereby undergoes the spinning process more
stably than conventional equivalents, to obtain a fiber with less
yarn unevenness. The yarn unevenness can be evaluated by an Uster
unevenness (U %). The polymer alloy fiber for use in the present
invention preferably has a U % of 0.1 to 5%, since the resulting
fibrous articles typically for use in apparel, interior decoration
and vehicle interior decoration show less dyeing speck and have
high quality. The U % is more preferably 0.1 to 2%, and further
preferably 0.1 to 1.5%. In contrast, a thick-thin yarn having a U %
of 3 to 10% can be used for non-linear yarn for use in apparel. The
U % can be controlled to a range from 0.1 to 5% by homogeneously
dispersing the islands-part polymer to the order of nanometers. The
U % can further be controlled by optimizing the combination of
polymers, weighing and feeding the polymers independently in
kneading, and/or optimizing spinning conditions such as the opening
diameter of the spinneret and cooling conditions. The thick-thin
yarn having a U % of 3% to 10% for obtaining a non-linear yarn can
be prepared by employing conventional technologies used typically
in PET.
[0185] The polymer alloy fiber preferably has a strength of 2
cN/dtex or more, since the resulting fiber can satisfactorily pass
through processes such as throwing and weaving/knitting process.
The strength is more preferably 2.5 cN/dtex or more, and further
preferably 3 cN/dtex or more.
[0186] The strength of the polymer alloy fiber can be controlled to
2 cN/dtex or more by spinning under such conditions that the
polymers are prevented from decomposing.
[0187] The strength can be controlled to 2.5 cN/dtex or more by
optimizing the kneading procedure. A higher strength can be
obtained by optimizing polymer conditions such as the blending
ratio of the higher soluble polymer, viscosity/concentration of
terminal groups of the polymer, and the comonomer component and/or
optimizing, for example, spinning/drawing conditions and crimping
conditions.
[0188] The polymer alloy fiber preferably has an elongation
percentage of 15 to 70%. The resulting fiber can satisfactorily
pass through processes such as throwing and/or weaving/knitting
process. The elongation percentage is preferably 70 to 200% for use
as a raw yarn for draw false-twisting. The resulting raw yarn can
satisfactorily pass through the false twisting process. The
elongation percentage is preferably about 70 to 500% for use as raw
yarn for drawing, since the resulting yarn can satisfactorily pass
through the drawing process. The elongation percentage of the
polymer alloy fiber can be generally controlled by adjusting the
spinning rate and/or draw ratio.
[0189] A conventional fiber that swells as a result of adsorption
of moisture/water, such as a polyamide fiber, cannot significantly
yield a "highly oriented undrawn yarn" having an elongation
percentage of about 70 to 200%. This is because the fiber swells
during spinning/winding, the wound package deforms and the fiber
cannot be wound. The polymer alloy fiber mainly comprising such a
polymer, however, can yield a highly oriented undrawn yarn by
blending a polymer that does not swell as a result of adsorbing
moisture/water, such as a polyester, in an amount of 5% by weight
or more.
[0190] The polymer alloy fiber is preferably crimped, for increased
bulkiness of the resulting fabric made from the nanoporous fiber.
In the case of a false-twisted yarn, the crimp rigidity (CR) as an
indication of crimping property is preferably 20% or more. The CR
is more preferably 30% or more, and further preferably 40% or more.
In the case of a mechanically crimped yarn or an air-jetted yarn,
the number of crimp as an indication of crimping is 5 or more per
25 mm. The polymer alloy fiber can also be crimped by forming into
a side-by-side or eccentric core-in-sheath conjugated yarn. In this
case, the number of crimp is preferably 10 or more per 25 mm. The
CR can be generally controlled by modifying false twisting
conditions such as crimping procedure and device, the number of
revolutions of twister, and temperature of heater. The CR can be
controlled to 20% or more by setting the temperature of the heater
at [(the melting point of the polymer)-70] (.degree. C.) or higher.
To further increase the CR, increase of the temperature of the
heater and/or reduction in blending ratio of the higher soluble
polymer blend is effective.
[0191] The number of crimp of a mechanically crimped yarn or
air-jetted yarn can be easily controlled to 5 or more per 25 mm by
appropriately selecting the crimping machine or modifying the
conditions such as feeding rate.
[0192] The number of crimp of a side-by-side or eccentric
core-in-sheath conjugated yarn can be controlled to 10 or more per
25 mm, for example, by setting the difference in melt viscosity
between polymers to be conjugated at 2 times or more, or by setting
the difference in thermal shrinkage between polymers upon spinning
separately to 5% or more.
[0193] The polymer alloy fiber can be prepared, for example, by the
following method, but the production method is not specifically
limited thereto.
[0194] Specifically, a lower soluble polymer and a higher soluble
polymer are melted and kneaded to obtain a polymer alloy comprising
the lower soluble polymer and the higher soluble polymer in which
the lower soluble polymer and/or higher soluble polymer is finely
dispersed. This is melt spun to obtain the polymer alloy fiber of
the present invention.
[0195] In this method, the melting and kneading procedure is
important. In other words, the polymers are forcedly kneaded by
using an extrusion-kneader or a static mixer to thereby
significantly reduce coarsely aggregated polymer particles.
[0196] The conventional technique (Japanese Unexamined Patent
Publication (Kokai) No. 56-107069) employs chip blending (dry
blending), thereby invites significant unevenness in blending and
fails to prevent the islands-part polymer from aggregating.
[0197] For forced kneading, a twin-screw extrusion-kneader is
preferably used as the extrusion-kneader, and a static mixer having
a number of splits of 100.times.10.sup.4 or more is preferably used
as the static mixer in the present invention. The polymers to be
kneaded are preferably weighed and fed separately for preventing
uneven blending and/or variation in blending ratio with time. In
this case, the polymers may be separately fed as pellets or as
molten polymers. The two or more different polymers may be fed to a
bottom portion of the extrusion-kneader. Alternatively, one of
these components may be fed in the midway of the extrusion-kneader
in a side feed manner.
[0198] When a twin-screw extrusion-kneader is used as the kneader,
it is preferred that the polymers are highly kneaded while reducing
the residence time of the polymers. The screw comprises a feeding
section and a kneading section. The length of the kneading section
is preferably set at 20% or more of the effective length of the
screw for highly kneading the polymers. The length of the kneading
section is preferably set at 40% or less of the effective length of
the screw. This avoids excessively high shear stress and shortens
the residence time, thus preventing thermal degradation of the
polymers and/or gelation of the polyamide component. The kneading
section is preferably arranged near to the discharge port of the
twin-screw extruder to thereby shorten the residence time after
kneading and to prevent reaggregation of the islands-part polymer.
In addition, a screw having a back-flow function to feed the
polymers in a reverse direction may be arranged in the
extrusion-kneader, for further higher kneading.
[0199] By using a bent-type kneader to aspirate a decomposed gas
during kneading and/or to reduce the moisture in the polymers, the
polymers are prevented from hydrolyzing, and the amount of terminal
amino groups in a polyamide or terminal carboxylic acid groups in a
polyester can be reduced.
[0200] Polymer alloy pellets can thus be prepared by using a
twin-screw extrusion-kneader. Examples of preferred combinations of
polymers from the viewpoint of multiplicity of use are:
[0201] Combination 1: a polyamide and a polyester; and
[0202] Combination 2: a polymer soluble in hot water and a polymer
selected from polyamides, polyesters and polyolefins.
[0203] The average diameter of dispersed polymer particles in
preferred Combination 1 comprising a polyamide and a polyester is
preferably 1 to 50 nm. The area ratio of coarsely dispersed polymer
particles each having a diameter in terms of circle of 100 nm or
more is preferably 3% or less of the total dispersed polymer
particles in a cross section of a pellet. Such pellets hardly yield
coarse islands in the resulting polymer alloy fiber. The amount of
terminal amino groups in the polymer alloy pellets is preferably
6.times.10.sup.-5 molar equivalent or less per gram of the
polyamide, for better spinnability or reduced yarn unevenness.
[0204] In preferred Combination 2 comprising a polymer soluble in
hot water and a polymer selected from polyamides, polyesters and
polyolefins, the blending ratio of the polymer soluble in hot water
serving as a higher soluble component is preferably 10 to 30% by
weight. Thus, an extruded gut derived from the pellets is
satisfactorily spun and cut, whereas the resulting nanoporous fiber
exhibits satisfactory functions. The b* value as an indicator of
coloring of the polymer alloy pellets is preferably 10 or less,
since the resulting fiber can have homogenous hue. Such a polymer
soluble in hot water generally has poor thermal stability and is
susceptible to coloring due to its molecular structure. However,
the coloring can be prevented by shortening the residence time.
Examples of the polymer soluble in hot water are polyesters
copolymerized with a large quantity of hydrophilic groups,
polyalkylene oxides, polyvinyl alcohols, and modified products of
these polymers. Among them, polyetheresters, a kind of polyalkylene
oxide modified products, are preferred for their dissolution rate
and thermal stability.
[0205] The kneader may be arranged separately from a spinning
machine, in which polymer alloy pellets produced in the kneader is
fed to the spinning machine. Alternatively, the kneader is directly
connected to a spinning machine, in which kneaded and molten
polymers are directly spun. When a static mixer is used as the
kneader, it may be placed in a spinning pack.
[0206] The chip blending (dry blending) can be carried out in the
following manner for reducing cost in spinning.
[0207] Initially, polymer pellets to be blended are independently
weighed and fed to a blending tank and are chip-blended therein.
The blending tank preferably has a capacity of 5 to 20 kg for
efficient blending while avoiding uneven blending. The blended
pellets are fed from the blending tank to an extrusion-kneader, to
obtain a molten polymer. The kneading may be carried out by using a
twin-screw extrusion-kneader or by feeding the molten polymer into
a static mixer arranged in a piping or a pack. Master pellets
containing a larger amount of the higher soluble polymer can be
used.
[0208] The master pellets in polymer alloy pellets comprising a
polyamide and a polyester preferably have the following parameters.
Specifically, the polyester is preferably copolymerized with 1.5 to
15% by mole of a sulfonate for better affinity for the polyamide.
The blending ratio thereof is preferably 30 to 90% by weight for
further efficient dilution of the master pellets. The average
weight of the pellets is preferably 2 to 15 mg for matching the
weight of the virgin polyamide and reducing uneven blending.
[0209] The average weight and shape of the pellets are preferably
near to those of polymer pellets to be diluted, for preventing
uneven blending. More specifically, the difference in average
weight between the polymer alloy pellets and the polymer pellets to
be diluted is preferably within a range from -20% to +20%.
[0210] The residence time from formation and melting of the polymer
alloy to discharge from a spinneret is a key factor for inhibiting
reaggregation of the islands-part polymer in spinning to thereby
reduce coarsely aggregated polymer particles. Thus, the residence
time for the polymer alloy from the tip of a melting section to the
spinneret is preferably set within 30 minutes. This requirement
must be met particularly in the case of an alloy comprising a nylon
and a PET copolymerized with hydrophilic groups, since the PET
copolymerized with hydrophilic groups is susceptible to
reaggregation.
[0211] The combination of polymers is an important factor to
disperse the islands-part polymer to the order of nanometers.
Specifically, a combination of a lower soluble polymer and a higher
soluble polymer with a higher affinity allows the higher soluble
polymer to disperse as nano-sized islands more easily. For example,
when a nylon and a polyethylene terephthalate (PET) are used as the
lower soluble polymer and the higher soluble polymer, respectively,
the PET is preferably a PET copolymerized with hydrophilic groups
copolymerized with a sulfonate, a hydrophilic component, such as
5-sodiosulfoisophthalic acid (SSIA) for better affinity for the
nylon. In particular, a hydrophilized PET having a degree of
copolymerization with SSIA of 4% by mole or more is preferred.
[0212] The ratio in melt viscosity of the sea-part polymer to the
islands-part polymer is also an important factor. Specifically, the
islands-part polymer tends to disperse on the order of nanometers
more easily due to an increasing shear force with an increasing
ratio in melt viscosity of the sea-part polymer to the islands-part
polymer. However, an excessively large ratio in viscosity may cause
uneven kneading and/or deteriorated spinnability. The viscosity
ratio is preferably from about 1/10 to 2. In the combination of a
polyester or polyester with a polymer soluble in hot water, the
viscosity ratio is considered to play a more important role than
the affinity between the polymers and is preferably set at 0.5 to
1.5.
[0213] Preferred embodiments of the method for melt-spinning a
polymer alloy fiber according to the present invention are as
follows.
[0214] In a method for melt-spinning a polymer alloy fiber,
comprising the steps of weighing and feeding a lower soluble
polymer and a higher soluble polymer independently to a twin-screw
extrusion-kneader, melting and blending the polymers in the
twin-screw extrusion-kneader to form a polymer alloy, and
melt-spinning the polymer alloy, the step of spinning is preferably
carried out so as to satisfy the following conditions (1) to
(3):
[0215] (1) the content of the higher soluble polymer in the polymer
alloy is 5 to 60% by weight;
[0216] (2) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2; and
[0217] (3) the length of a kneading section of the twin-screw
extrusion-kneader is 20% to 40% of the effective length of the
screws.
[0218] Alternatively, in a method for melt-spinning a polymer alloy
fiber, comprising the steps of weighing and feeding a lower soluble
polymer and a higher soluble polymer independently to a static
mixer having a number of splits of 100.times.10.sup.4 or more,
melting and blending the polymers in the static mixer to form a
polymer alloy, and melt-spinning the polymer alloy, the step of
spinning is preferably carried out so as to satisfy the following
conditions (4) and (5):
[0219] (4) the content of the higher soluble polymer in the polymer
alloy is 5 to 60% by weight; and
[0220] (5) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2.
[0221] Further alternatively, in a method for melt-spinning a
polymer alloy fiber, comprising storing and dry-blending two or
more different pellets comprising a lower soluble polymer and a
higher soluble polymer, respectively, in a blending tank before
melting of the pellets, feeding the dry-blended pellets to a
melting section, and blending and melt-spinning the dry-blended
pellets, the step of spinning is preferably carried out so as to
satisfy the following conditions (6) to (8):
[0222] (6) the content of the higher soluble polymer in the fiber
is 5 to 60% by weight;
[0223] (7) the ratio in melt viscosity of the lower soluble polymer
to the higher soluble polymer is 0.1 to 2; and
[0224] (8) the blending tank can contain 5 to 20 kg of pellets.
[0225] Namely, it is important to set the blending ratio of the
higher soluble polymer at 5 to 60% by weight and to set the melt
viscosity ratio of the lower soluble polymer to the higher soluble
polymer in a range from 0.1 to 2. In addition, important factors
are to set the length of a kneading section in a twin-screw
extrusion-kneader, if used, at 20 to 40% of the effective length of
the screws in melt-blending and melt-spinning using such a
twin-screw extrusion-kneader, or to use a static mixer having a
number of splits of 100.times.10.sup.4 or more in melt-blending and
melt-spinning using such a static mixer, or to use a blending tank
for pellets having a capacity of 5 to 20 kg in dry blending and
melt-spinning. The dry blending is inferior in blending uniformity
but superior in cost to the melt-blending, since the former
comprises a simpler process. In the case of dry blending, the
above-mentioned master pellets are preferably used to prevent
uneven blending to some extent.
[0226] The production methods according to the present invention
have the above-mentioned features, thereby prevent the formation of
coarsely aggregated polymer particles, keep good balance in
viscoelasticity of the polymer alloy, achieve stable spinning and
discharging, significantly improve stringiness or spinnability and
markedly reduce yarn unevenness, as compared with conventional
equivalents.
[0227] For higher spinning stability, the polymers preferably have
low concentrations of terminal groups. In the case of polyamides,
the amount of terminal amino groups is preferably
5.5.times.10.sup.-5 molar equivalent or less per gram. Such
polyamides have less thermal stability than polyesters and are
susceptible to gelation as a result of thermal degradation. In
addition, the present inventors have found in the investigations
for the present invention that a polymer alloy comprising a
polyamide and a polyester is further more susceptible to gelation
than a polyamide alone. This is probably because the molecular
chain terminal of the polyester plays a catalytic role. Such a
gelated polyamide invites yarn breaking and/or yarn unevenness,
leads to increased process pressures such as filtration pressure of
the polymer and back pressure of the spinneret to thereby lower the
upper limit of the discharge rate or shorten the pack life. The
productivity per unit time is markedly decreased and yarn breaking
frequently occurs. Accordingly, such a polyamide/polyester alloy
must be avoided from gelation. Thus, the amount of terminal amino
groups should preferably be 5.5.times.10.sup.-5 molar equivalent or
less per gram by, for example, blocking the amine terminals of the
polyamide to be used in the polymer alloy typically with acetic
acid. When the polyamide/polyester alloy is once pelletized, the
amount of terminal amino groups is preferably set at
6.times.10.sup.-5 molar equivalent or less per gram of the weight
of the polyamide in the polymer alloy pellets.
[0228] The spinning is preferably carried out at temperatures of
300.degree. C. or lower for preventing thermal decomposition and
gelation of the polymers.
[0229] The spinneret preferably has a diameter larger than regular
one. This reduces the shear stress on the polymer alloy in a
spinneret nozzle to keep well-balanced viscoelasticity to thereby
improve the spinning stability. More specifically, the spinneret is
preferably so configured as to discharge the polymer alloy at a
linear velocity of 15 m or less per minute. In addition, cooling of
the line of thread is also important. The distance from the
spinneret to a position at which positive cooling starts is
preferably set at 1 to 15 cm. Thus, the polymer alloy that tends to
be unstable in elongational flow is rapidly solidified to thereby
stabilize the spinning.
[0230] The spinning draft is preferably set at 100 or more for
further finely dispersing the islands-part polymer. The spinning
rate is preferably set at 800 meters or more per minute for
reducing yarn unevenness during spinning of the undrawn yarn. The
spinning rate is more preferably set at 2500 meters or more per
minute to thereby develop the fiber structure, for reducing change
in dimensions and physical properties of the yarn with time.
[0231] The prepared polymer alloy fiber may be subjected to draw
thermal treatment or draw false twisting after being wound or may
be directly subjected to drawing or air-jetting without being
wound.
[0232] The thermal treatment temperature in crimping is preferably
set lower than [(the melting point of the lower soluble
polymer)-50.degree. C.] for preventing fusion in the crimping
process and improving the quality of crimps. The fiber may be
converted into short staples and then converted into a nonwoven
fabric or a spun yarn.
[0233] The resulting yarn can be subjected to yarn mixing such as
air yarn mixing or combined false-twisting, to mixing and twisting
with another yarn, or to mixing of cut fibers or spinning of mixed
cut fibers. The polymer alloy fiber alone or in combination with
another yarn can be formed into a woven or knitted fabric or a
nonwoven fabric or can be formed into a nonwoven fabric by spun
bond or melt blow.
[0234] A fabric at least partially comprising a nanoporous fiber
can be obtained by dissolving off the higher soluble polymer from
the resulting fabric at least partially comprising the polymer
alloy fiber.
[0235] The fabric can be naturally used as a fabric at least
partially comprising the polymer alloy fiber without dissolving off
the higher soluble polymer. In particular, a highly oriented
undrawn yarn can be prepared from a polyamide as described above,
which cannot be achieved by conventional equivalents. Thus, a
fabric comprising a crimped yarn or a combined filament yarn, such
as a combined false twisted yarn, prepared by utilizing this highly
oriented undrawn yarn has an excellent hands with further more
bulkiness and softness than conventional equivalents and is of high
value even used as intact. Some fabrics comprising 100% of the
polymer alloy fiber, other than a combined filament yarn, may
exhibit improved thermal stability and/or mechanical properties by
the action of the nanosized polymer alloy and are of high value as
intact.
[0236] If a fabric comprising 100% of the nanoporous fiber has
insufficient dimensional stability and/or wear resistance, these
requirements may be satisfied by using another yarn in combination,
as mentioned above. In this case, the polymer alloy fiber serving
as a precursor of the nanoporous fiber is subjected to reduction
finish preferably at a rate of 20% by weight or more per hour on
the weight basis of the polymer alloy in dissolution off of the
higher soluble polymer.
[0237] As is described above, the nanoporous fibers of the present
invention can be prepared by using the polymer alloy fiber which is
prepared by a method unlike conventional equivalents. They have
pores with less dimensions than conventional equivalents, are
substantially free from coarse pores, can yield excellent materials
usable in clothing and other various fields and are
epoch-making.
EXAMPLES
[0238] The present invention will now be described in detail by way
of the following examples. The physical properties in the examples
were determined by the following methods.
[0239] A. Melt Viscosity of Polymer:
[0240] The melt viscosity of a sample polymer was determined using
Capillograph 1B available from Toyo Seiki Seisaku-Sho, Ltd. The
residence time of the sample polymer from charging of the sample to
the beginning of determination was set at 10 minutes.
[0241] B. Relative Viscosity of Nylon:
[0242] Sample nylon pellets were dissolved in a 98% sulfuric acid
solution to a concentration of 0.01 mg/ml, and the relative
viscosity was determined at 25.degree. C.
[0243] C. Intrinsic Viscosity [.eta.] of Polyester:
[0244] The intrinsic viscosity was determined in o-chlorophenol at
25.degree. C.
[0245] D. Melting Point:
[0246] The melting point was defined as the peak top temperature at
which a sample polymer melted in a second run as determined using
Perkin Elmaer DSC-7 at a temperature elevation rate of 16.degree.
C. per minute ad an amount of the sample of 10 mg.
[0247] E. Mechanical Properties:
[0248] A load-elongation curve was determined at room temperature
(25.degree. C.) and a tension speed of 100% per minute under
conditions shown in Japanese Industrial Standards (JIS) L1013. In
this procedure, the strength was defined by dividing the load at
break by the initial fineness, and the elongation was defied by
dividing elongation at break by the initial length of the sample.
From these parameters, a strength elongation percentage curve was
determined.
[0249] F. Uster Unevenness (U %) of Polymer Alloy Fiber:
[0250] The Uster unevenness was determined using USTER TESTER 4
available from Zellweger Uster in a normal mode at a yarn feed
speed of 200 m per minute.
[0251] G. Thermal Shrinkage: Thermal shrinkage
(%)=[(L0-L1)/L0)].times.100(%)
[0252] L0: The original length of a skein wound from drawn yarn as
determined at an initial tension of 0.09 cN/dtex
[0253] L1: The length of the skein at an initial tension of 0.09
cN/dtex after determination of L0, treatment in boiled water for
fifteen minutes under substantially no load and air-drying.
[0254] H. TEM Observation of Cross Section of Fiber:
[0255] Ultrathin peaces of a sample fiber in a cross-sectional
direction or a longitudinal sectional direction were prepared, and
the cross sections of the fiber were observed using a transmission
electron microscope (TEM). Where necessary, the sections were
subjected to metal staining.
[0256] TEM device: Model H-7100FA available from Hitachi Ltd.
[0257] I. Diameters of Pores or Island-Component Polymer:
[0258] The diameter of pores was determined in the following
manner. The diameters of islands in terms of circle were determined
from TEM photographs of the cross section of the fiber using an
image processing software (WINROOF). If the shapes of the islands
were excessively fine or complicated and the analyses thereof by
WINROOF was difficult, the shapes were analyzed by visual
observation manually. The average diameter was determined as a
simple number-average of the determined diameters.
[0259] The average diameter was determined by using 300 or more
pores selected at random in one cross section. The diameter
determination was carried out carefully in consideration of the
condition of the sample, because such ultrathin samples for TEM
observation often cause breakage. Inorganic fine particles and
voids therearound were not included in the pores. The diameter of
the islands-part polymer was determined in accordance with the
determination of the diameters of the pores.
[0260] J. Evaluation of Color Property:
[0261] A prepared sample was dyed according to a conventional
procedure, and the color property was compared with that of a
comparative sample dyed under the same conditions. The comparative
sample was prepared by spinning polymers constituting a nanoporous
fiber according to a conventional procedure in the following
manner.
[0262] In the case of a nylon, a sample fibrous article was dyed
with a stain solution containing a dye "Nylosan Blue N-GFL"
available from Clariant Japan Co., Ltd. at pH 5 in a concentration
of 0.8% by weight of the fibrous article at a liquor-goods ratio of
100 at 90.degree. C. for 40 minutes.
[0263] In the case of a polyester, a sample fibrous article was
dyed with a stain solution containing a dye "Foron Navy S-2GL"
available from Clariant Japan Co., Ltd. at pH 5 in a concentration
of 0.8% by weight of the fibrous article at a liquor-goods ratio of
100 at 130.degree. C. (110.degree. C. in the case of polylactic
acid) for 40 minutes.
[0264] The color property of the sample was determined according to
the following four criteria. "Excellent" and "Good" were passed the
test, and "Fair" and "Failure" were not passed the test.
[0265] Excellent: almost equal to or high than that of the
comparative sample
[0266] Good: somewhat lower than that of the comparative sample but
enough for use in clothing
[0267] Fair: somewhat lower than that of the comparative sample
[0268] Failure: significantly lower than that of the comparative
sample
[0269] K. Ratio of Moisture Adsorption (.DELTA.MR):
[0270] About 1 to 2 g of a sample was weighed in a weighing bottle,
dried at 110.degree. C. for 2 hours, and the weight of the dried
sample (W0) was determined. Next, the sample substance was held to
20.degree. C. at relative humidity of 65% for 24 hours, whose
weight was then determined (W65), and the sample substance was then
held to 30.degree. C. at relative humidity of 90% for 24 hours,
whose weight was then determined (W90). The ratio of moisture
adsorption (.DELTA.MR) was determined by calculation according to
the following equations. MR65=[(W65-W0)/W0].times.100% (1)
MR90=[(W90-W0)/W0].times.100% (2) .DELTA.MR=MR90-MR65 (3)
[0271] L. Reversible Water Swelling and Percentage of Swelling in
Longitudinal Direction of Yarn:
[0272] The original length (L0') of a sample fiber was determined
after drying the fiber at 60.degree. C. for 4 hours. The fiber was
immersed in water at 25.degree. C. for 10 minutes and was taken
out, and the length of the fiber after treatment (L1') was
determined immediately thereafter. The length of the fiber after
drying (L2') was then determined after drying the fiber at
60.degree. C. for 4 hours.
[0273] The procedure of drying and immersion in water was repeated
a total of three times. The sample was evaluated to have reversible
water swelling when it showed a percentage of swelling in a
longitudinal direction of the yarn in the third procedure of 50% or
more of that in the first procedure. The percentage of swelling in
a longitudinal direction of the yarn was determined by calculation
according to the following equation. The length of the fiber was
determined by binding the sample fiber with two colored yarns at an
interval of about 100 mm, and measuring the length between the two
yarns. Percentage of swelling (%) in longitudinal direction of the
yarn=((L1'-L0')/L0').times.100(%)
[0274] M. Percentage of Water Retention:
[0275] The percentage of water retention was determined in the
following manner. Initially, a sample was allowed to adsorb water
sufficiently by immersing in water at 25.degree. C. for one hour,
hanged on a hanger for one minute, and dewatered in a domestic
washing machine for 3 minutes to remove excess water on the surface
of the fiber or in cavities between fibers. In this procedure, the
weight of the fabric sample (W.sub.1) was determined, and, after
drying at 60.degree. C. for one hour, the dry weight (W.sub.0) of
the sample fabric was determined. Percentage of water retention
(%)={(W.sub.1-W.sub.0)/W.sub.0}.times.100(%)
[0276] N. Ammonia Adsorbing Rate
[0277] 1 g of a sample fabric comprising 100% of a nanoporous fiber
was placed in a 5-liter Tedlar bag, and 3 liters of a gas
containing ammonia was introduced into the bag to adjust the
initial concentration (C.sub.0) at 40 ppm. The gas was sampled from
the Tedlar bag 2 hours later, and the ammonia concentration
(C.sub.1) was determined. Separately, a blank test without using a
fabric sample is carried out, and the ammonia concentration 2 hours
later (C.sub.B) was determined. The ammonia adsorbing rate was
determined by calculation according to the following equation.
Ammonia adsorbing rate
(%)={(C.sub.B-C.sub.1)/C.sub.B}.times.100(%)
[0278] O. Crimping Property CR of False-Twisted Yarn:
[0279] A sample false-twisted yarn was wound, treated in boiling
water for 15 minutes under substantially no load and air-dried for
24 hours. The sample was immersed in water under a load of 0.088
cN/dtex (0.1 gf/d), and the length of the skein 2 minutes later
(L0'') was determined. Then the load of 0.088 cN/dtex was replaced
with a slight load of 0.0018 cN/dtex (2 mgf/d) in water, and the
length of the skein 2 minutes later (L1'') was determined. CR was
determined by calculation according to the following equation.
CR(%)=[(L0''-L1'')/L0''].times.100(%)
[0280] P. Number of Crimps:
[0281] A sample fiber 50 mm long was sampled, the number of crimp
(peaks) per 25 mm was determined, and the number of crimp was
defined as the half of the above-determined value.
[0282] Q. Color Tone (b*):
[0283] The color tone b* was determined using a MINOLTA
SPECTROPHOTOMETER CM-3700d with a light source of D65 (color
temperature of 6504K) in a visual field of 10 degrees.
Example 1
[0284] A N6 (80% by weight) and a copolymerized PET (20% by weight)
were melted and kneaded in a twin-screw extrusion-kneader at
260.degree. C. to obtain polymer alloy pellets. The N6 had a
relative viscosity of 2.15, a melt viscosity of 274 poises
(280.degree. C. at a rate of shear of 2432 sec.sup.-1), a melting
point of 220.degree. C., and an amount of terminal amino groups of
5.0.times.10.sup.-5 molar equivalent per gram as a result of
blocking amine terminals with acetic acid. The copolymerized PET
had an intrinsic viscosity of 0.60, a melt viscosity of 1400 poises
(280.degree. C. at a rate of shear of 2432 sec.sup.-1) and a
melting point of 250.degree. C., had been copolymerized with 5% by
mole of 5-sodiosulfoisophthalic acid and contained 0.05% by weight
of titanium oxide.
[0285] The transmission electron micrograph of a cross section of
the polymer alloy pellets is shown in FIG. 5. The copolymerized PET
as islands had diameters in terms of circle of 20 to 30 nm (average
diameter of dispersed particles of 26 nm) and were substantially
free from coarse islands each having a diameter in terms of circle
of 100 nm or more. Thus, the copolymerized PET was homogeneously
dispersed with size on the order of nanometers in N6.
[0286] The average weight of the pellets was 3 mg, and the amount
of terminal amino groups is 3.3.times.10.sup.-5 molar equivalent
per gram of the weight of N6. The kneading conditions are as
follows.
[0287] Screw type: one-direction fully interlocking double
shred
[0288] Screw: diameter of 37 mm, effective length of 1670 mm,
[0289] L/D=45.1 [0290] The length of the kneading section was 28%
of the effective length of the screw. [0291] The kneading section
was arranged on the discharge side from one-thirds of the effective
length of the screw. [0292] Having three back flow sections in the
midway
[0293] Feed of polymer: N6 and the copolymerized PET were
independently weighed and were separately fed to the kneader.
[0294] Temperature: 260.degree. C.
[0295] Vent: 2 points
[0296] The polymer alloy was melted in a melting section 2 at
270.degree. C. and introduced to a spin block at a spinning
temperature of 275.degree. C. The molten polymer alloy was
filtrated through a metallic nonwoven fabric having a diameter of
ultrafiltration of 15 .mu.m and subjected to melt spinning (FIG.
28). The residence time from the melting section 2 to discharge was
10 minutes. In this procedure, a spinneret having an orifice
diameter of 0.3 mm and an orifice length of 0.65 mm was used, at a
discharge rate per orifice of 2.1 g per minute and a linear
velocity of the discharged polymer alloy in the spinneret of 28
meters per minute. The distance between the lower end of the
spinneret to the start point of cooling (upper end of a cooling
equipment 5) was 9 cm. The discharged thread was cooled and
solidified by a cooling air at 20.degree. C. over one meter, fed
with an oil by an finishing guide 7 arranged 1.8 meter down the
spinneret 4 and wound through a first take-up roller 8 and a second
take-up roller 9 not heated at a rate of 3800 meters per
minute.
[0297] In this procedure, the fiber showed good spinnability and
was free from, for example, Barus phenomenon in which the
discharged polymer swells directly below the spinneret, or end
breakage due to insufficient stringiness or spinnability. The fiber
invited no yarn breaking during continuous spinning for 24 hours.
The yarn did not cause deformation of the wound package due to
swelling with time, which constitutes a problem in regular nylon
yarns, and showed good handleability.
[0298] The undrawn polymer alloy yarn had satisfactory physical
properties such as a strength of 2.6 cN/dtex, an elongation
percentage of 138% and a U % of 0.9%. This undrawn yarn was
subjected to draw false-twisting using a device shown in FIG. 29,
to obtain a false-twisted polymer alloy yarn with false-twisting
directions of S and Z. This procedure was carried out at a draw
ratio of 1.5, a temperature of a heater 13 of 165.degree. C., using
a friction type false twisting machine with
three-axes-urethane-disk as a twister 15. The ratio of the surface
velocity of rotated disks to the speed of texturing (D/Y ratio) was
set at 1.65. The yarn was satisfactorily processed without end
breakage and winding around the roller and twister.
[0299] The resulting 87 dtex, 24-filament false-twisted yarn had
excellent physical properties including a strength of 2.7 cN/dtex,
an elongation percentage of 21%, a thermal shrinkage of 8%, a U %
of 1.0% and a CR of 38% (Table 2) and showed good crimping quality
without not-untwisted portions.
[0300] The cross section of a mono-filament of the resulting
crimped polymer alloy yarn was observed under a TEM and was found
to have an islands-in-sea structure comprising N6 as a sea (dark
region) and the copolymerized PET as islands (bright region) (FIG.
3) with an average diameter of the islands of 25 nm. Thus, a
polymer alloy fiber comprising the copolymerized PET homogeneously
dispersed with size on the order of nanometers was prepared.
[0301] The area ratio of islands each having a diameter of 200 nm
or more to the total islands was 0.1% or less, and the area ratio
of islands each having a diameter of 100 nm or more was 0.9%. The
"area ratio to the total islands" refers to the area ratio to the
total area of the islands parts and serves as an indicator of
coarse polymer aggregates. The TEM observation of the longitudinal
section of the fiber shows that the islands constitute a lined
structure (FIG. 4). The transmission electron micrograph of a cross
section of the melt-kneaded polymer alloy chip is shown in FIG. 5,
showing that the islands-part polymer is ultrafinely dispersed with
a particle diameter of 20 to 30 nm, being equivalent to the
diameter of the islands-part polymer at cross section of a fiber
(FIG. 3). The polymer was elongated by a factor of about 200 times
from discharge from the spinneret through draw false-twisting.
Thus, the diameter of the islands-part polymer of the fiber in a
cross section should be one-fourteenths or less that in the
material polymer alloy. However, the diameter of the islands-part
polymer at cross section of a fiber is substantially equal to that
in the material chip. This indicates that the islands-part polymer
reaggregated between melting of the polymer alloy and discharging
from the spinneret. To allow the islands-part polymer to disperse
homogeneously with size on the order of nanometers while preventing
the reaggregation, the spinning conditions should be essentially
chosen appropriately, as in the present example.
[0302] The false-twisted polymer alloy yarns with false-twisting
directions of S and Z were aligned and knitted into a round braid
of 20 G. The round braid was treated with a 3% by weight aqueous
sodium hydroxide solution (95.degree. C., liquor ratio of 1:50) for
one hour to dissolve off 99% or more of the copolymerized PET from
the false-twisted polymer alloy yarn to thereby obtain a fibrous
article comprising a nanoporous N6 fiber and having a bulkiness of
63 cm.sup.3/g.
[0303] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property without dyeing
speck. This article had a ratio of moisture adsorption (.DELTA.MR)
of 5.6% and exhibited much higher hygroscopicity than cotton.
[0304] The side of the nanoporous N6 fiber sampled from the round
braid was observed under a SEM to find that the fiber had a smooth
surface without unevenness at a magnification of about 2000 times.
The cross section of the nanoporous N6 fiber was observed under a
TEM (FIG. 1) to find pores each having a diameter of about 20 to 30
nm. The pores had an average of 25 nm and were substantially free
from coarse pores each having a diameter of 50 nm or more.
[0305] This fiber had unconnected pores as shown in FIG. 1 and had
a strength of 2.0 cN/dtex and an elongation percentage of 25%,
showing that the fiber had sufficient mechanical properties as a
fibrous article. This exhibited reversible water swelling, and the
yarn sampled from the round braid comprising the nanoporous N6
fiber after setting at 180.degree. C. for one minute had a
percentage of swelling in a longitudinal direction of the yarn of
7.3%. The physical properties of the nanoporous N6 fiber are shown
in Table 1.
Example 2
[0306] The N6 and the copolymerized PET were subjected to
melt-kneading by the procedure of Example 1, except for blending
95% by weight of N6 and 5% by weight of the copolymerized PET. The
kneaded product was subjected to melt spinning and draw
false-twisting by the procedure of Example 1, except for changing
the discharge rate per one orifice and the number of spinneret
orifices, to obtain a 90 dtex, 34-filament crimped polymer alloy
yarn. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours.
[0307] The resulting highly oriented undrawn yarn had excellent
properties including a strength of 2.7 cN/dtex and a U % of 0.8%.
The yarn showed good processability without any yarn breaking in
the draw false-twisting process. The crimped yarn had a high
bulkiness in terms of a CR of 45% and exhibited excellent crimping
quality with satisfactory untwisting. The cross section of the
resulting crimped polymer alloy yarn was observed under a TEM and
was found to have an islands-in-sea structure. The resulting
polymer alloy fiber comprises the copolymerized PET homogeneously
dispersed with size on the order of nanometers. The islands had an
average diameter of 20 nm. The area ratio of islands each having a
diameter of 200 nm or more to the total islands was 0.1% or less,
and the area ratio of islands each having a diameter of 100 nm or
more was 1% or less. The observation of a cross section of the
fiber shows that the islands-part polymer has a lined structure.
The physical properties of the false-twisted yarn are shown in
Table 2.
[0308] The crimped polymer alloy yarn was subjected to
soft-twisting of 300 T/m, and a plain woven fabric was formed by
using the soft-twisted yarn as a warp and a weft, from which 99% or
more of the copolymerized PET was removed by an alkali treatment by
the procedure of Example 1, to thereby obtain a woven fabric
comprising a nanoporous N6 fiber.
[0309] The woven fabric comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property without dyeing
speck. The cross section of the nanoporous N6 fiber sampled from
the woven fabric was observed under a TEM, to find that holes from
which the islands-part polymer was removed constitute unconnected
pores having an average diameter of 25 nm without coarse pores
having a diameter of 50 nm or more. The nanoporous N6 fiber has
excellent physical properties as shown in Table 1.
Example 3
[0310] The N6 and the copolymerized PET were subjected to
melt-kneading by the procedure of Example 1, except for blending
90% by weight of N6 and 10% by weight of the copolymerized PET. The
kneaded product was subjected to melt spinning and draw
false-twisting by the procedure of Example 1, except for changing
the discharge rate per one orifice and the number of spinneret
orifices, to obtain a 90 dtex, 34-filament crimped polymer alloy
yarn. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours. The resulting
highly oriented undrawn yarn showed excellent properties including
a strength of 2.7 cN/dtex and a U % of 0.8%. The yarn showed good
processability without any yarn breaking in the draw false-twisting
process. The crimped yarn had a high bulkiness in terms of a CR of
40% and exhibited excellent crimping quality with satisfactory
untwisting.
[0311] The cross section of the crimped polymer alloy yarn was
observed under a TEM and was found to have an islands-in-sea
structure. The islands had an average diameter of 25 nm, showing
that the polymer alloy fiber comprises the copolymerized PET
homogeneously dispersed with size on the order of nanometers. The
area ratio of islands each having a diameter of 200 nm or more to
the total islands was 0.1% or less, and the area ratio of islands
each having a diameter of 100 nm or more was 1% or less. The
observation of a cross section of the fiber shows that the
islands-part polymer has a lined structure. The physical properties
of the false-twisted yarn are shown in Table 2.
[0312] The crimped polymer alloy yarn was subjected to
soft-twisting of 300 T/m, and a plain woven fabric was formed by
using the soft-twisted yarn as a warp and a weft, from which 99% or
more of the copolymerized PET was removed by an alkali treatment by
the procedure of Example 1, to thereby obtain a woven fabric
comprising a nanoporous N6 fiber. The woven fabric comprising the
nanoporous N6 fiber was dyed and was found to have excellent color
property without dyeing speck. The cross section of the nanoporous
N6 fiber sampled from the woven fabric was observed under a TEM, to
find that holes from which the islands-part polymer was dissolved
off constitute unconnected pores having a diameter of 20 nm or less
without coarse pores having a diameter of 50 nm or more. The
nanoporous N6 fiber has excellent physical properties as shown in
Table 1
Example 4
[0313] The N6 and the copolymerized PET were subjected to
melt-kneading by the procedure of Example 1, except for blending
50% by weight of N6 and 50% by weight of the copolymerized PET. The
kneaded product was subjected to melt spinning and draw
false-twisting by the procedure of Example 1, except for changing
the discharge rate per one orifice and the number of spinneret
orifices, to obtain a 150 dtex, 34-filament crimped polymer alloy
yarn. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours.
[0314] The resulting highly oriented undrawn yarn showed excellent
properties of a strength of 2.5 cN/dtex and a U % of 1.0%. The yarn
showed good processability without any yarn breaking in the draw
false-twisting process. The crimped yarn exhibited excellent
crimping quality with satisfactory untwisting. A transmission
electron micrograph of a cross section of the crimped polymer alloy
yarn is shown in FIG. 6, showing that the copolymerized PET
constitutes beaded islands each having a diameter of 10 to 20 nm
and is free from coarsely aggregated polymer particles. The area
ratio of islands each having a diameter of 200 nm or more to the
total islands was 0.1% or less, and the area ratio of islands each
having a diameter of 100 nm or more was 1% or less. The observation
of a cross section of the fiber shows that the islands-part polymer
has a lined structure. The physical properties of the false-twisted
yarn are shown in Table 2.
[0315] The crimped polymer alloy yarn was subjected to
soft-twisting of 300 T/m, and a plain woven fabric was formed by
using the soft-twisted yarn as a warp and a weft, from which 99% or
more of the copolymerized PET was removed by an alkali treatment by
the procedure of Example 1, to thereby obtain a woven fabric
comprising a nanoporous N6 fiber. The woven fabric comprising the
nanoporous N6 fiber was dyed and was found to have excellent color
property without dyeing speck. The cross section of the nanoporous
N6 fiber sampled from the woven fabric was observed under a TEM, to
find that holes from which the islands-part polymer was dissolved
off constitute unconnected pores having an average diameter of 25
nm without coarse pores having a diameter of 50 nm or more (FIG.
7). The nanoporous N6 fiber has excellent physical properties as
shown in Table 1.
Example 5
[0316] The N6 and the copolymerized PET were subjected to melt
kneading, melt spinning and draw false-twisting by the procedure of
Example 1, except for setting the ratio in melt viscosity of N6 to
the copolymerized PET at 0.9 and the amount of terminal amino
groups at 6.5.times.10.sup.-3 molar equivalent per gram of N6. The
N6 in the polymer alloy contained a large amount of terminal amino
groups (6.2.times.10.sup.-3 molar equivalent per gram). Thus, the
fiber showed somewhat lower spinnability than that in Example 1,
although it is trivial as showing two yarn breakings during
continuous spinning for 24 hours. The resulting highly oriented
undrawn yarn exhibited somewhat large yarn unevenness and had a U %
of 2%. The highly oriented undrawn yarn had a strength of 2.5
cN/dtex. Untwisting in the draw false-twisting process was somewhat
unstable and the resulting yarn showed some not-untwisted portions
as compared with Example 1.
[0317] The resulting crimped polymer alloy yarns were free from
coarsely aggregated polymer particles. The area ratio of islands
each having a diameter of 200 nm or more to the total islands was
0.1% or less, and the area ratio of islands each having a diameter
of 100 nm or more was 1% or less. The islands-part polymer
constituted a lined structure. The crimped yarn had a CR of 32% but
exhibited somewhat large yarn unevenness of a U % of 2.2% due to
large yarn unevenness during spinning, as compared with Example 1.
The physical properties of the false-twisted yarn are shown in
Table 2.
[0318] The crimped polymer alloy yarn was subjected to circular
knitting by the procedure of Example 1, and 99% or more of the
copolymerized PET was removed from the resulting round braid by an
alkali treatment, to thereby obtain a round braid comprising a
nanoporous N6 fiber having unconnected pores each having a diameter
of 100 nm or less. The round braid comprising the nanoporous N6
fiber was dyed and was found to have excellent color property but
exhibit some dyeing speck. The nanoporous N6 fiber had excellent
physical properties as shown in Table 2.
Example 6
[0319] The polymer alloy prepared according to Example 1 was
subjected to melt spinning in the same way as Example 1. A
spinneret used in this procedure contained a weighing section 18
having a diameter of 0.2 mm on the top of a discharge orifice as
shown in FIG. 30 and had an orifice diameter 20 of 0.5 mm and an
orifice length 19 of 1.25 mm. The discharge rate per one orifice
was set at 2.1 g per minute, and the linear velocity of the
discharged polymer alloy in the spinneret was set at 10 meters per
minute. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours. The yarn did not
cause deformation of the wound package due to swelling with time,
which constitutes a problem in regular nylon yarns, and showed good
handleability. This was then subjected to draw false-twisting by
the procedure of Example 1, except for setting the draw ratio at
1.3.
[0320] The resulting 50 dtex, 12-filament false-twisted yarn
exhibited excellent physical properties including a strength of 3.5
cN/dtex, an elongation percentage of 29%, a thermal shrinkage of 8%
and a CR of 38% (Table 2). The cross section of the crimped polymer
alloy yarn was observed under a TEM and was found that the yarn had
an islands-in-sea structure comprising N6 as a sea (dark region)
and the copolymerized PET as islands (bright regions). The islands
had an average diameter of 25 nm, showing that the polymer alloy
fiber comprises the copolymerized PET homogeneously dispersed with
size on the order of nanometers. The area ratio of islands each
having a diameter of 200 nm or more to the total islands was 1% or
less. The TEM observation of the longitudinal section of the fiber
shows that the islands has a lined structure. The physical
properties of the false-twisted yarn are shown in Table 2.
[0321] A round braid was prepared by using the crimped polymer
alloy yarn as an S-twist/Z-twist two ply yarn and was immersed in a
3% aqueous sodium hydroxide solution (90.degree. C., liquor ratio
of 1:100) for one hour to thereby remove 99% or more of the
copolymerized PET in the polymer alloy fiber upon hydrolysis. After
washing with water and drying, a round braid comprising a
nanoporous N6 fiber was obtained.
[0322] The cross section of the nanoporous N6 fiber was observed
under a TEM to find that the fiber contained no coarse pores each
having a diameter of 50 nm or more and had an average diameter of
pores of 25 nm. In the TEM observation, the dark region corresponds
to the N6 polymer, and the bright regions correspond to the pores,
showing that the pores are unconnected pores.
[0323] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property. In addition, this
article had a ratio of moisture adsorption (.DELTA.MR) of 5.6% and
showed much higher hygroscopicity than cotton. The article had a
strength of 2.6 cN/dtex and an elongation percentage of 30%,
showing to have sufficient mechanical properties as a fibrous
article. This exhibited reversible water swelling, and the yarn
sampled from the round braid comprising the nanoporous N6 fiber
after setting at 180.degree. C. for one minute had a percentage of
swelling in a longitudinal direction of the yarn of 7%. The
physical properties of the nanoporous N6 fiber are shown in Table
1.
Example 7
[0324] Materials were subjected to melt kneading, melt spinning and
draw false-twisting by the procedure of Example 6, except for using
a N6 having a melt viscosity of 1260 poises (280.degree. C. at a
rate of shear of 2432 sec.sup.-1) and containing terminal amino
groups in an amount of 5.0.times.10.sup.-5 molar equivalent per
gram of N6, setting the ratio in melt viscosity at 0.9 and changing
the discharge rate per one orifice and the number of spinneret
orifices. The resulting 105 dtex, 96-filament crimped polymer alloy
yarn had a strength of 3.8 cN/dtex, an elongation percentage of
29%, a thermal shrinkage of 8% and a CR of 35% (Table 2). The cross
section of the fiber of the crimped polymer alloy yarn was observed
under a TEM, to find that the yarn was free from coarsely
aggregated polymer particles, that the area ratio of islands each
having a diameter of 200 nm or more to the total islands was 0.1%
or less, and that the area ratio of islands each having a diameter
of 100 nm or more was 1% or less. The TEM observation of the
longitudinal section of the fiber shows that the islands has a
lined structure.
[0325] A round braid was prepared by using the crimped polymer
alloy yarn as an S-twist/Z-twist two ply yarn by the procedure of
Example 1, from which 99% or more of the copolymerized PET was
removed by an alkali treatment, to thereby obtain a round braid
comprising a nanoporous N6 fiber.
[0326] The cross section of the nanoporous N6 fiber was observed
under a TEM, to find that pores from which the islands-part polymer
had been removed had an average diameter of 20 nm and were free
from coarse pores each having a diameter of 50 nm or more. The
pores were unconnected pores.
[0327] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property. The nanoporous N6
fiber has excellent physical properties as shown in Table 1.
TABLE-US-00001 TABLE 1 Average pore Area Area Percentage diameter
ratio 1 ratio 2 Strength .DELTA.MR Color Adsorbing of water (nm)
(%) (%) (cN/dtex) (%) property rate (%) retention (%) Example 1 25
0 0 2.0 5.6 Excellent 60 85 Example 2 25 0 0 3.8 3.6 Excellent 45
67 Example 3 25 0 0 3.0 4.2 Excellent 52 76 Example 4 25 0 0 2.0
6.0 Excellent 62 90 Example 5 20 0 0 1.8 5.0 Good 55 80 Example 6
25 0 0 2.6 5.6 Excellent 60 82 Example 7 20 0 0 3.0 5.5 Excellent
60 82 Average pore diameter: Average pore diameter estimated based
on TEM observation Area ratio 1: Area ratio of pores having a
diameter of 200 nm or more to the total fiber Area ratio 2: Area
ratio of pores having a diameter of 50 nm or more to the total
fiber Adsorbing rate: Ammonia adsorbing rate
[0328] TABLE-US-00002 TABLE 2 N6 polymer Average NH.sub.2 Area
diameter Thermal concentration ratio of islands Strength CR U %
shrinkage (mol/g) wt % (%) (nm) Spinnability (cN/dtex) (%) (%) (%)
Example 1 5.0 .times. 10.sup.-5 80 0.1 or less 25 Good 2.7 38 1.0 8
Example 2 5.0 .times. 10.sup.-5 95 0.1 or less 20 Good 4.0 45 0.8
12 Example 3 5.0 .times. 10.sup.-5 90 0.1 or less 25 Good 3.5 40
0.9 11 Example 4 5.0 .times. 10.sup.-5 50 0.1 or less 18 Good 2.5
35 1.2 8 Example 5 6.5 .times. 10.sup.-5 80 0.1 or less 20 Fair 2.5
32 2.2 9 Example 6 5.0 .times. 10.sup.-5 80 0.1 or less 25 Good 3.5
38 1.5 8 Example 7 5.0 .times. 10.sup.-5 80 0.1 or less 20 Good 3.8
35 1.5 8 Area ratio: Area ratio of pores having a diameter of 200
nm or more to the total islands
Example 8
[0329] The N6 and the copolymerized PET used in Example 1 were
melted at 270.degree. C. and 290.degree. C., respectively using an
apparatus shown in FIG. 31 and were divided and mixed at
104.times.10.sup.4 splits by a static mixer 21 ("Hi-Mixer",
available from Toray Engineering Co., Ltd., 10 steps) arranged in a
pack 3. The mixture was filtrated through a metallic nonwoven
fabric filter having an absolute filtration diameter of 20 .mu.m
and was discharged from spinneret orifices each having a diameter
of 0.35 mm at a spinning temperature of 280.degree. C. and a
distance from the spinneret 4 to the top of the cooling equipment 5
of 7 cm. The resulting article was drawn at a spinning rate of 900
meters per minute and was wound via a second take-up roller 9. The
fiber showed good spinnability without any yarn breaking during
continuous spinning for 24 hours. This article was then subjected
to draw thermal treatment using a device shown in FIG. 32 at a draw
ratio of 3.2, a temperature of a first hot roller 24 of 70.degree.
C. and a temperature of a second hot roller 25 of 130.degree. C.
The fiber showed good drawability without any yarn breaking during
the draw thermal treatment.
[0330] Thus, a 56 dtex, 12-filament polymer alloy fiber having a U
% of 1.5% was prepared. The cross section of the fiber was observed
under a TEM to find that an N6 portion dyed thick and a PET portion
dyed thin by metal staining constituted a special layered
structure, and the PET layer had a thickness of about 20 nm (FIG.
8). In a portion about 150 nm deep from the fiber surface layer,
the special layered structure broken and was converted into an
islands-in-sea structure. However, the area ratio of the special
layered structure to the total cross section of the fiber was 98%,
showing that the special layered structure occupied almost all of
the fiber section (FIG. 9). The longitudinal section of the polymer
alloy fiber was observed under a TEM to find that layers extended
as lines (FIG. 10). The physical properties of the polymer alloy
fiber are shown in Table 4.
[0331] The polymer alloy fiber was formed into a round braid with
good processability without any trouble in the knitting process.
The round braid was immersed in a 3% aqueous sodium hydroxide
solution at 95.degree. C. for one hour, to completely remove the
PET from the polymer alloy fiber, to thereby obtain a round braid
comprising a nanoporous N6 fiber.
[0332] The round braid showed hygroscopicity in terms of .DELTA.MR
of 5.7%, much higher than that of cotton.
[0333] The cross section of the nanoporous fiber was observed under
a TEM (FIG. 11) to find that the nanoporous fiber had a finer
pattern of dark region and bright regions than the original polymer
alloy fiber upon metal staining. The dark region corresponds to a
portion with high density of N6, and the bright regions correspond
to portions with a low density of N6. The bright regions are
considered to correspond to pores. The pores have an average
diameter of 10 to 20 nm. These results show that the fiber was free
from coarse pores each having a diameter of 50 nm or more. FIG. 11
does not clearly show whether the pores are unconnected pores or
connected pores, but the pores are determined as unconnected pores,
because the low density portions are arrayed in lines in the
observation of a longitudinal section (FIG. 12).
[0334] The round braid prepared from the nanoporous N6 fiber was
dyed and was found to have excellent color property. The nanoporous
N6 fiber had excellent physical properties as shown in Table 3.
Example 9
[0335] The N6 and the copolymerized PET were subjected to melt
spinning by the procedure of Example 8, except for blending 50% by
weight of N6 and 50% by weight of the copolymerized PET. The fiber
showed good spinnability without any yarn breaking during
continuous spinning for 24 hours. This article was subjected to
draw thermal treatment by the procedure of Example 8 and showed
good drawability without any yarn breaking.
[0336] The cross section of the polymer alloy fiber was observed
under a TEM, and the result is shown in FIG. 13. The copolymerized
PET constituted beaded islands comprising connected fine islands
each having a diameter of about 10 to 20 nm and was free from
coarsely aggregated polymer particles. The area ratio of islands
each having a diameter of 200 nm or more to the total islands was
0.1% or less, and the area ratio of islands each having a diameter
of 100 nm or more was 1% or less. The TEM observation of the
longitudinal section of the fiber shows that the islands has a
lined structure. The yarn had excellent physical properties as
shown in Table 4.
[0337] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 8, from which 99% or more of the
copolymerized PET was removed by an alkali treatment, to thereby
obtain a round braid comprising a nanoporous N6 fiber.
[0338] The cross section of the nanoporous N6 fiber observed under
a TEM is shown in FIG. 14, showing a fine thick-thin pattern (dark
and light pattern) of about 10 to 20 nm and pores each having a
diameter of 20 nm or less. The average diameter of pores is
estimated from this result as being 10 to 20 nm. The observation of
the longitudinal section of the fiber (FIG. 15) shows unclear
lines, indicating that the pores are connected with each other to
form connected pores. Thus, nanoporous fibers having connected
pores can be obtained only by employing the specific combination of
polymers, specific kneading procedure and specific blending
ratio.
[0339] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property. The nanoporous N6
fiber had excellent physical properties as shown in Table 3.
Example 10
[0340] The polymer alloy prepared according to Example 1 was
subjected to melt spinning by the procedure of Example 1, except
for changing the discharge rate and the number of spinneret
orifices, and setting the spinning rate at 900 meters per minute.
The residence time from the melting section 2 to discharge was 12
minutes. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours. The yarn did not
cause deformation of the wound package due to swelling with time,
which constitutes a problem in regular nylon yarns, and showed good
handleability. This article was subjected to draw thermal treatment
by the procedure of Example 8, except for setting the draw ratio at
3.2, the temperature of the first hot roller 24 at 70.degree. C.
and the temperature of the second hot roller 25 at 130.degree. C.
(FIG. 32).
[0341] The resulting 70 dtex, 34-filament polymer alloy fiber had
excellent properties including a strength of 3.7 cN/dtex, an
elongation percentage of 47%, a U % of 1.2% and a thermal shrinkage
of 11%.
[0342] The cross section of the polymer alloy fiber was observed
under a TEM to find that the fiber had an islands-in-sea structure
comprising N6 as a sea (dark region) and the copolymerized PET as
islands (bright region) (FIG. 16). The islands had an average
diameter of 38 nm. These results show that the resulting polymer
alloy fiber comprises the copolymerized PET ultrafinely dispersed.
The area ratio of islands each having a diameter of 200 nm or more
to the total islands was 1.2%. The TEM observation of the
longitudinal section of the fiber shows that the islands has a
lined structure (FIG. 17). The physical properties of the polymer
alloy fiber are shown in Table 4.
[0343] A round braid was prepared by using the polymer alloy fiber
and immersed in a 3% aqueous sodium hydroxide solution (90.degree.
C., liquor ratio of 1:100) for one hour to thereby remove 99% or
more of the copolymerized PET from the polymer alloy fiber upon
hydrolysis, followed by washing with water and drying.
[0344] The side of the nanoporous N6 fiber was observed with an
optical microscope, to find that the fiber had a diameter somewhat
lower than that of the fiber before the alkali treatment, showing
that the fiber shrank in its radius direction as a result of the
removal of the islands-part polymer.
[0345] The side of the nanoporous N6 fiber was observed under a SEM
to find that the fiber had a smooth surface without unevenness at a
magnification of about 2000 times. The cross section of the
nanoporous N6 fiber was observed under a TEM (FIG. 18) to find that
the fiber had a pattern of dark and bright regions finer than that
of the original polymer alloy fiber (FIG. 16) upon metal staining.
The dark regions are regions at high density of N6, and bright
regions are regions at low density of N6. The bright regions are
considered to correspond to pores. These results show that the
pores each have a smaller size than the original islands-part
polymer as a result of the removal of the islands-part polymer,
have an average diameter of 10 to 20 nm and are free from coarse
pores each having a diameter of 50 nm or more. The patterns of dark
and bright regions in FIG. 18 (the cross section of the fiber) and
FIG. 19 (the longitudinal section of the fiber) show that these
pores are unconnected pores.
[0346] The round braid prepared from the nanoporous N6 fiber was
dyed and was found to have excellent color property. The ratio of
moisture adsorption (.DELTA.MR) was 6%, showing much higher
hygroscopicity than cotton. The nanoporous N6 fiber had a strength
of 2.0 cN/dtex and an elongation percentage of 70%, showing that
the fiber had sufficient mechanical properties as a fibrous
article. The physical properties of the nanoporous N6 fiber are
shown in Table 3.
Example 11
[0347] The N6 and the copolymerized PET were subjected to melt
kneading by the procedure of Example 1, except for blending 40% by
weight of N6 and 60% by weight of the copolymerized PET, to thereby
obtain master pellets. The pellets had an average weight per pellet
of 3 mg and an amount of terminal amino groups of
3.5.times.10.sup.-5 molar equivalent per gram of N6.
[0348] The master pellets and the virgin N6 pellets (average weight
per pellet of 3 mg) used in melt kneading were charged into
different hoppers 1, weighed in weighing sections 28, respectively,
and fed to a blending tank 29 having a capacity of 7 kg (FIG. 33).
The blending ratio of the master pellets to the virgin N6 pellets
was 1/3 by weight, and 20 ppm of an antistatic agent (EMULMIN 40
available from Sanyo Chemical Industries, Ltd.) was incorporated
for preventing adhesion of pellets to the wall of the blending
tank. The pellets were blended in the blending tank, fed to a
twin-screw extrusion-kneader 30 and subjected to melt kneading, to
thereby obtain a polymer alloy comprising 15% by weight of the
copolymerized PET. In this procedure, the length of the kneading
section was set at 33% of the effective length of the screws, and
the kneading temperature was set at 260.degree. C. The polymer
alloy was subjected to melt spinning by the procedure of Example 1,
to obtain a highly oriented undrawn yarn. The yarn could be
satisfactorily spun without any yarn breaking during continuous
spinning for 24 hours. The yarn did not cause deformation of the
wound package due to swelling with time, which constitutes a
problem in regular nylon yarns, and showed good handleability. The
undrawn polymer alloy yarn showed excellent physical properties of
a strength of 2.5 cN/dtex, an elongation percentage of 130% and a U
% of 1.4%. This article was subjected to draw thermal treatment by
the procedure of Example 8, except for setting the draw ratio at
1.5, the temperature of the first hot roller 24 at 90.degree. C.
and the temperature of the second hot roller 25 at 130.degree. C.
The polymer alloy fiber was of 87 dtex and 24 filaments and had
excellent physical properties of a strength of 3.2 cN/dtex, an
elongation percentage of 33%, a thermal shrinkage of 8% and a U %
of 1.6% (Table 4). The cross section of the polymer alloy fiber was
observed under a TEM to find that the fiber had an islands-in-sea
structure comprising N6 as a sea (dark region) and the
copolymerized PET as islands (bright region). The islands had an
average diameter of 45 nm. These results show that the resulting
polymer alloy fiber comprises the copolymerized PET ultrafinely
dispersed. The area ratio of islands each having a diameter of 200
nm or more to the total islands was 1.6%. The TEM observation of
the longitudinal section of the fiber shows that the islands has a
lined structure.
[0349] This article was knitted into a round braid of 20 G and
treated with a 3% by weight aqueous sodium hydroxide solution
(95.degree. C., liquor ratio of 1:50) for one hour, to dissolve off
and remove 99% or more of the copolymerized PET from the polymer
alloy fiber.
[0350] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property but to show slight
dyeing speck. The article had a ratio of moisture adsorption
(.DELTA.MR) of 5.0% and exhibited much higher hygroscopicity than
cotton.
[0351] The cross section of the nanoporous N6 fiber was observed
under a TEM to find that the fiber had unconnected pores having a
diameter of about 20 to 50 nm. The pores had an average diameter of
30 nm, and the area ratio of coarse pores each having a diameter of
50 nm or more was 1.0%. The round braid had a strength of 2.0
cN/dtex and an elongation percentage of 25%, showing that the round
braid had sufficient mechanical properties as a fibrous article.
The physical properties of the nanoporous N6 fiber are shown in
Table 3.
Example 12
[0352] The N6 and the copolymerized PET used in melt kneading in
Example 1 were charged into different hoppers 1, weighed in
weighing sections 28, respectively, and fed to a blending tank 29
having a capacity of 7 kg (FIG. 33). The N6 and the copolymerized
PET were used in amounts of 85% by weight and 15% by weight,
respectively, and 20 ppm of an antistatic agent (EMULMIN 40
available from Sanyo Chemical Industries, Ltd.) was incorporated
for preventing adhesion of pellets to the wall of the blending
tank. The pellets were blended in the blending tank, fed to a
twin-screw extrusion-kneader 30 and subjected to melt kneading, to
thereby obtain a polymer alloy. In this procedure, the length of
the kneading section was set at 33% of the effective length of the
screws, and the kneading temperature was set at 260.degree. C. The
polymer alloy was subjected to melt spinning by the procedure of
Example 1, to obtain a highly oriented undrawn yarn. Broken end
occurred once during continuous spinning for 24 hours. The yarn did
not cause deformation of the wound package due to swelling with
time, which constitutes a problem in regular nylon yarns, and
showed good handleability. The undrawn polymer alloy yarn showed
excellent physical properties of a strength of 2.4 cN/dtex, an
elongation percentage of 125% and a U % of 1.6%. The yarn was
subjected to draw false-twisting by the procedure of Example 1 but
showed somewhat unstable untwisting as compared with Example 1. The
resulting 87 dtex 24-filament false-twisted yarn had a strength of
2.4 cN/dtex, an elongation percentage of 21%, a thermal shrinkage
of 9%, a U % of 2.2% and a CR of 30% showed some but trivial
not-untwisted portions as compared with Example 1 (Table 4). The
cross section of the crimped polymer alloy yarn was observed under
a TEM to find that the yarn had an islands-in-sea structure
comprising N6 as a sea (dark region) and the copolymerized PET as
islands (bright region). The islands had an average diameter of 52
nm, showing that the polymer alloy fiber comprised the
copolymerized PET ultrafinely dispersed. The area ratio of islands
each having a diameter of 200 nm or more to the total islands was
2.0%. The TEM observation of the longitudinal section of the fiber
shows that the islands has a lined structure.
[0353] This was knitted into a round braid of 20 G and treated with
a 3% by weight aqueous sodium hydroxide solution (95.degree. C.,
liquor ratio of 1:50) for one hour to thereby dissolve off and
remove 99% or more of the copolymerized PET from the false-twisted
polymer alloy yarn.
[0354] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property but show some dyeing
speck. The round braid had a ratio of moisture adsorption
(.DELTA.MR) of 5.0% and exhibited much higher hygroscopicity than
cotton.
[0355] The cross section of the nanoporous N6 fiber was observed
under a TEM to find that the fiber had unconnected pores each
having a diameter of about 20 to 50 nm. The average of the pores
was 35 nm, and the area ratio of coarse pores each having a
diameter of 50 nm or more was 1.6%. The fiber had a strength of 1.8
cN/dtex and an elongation percentage of 25%, showing that the fiber
had sufficient mechanical properties as a fibrous article. The
physical properties of the nanoporous N6 fiber are shown in Table
3.
Example 13
[0356] The melt spinning procedure of Example 10 was carried out to
conduct spinning and direct drawing using a device shown in FIG.
34, except for changing the discharge rate per one orifice and the
number of spinneret orifices and setting the circumferential speed
of a first hot roller 31 at 2000 meters per minute, the temperature
of the first hot roller 31 at 40.degree. C., the circumferential
speed of a second hot roller 32 at 4500 meters per minute and the
temperature of the second hot roller 32 at 150.degree. C. Thus, a
55 dtex 12-filament polymer alloy fiber having a strength of 4.4
cN/dtex, an elongation percentage of 37%, a U % of 1.2% and a
thermal shrinkage of 12% was prepared. The fiber showed good
spinnability without any yarn breaking during continuous spinning
for 24 hours. The resulting polymer alloy fibers were free from
coarsely aggregated polymer particles. The area ratio of islands
each having a diameter of 200 nm or more was 0.1% or less, and the
area ratio of islands each having a diameter of 100 nm or more was
1% or less. The TEM observation of the longitudinal section of the
fiber shows that the islands has a lined structure. The yarn had
excellent physical properties as shown in Table 4.
[0357] The polymer alloy fibers were subjected to circular knitting
by the procedure of Example 10, from which 99% or more of the
copolymerized PET was removed by an alkali treatment, to thereby
obtain a round braid comprising a nanoporous N6 fiber.
[0358] The cross section of the nanoporous N6 fiber was observed
under a TEM to find that the fiber had dark and bright regions as a
result of metal staining finer than the original polymer alloy
fiber, showing that the pores had sizes smaller than the original
islands-part polymer as a result of the removal of the islands-part
polymer, and that the average diameter of the pores was 10 to 20 nm
and were free from coarse pores each having a diameter of 50 nm or
more. The TEM observation shows that these pores are unconnected
pores. The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property. The nanoporous N6
fiber had excellent physical properties as shown in Table 3.
Comparative Example 1
[0359] Melt spinning was carried out by the procedure of Example 1,
except for kneading the materials by simple chip blending (dry
blending) with the use of a device shown in FIG. 28 instead of the
twin-screw extrusion-kneader. As a result, the polymers showed poor
spinnability, could not be stably discharged during spinning and
often invited yarn breakings during spinning. Thus, a yarn could
not be stably wound. Accordingly, the spinning rate was changed to
900 meters per minute, which failed to wound a yarn stably.
However, the resulting nominal undrawn yarn was subjected to draw
thermal treatment at a draw ratio of 3.2, a temperature of the
first hot roller 24 of 70.degree. C. and a temperature of the
second hot roller 25 of 130.degree. C., to obtain a polymer alloy
fiber. The cross section of the polymer alloy fiber was observed
under a TEM to find that uneven blending was significant, some
coarsely aggregated polymer particles were observed, and the area
ratio of islands each having a diameter of 200 nm or more to the
total islands was 10% (Table 4). A round braid was prepared from
this and was subjected to an alkali treatment by the procedure of
Example 6 to obtain a porous N6 fiber. This fiber, however, had a
large area ratio of coarse pores each having a diameter of 200 nm
or more of 2.0%, scattered a large quantity of light, appeared
whitish and exhibited poor color property (Table 3).
[0360] The above-prepared polymer alloy fiber was subjected to
false twisting using a spinner pin as a rotator 15, at a
temperature of a heater 13 of 165.degree. C. and a draw ratio of
1.01, which invited unstable untwisting and frequent yarn
breakings. The resulting nominal false-twisted yarn had a markedly
large amount of not-untwisted portions and exhibited poor
quality.
Comparative Example 2
[0361] The materials were subjected to melt kneading by the
procedure of Example 1, except for setting the length of the
kneading section at 10% of the effective length of the screws, to
obtain polymer alloy chips. The chips were subjected to TEM
observation to find that the copolymerized PET was dispersed
unevenly, in which some particles were dispersed with a diameter of
about 30 nm but may others were dispersed with a diameter of 100 nm
or more (FIG. 20). The area ratio of coarsely dispersed polymer
particles each having a diameter in terms of circle of 100 nm or
more was 50% or more to the total dispersed polymer in a cross
section of the pellet.
[0362] The polymer alloy pellets were subjected to melt spinning by
the procedure of Example 1, but showed poor spinnability and
invited frequent yarn breakings during spinning, and a yarn could
not be stably wound. Accordingly, the spinning rate was changed to
900 meters per minute, which failed to wound a yarn stably. The
resulting nominal undrawn yarn was subjected to draw thermal
treatment by the procedure of Comparative Example 1, to obtain a
polymer alloy fiber. The cross section of the polymer alloy fiber
was observed under a TEM to find that the fiber showed significant
uneven blending, had some coarsely aggregated polymer particles, in
which the area ratio of islands each having a diameter of 200 nm or
more to the total islands was 8% (Table 4). A round braid was
prepared from this and was subjected to an alkali treatment by the
procedure of Comparative Example 1, to obtain a porous N6 fiber.
The resulting porous fiber, however, had a large area ratio of
coarse pores each having a diameter of 200 nm or more of 1.9%,
scattered a large quantity of light, appeared whitish and exhibited
poor color property (Table 3).
[0363] The resulting polymer alloy fiber was subjected to false
twisting by the procedure of Comparative Example 1, but invited
unstable untwisting and frequent yarn breakings. The resulting
nominal false-twisted yarn had a markedly large amount of
not-untwisted portions and exhibited poor appearance quality.
TABLE-US-00003 TABLE 3 Area Area Percentage Average pore ratio 1
ratio 2 Strength .DELTA.MR Color Adsorbing of water diameter (nm)
(%) (%) (cN/dtex) (%) property rate (%) retention (%) Example 8 20
or less 0 0 2.1 5.7 Excellent 60 83 Example 9 20 or less 0 0 2.0
3.6 Excellent 62 84 Example 10 20 or less 0 0 2.0 6.0 Excellent 60
83 Example 11 30 0 1.0 2.0 5.0 Good 58 80 Example 12 35 0 1.6 1.8
5.0 Good 55 80 Example 13 20 or less 0 0 3.4 5.8 Excellent 60 80
Comparative Example 1 -- 2.0 -- 1.3 4.3 Failure -- -- Comparative
Example 2 -- 1.9 -- 1.3 4.2 Failure -- -- Average pore diameter:
Average pore diameter estimated based on TEM observation Area ratio
1: Area ratio of pores having a diameter of 200 nm or more to the
total fiber Area ratio 2: Area ratio of pores having a diameter of
50 nm or more to the total fiber Adsorbing rate: Ammonia adsorbing
rate
[0364] TABLE-US-00004 TABLE 4 Area Average Thermal Kneading ratio
diameter of Strength U % shrinkage procedure (%) islands (nm)
Spinnability (cN/dtex) (%) (%) Example 8 Static 0.1 or less 20 Good
3.5 1.5 12 (thick) Example 9 Static 0.1 or less 15 Good 3.2 1.5 12
Example 10 EXT 1.2 38 Good 3.7 1.2 11 Example 11 Blending 1.6 45
Good 3.2 1.6 8 tank .fwdarw. EXT Example 12 Blending 2.0 52 Fair
2.4 2.2 9 tank .fwdarw. EXT Example 13 EXT 0.1 or less 26 Good 4.4
1.2 12 Comparative Example 1 Chip 10 130 Failure 2.8 8.2 11
blending Comparative Example 2 EXT 8 120 Failure 2.8 8.0 11 Area
ratio: Area ratio of pores having a diameter of 200 nm or more to
the total islands Static: Static mixer (having a number of splits
of 104 .times. 10.sup.4) EXT: twin-screw extrusion-kneader Blending
tank .fwdarw. EXT: Twin-screw extrusion-kneader after chip blending
a small amount of materials in a blending tank Chip blending: Dry
blending of pellets
Example 14
[0365] N6 and the copolymerized PET were subjected to melt
kneading, melt spinning, and draw thermal treatment by the
procedure of Example 10, except for using a high-viscosity N6
having a melt viscosity of 1540 poises (280.degree. C. at a rate of
shear of 2432 sec.sup.-1) and containing terminal amino groups in
an amount of 5.0.times.10.sup.-5 molar equivalent per gram, setting
the blending ratio of N6 to the copolymerized PET at 1.1, and
changing the discharge rate per one orifice and the number of
spinneret orifices, to thereby obtain 105 dtex, 96-filament polymer
alloy fibers. They showed good spinnability and were free from yarn
breaking during continuous spinning for 24 hours. The resulting
polymer alloy fibers were free from coarsely aggregated polymer
particles, in which the area ratio of islands each having a
diameter of 200 nm or more was 0.1% or less, and the area ratio of
islands each having a diameter of 100 nm or more was 1% or less.
The yarn had excellent physical properties as shown in Table 6. The
longitudinal section of the fiber was observed under a TEM, to find
that the islands had a lined structure.
[0366] The polymer alloy fibers were subjected to circular
knitting, from which 99% or more of the copolymerized PET was
removed by an alkali treatment by the procedure of Example 10, to
thereby obtain a round braid comprising a nanoporous N6 fiber.
[0367] The nonporous N6 fiber was observed with an optical
microscope and an SEM, respectively, to find that the fiber shrank
in its radius direction as a result of the removal of the
islands-part polymer, and the fiber had a smooth surface without
unevenness at a magnification of about 2000 times. The cross
section of the nanoporous N6 fiber was observed under a TEM to find
that the fiber had dark and bright regions as a result of metal
staining finer than the original polymer alloy fiber, showing that
the pores had sizes smaller than the original islands-part polymer
as a result of the removal of the islands-part polymer, and that
the average diameter of the pores was 10 to 20 nm and were free
from coarse pores each having a diameter of 50 nm or more. The
pores were unconnected pores.
[0368] The round braid comprising the nanoporous N6 fiber was dyed
and was found to have excellent color property. The nanoporous N6
fiber had excellent physical properties as shown in Table 5.
Example 15
[0369] The N6 used in Example 10 (50% by weight) and a PET
copolymerized with 12% by mole of 5-sodiosulfoisophthalic acid and
26% by mole of isophthalic acid (50% by weight) were kneaded in a
twin-screw extrusion-kneader at 245.degree. C., to thereby obtain
polymer alloy chips. The polymer alloy was subjected to melt
spinning by the procedure of Example 3, except for setting the
spinning temperature at 250.degree. C. and the spinneret diameter
at 0.6 mm and changing the discharge rate per one orifice, and the
resulting undrawn yarn was wound at a spinning rate of 800 meters
per minute. This was subjected to draw thermal treatment at a draw
ratio of 3.4, a temperature of the first hot roller 24 of
90.degree. C. and a temperature of the second hot roller 25 of
130.degree. C., to thereby obtain a 85 dtex, 36-filament polymer
alloy yarn. The yarn could be satisfactorily spun without any yarn
breaking during continuous spinning for 24 hours. The cross section
of the polymer alloy fiber was observed under a TEM, and the result
is shown in FIG. 21. The copolymerized PET constituted islands in
the form of layers having a minor axis of about 10 to 30 nm and a
major axis of about 50 to 100 nm and was free from coarsely
aggregated polymer particle. The area ratio of islands each having
a diameter of 200 nm or more to the total islands was 0.1% or less,
and the area ratio of islands each having a diameter of 100 nm or
more was 1% or less. The TEM observation of the longitudinal
section of the fiber shows that the islands has a lined structure.
The yarn had excellent physical properties as shown in Table 6.
[0370] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 10 and treated with a 3% by weight
aqueous sodium hydroxide solution (90.degree. C., liquor ratio of
1:50) for one hour to dissolve off and remove 99% or more of the
copolymerized PET, to thereby obtain a round braid comprising a
nanoporous N6 fiber. The fiber significantly shrank in its radius
direction with a shrinkage in radius direction of about 22% and a
shrinkage in terms of cross sectional area of about 40%. The side
of the constitutional fiber of the nylon 6 yarn after removing the
copolymerized PET was observed with an SEM (2000 times) and was
found neither streaky grooves nor voids from which the
copolymerized PET had been removed.
[0371] The cross section of the nanoporous N6 fiber was observed
under a TEM, and the result is shown in FIG. 22, showing that the
average diameter of the pores was 10 to 20 nm and were free from
coarse pores each having a diameter of 50 nm or more. These pores
were considered to be connected with each other to form connected
pores.
[0372] The round braid prepared from the nanoporous N6 fiber was
dyed and was found to have excellent color property. The water
swelling of the nanoporous N6 fiber was determined to find that the
yarn had a high percentage of swelling in its longitudinal
direction of 11.1%. The article showed substantially no decrease in
percentage of swelling in a longitudinal direction of the yarn even
in a third measurement and exhibited satisfactory reversibility and
durability. The water swelling of the nanoporous N6 fiber was
determined again after heat treating the round braid at 160.degree.
C. for 10 minutes. The fiber showed a somewhat decreased percentage
of swelling in the longitudinal direction of the yarn of 7.3% as
compared with that before thermal treatment, which is, however,
significantly larger than that of regular N6 fibers, 3%. This
indicates that the percentage of swelling in a longitudinal
direction of the yarn can be controlled by a thermal treatment,
which facilitates the designing of fabrics. The nanoporous N6 fiber
had excellent physical properties as shown in Table 5.
Example 16
[0373] The melt spinning, draw thermal treatment procedure of
Example 10 was repeated, except for using, as the copolymerized
PET, a copolymerized PET having a melting point of 225.degree. C.,
containing 0.05% by weight of titanium oxide and being
copolymerized with 7% by mole of isophthalic acid and 4% by mole of
an ethylene oxide adduct of bisphenol A, for using 50% by weight of
N6 and 50% by weight of the copolymerized PET, and setting the
spinneret diameter at 0.7 mm. The spinning was somewhat unstable as
compared that in Example 10, but it was trivial, and yarn breaking
occurred twice during continuous spinning for 24 hours. The cross
section of the polymer alloy fiber was observed under a TEM, and
the result is shown in FIG. 23. The fiber had little coarsely
aggregated polymer particles, but the average diameter of islands
was 143 nm, and the area ratio of islands each having a diameter of
200 nm or more to the total islands was 5%. The TEM observation of
the longitudinal section of the fiber shows that the islands has a
lined structure. The physical properties of the yarn are shown in
Table 6.
[0374] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 10, from which 99% or more of the
copolymerized PET was removed by an alkali treatment, to thereby
obtain a round braid comprising a nanoporous N6 fiber.
[0375] The nanoporous N6 fiber was observed with an optical
microscope to find that the fiber shrank in its radius direction as
a result of the removal of the islands-part polymer, as in Example
10. The cross section of the nanoporous N6 fiber was observed under
a TEM, and the result is shown in FIG. 24. Holes from which the
islands-part polymer had been removed were crushed to form pores
having a width of about 10 to 30 nm and a length of about 100 nm
including some coarse pores each having a diameter of 50 to 100 nm.
However, the area ratio of coarse pores each having a diameter of
200 nm or more was 0.5%. The color property of this article was
determined to find that the article had color property at usable
level for clothing, although it was inferior to that in Example 10.
The pores of the fiber were unconnected pores.
Example 17
[0376] The melt kneading procedure of Example 1 was repeated,
except for using, instead of the copolymerized PET, a polyalkylene
oxide derivative, "Paogen PP-15" available from Daiichi Kogyo
Seiyaku Co., Ltd., serving as a polymer soluble in hot water and
setting the temperature at 240.degree. C. The resulting polymer
alloy chip had b* of 4.5. The kneaded product was subjected to melt
spinning, draw thermal treatment by the procedure of Example 10,
except for changing the discharge rate per one orifice and the
number of spinneret orifices and setting a spinning rate at 4000
meters per minute and a draw ratio at 1.2, to thereby obtain a 55
dtex, 68-filament polymer alloy fiber. The yarn could be
satisfactorily spun without any yarn breaking during continuous
spinning for 24 hours. The cross section of the polymer alloy fiber
was observed under a TEM to find that the fiber was free from
coarsely aggregated polymer particles, and the area ratio of
islands each having a diameter of 200 nm or more to the total
islands was 1.3%. The islands-part polymer was dispersed as lines.
The yarn had excellent physical properties as shown in Table 6.
[0377] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 10 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain a round braid comprising a
nanoporous N6 fiber.
[0378] The cross section of the nanoporous N6 fiber was observed
under a TEM, to find that the pores were unconnected pores, had an
average diameter of 30 nm and were free from coarse pores each
having a diameter of 50 nm or more. The pores of this fiber were
unconnected pores.
[0379] The round braid prepared from the nanoporous N6 fiber was
dyed and was found to have excellent color property. The nanoporous
N6 fiber had excellent physical properties as shown in Table 5.
Example 18
[0380] The melt kneading procedure of Example 1 was repeated,
except for using, instead of the copolymerized PET, a poly(L-lactic
acid) having an optical purity of 99.5% or more, a weight-average
molecular weight of 15.times.10.sup.4, a melt viscosity of 857
poises (240.degree. C., 2432 sec.sup.-1) and a melting point of
170.degree. C. and setting the kneading temperature at 220.degree.
C. The weight-average molecular weight of the polylactic acid was
determined in the following manner. A solution of a sample in
chloroform was mixed with THF (tetrahydrofuran) to obtain a
specimen solution. The specimen solution was subjected to
measurement at 25.degree. C. using a gel permeation chromatograph
(GPC) Waters 2690 available from Waters, and the weight-average
molecular weight in terms of polystyrene was determined. The N6
used in Example 1 had a melt viscosity of 570 poises at 240.degree.
C., 2432 sec.sup.-1. The kneaded product was subjected to melt
spinning by the procedure of Example 1, except for changing the
discharge rate per one orifice and the number of spinneret orifices
and setting the spinning rate at 3500 meters per minute, to thereby
obtain a highly oriented undrawn yarn of 105 dtex, 36 filaments
having a strength of 3.1 cN/dtex, an elongation percentage of 107%
and a U % of 1.2%. The yarn could be satisfactorily spun without
any yarn breaking during continuous spinning for 24 hours. This was
subjected to draw false-twisting by the procedure of Example 1,
except for setting the draw ratio at 1.4 to thereby obtain a 76
dtex, 36-filament false-twisted yarn having a strength of 4.0
cN/dtex, an elongation percentage of 29%, a U % of 1.3% and a CR of
35%. In this procedure, the temperature of the heater was set at
160.degree. C. in consideration of the melting point of the
poly(L-lactic acid). Thus, the resulting false-twisted yarn was
substantially free from not-untwisted portions, had excellent
appearance quality and exhibited good processability in draw
false-twisting. The cross section of the fiber of the crimped
polymer alloy yarn was observed under a TEM to find that the fiber
was free from coarsely aggregated polymer particles, the area ratio
of islands-part polymer particles having a diameter of 200 nm or
more to the total islands parts was 0.1% or less, and the an
average diameter of the islands-part polymer was 80 nm. The yarn
had excellent physical properties as shown in Table 6.
[0381] The crimped polymer alloy yarn was subjected to circular
knitting and to an alkali treatment by the procedure of Example 1
to remove 99% or more of the poly(L-lactic acid), to thereby obtain
a round braid comprising a nanoporous N6 fiber. The round braid
prepared from the nanoporous N6 fiber was dyed and was found to
have excellent color property.
[0382] The cross section of the nanoporous N6 fiber sampled from
the round braid was observed under a TEM, to find that holes from
which the islands-part polymer had been removed constituted pores
having a diameter of about 30 nm without coarse pores having a
diameter of 50 nm or more. The resulting nanoporous fiber had a
strength higher than that in Example 1. This is probably because
sulfo groups contained in the copolymerized PET used in Example 1
may form a pseudo-crosslinking structure and inhibit the formation
of fiber structure of N6, but PLA used herein less invites such
adverse effects.
Comparative Example 3
[0383] An N6 having a relative viscosity of 2.8, a melt viscosity
of 1260 poises (280.degree. C. at a rate of shear of 2432
sec.sup.-1) (50% by weight) and a polyethylene terephthalate
copolymerized with 2.5% by mole of 5-sodiosulfoisophthalic acid and
3.5% by mole of an ethylene oxide adduct of bisphenol A (50% by
weight) were subjected to simple chip blending, and the blend was
melted at 290.degree. C., discharged from a spinneret having a
round orifice with a diameter of 0.6 mm and subjected to melt
spinning using a device shown in FIG. 28 at a spinning rate of 1200
meters per minute. However, the polymers could not be stably
discharged during spinning, the spinnability was poor and yarn
breakings often occurred during spinning. Thus, a yarn could not be
stably wound. The resulting nominal undrawn yarn was drawn using a
hot plate at 120.degree. C. at a draw ratio of 2.7. This yielded a
85 dtex, 24-filament polymer alloy fiber. The cross section of the
fiber was observed under a TEM to find that the fiber showed
significant uneven blending and contained some coarsely aggregated
polymer particle, and the area ratio of islands each having a
diameter of 200 nm or more to the total islands was 10%.
[0384] An alkali treatment was carried out to dissolve off and
remove 99% or more of the copolymerized PET. The diameter of the
fiber did not substantially change in this procedure. The color
property of this fiber was determined to find that the area ratio
of coarse pores each having a diameter of 200 nm or more was as
large as 5.0%, the fiber thereby scattered a large quantity of
light, appeared whitish and exhibited poor color property.
Comparative Example 4
[0385] The N6 used in Comparative Example 3 (70% by weight) and a
polyethylene terephthalate having an intrinsic viscosity of 0.60
and being copolymerized with 4.5% by mole of
5-sodiosulfoisophthalic acid and 8.5% by weight of a polyethylene
glycol having a molecular weight of 4000 (30% by weight) were
subjected to simple chip blending, and the blend was melted at
280.degree. C., discharged from a spinneret having round orifices
with a diameter of 0.6 mm and subjected to melt spinning using a
device shown in FIG. 28 at a spinning rate of 1000 meters per
minute. However, the polymers could not be stably discharged during
spinning, the spinnability was poor and yarn breakings often
occurred during spinning. Thus, a yarn could not be stably wound.
The resulting nominal undrawn yarn was subjected to draw thermal
treatment at a draw ratio of 3.35, a temperature of the first hot
roller 24 of 90.degree. C. and a temperature of the second hot
roller 25 of 130.degree. C. This yielded a 85 dtex, 24-filament
polymer alloy fiber. The cross section of the fiber was observed
under a TEM to find that the fiber showed significant uneven
blending and contained some coarsely aggregated polymer particles,
and the area ratio of islands each having a diameter of 200 nm or
more to the total islands was 8%.
[0386] By an alkali treatment, 90% or more of the copolymerized PET
was dissolved off from the fiber. The diameter of the fiber did not
substantially change during this procedure. The color property of
the article was determined, to find that the fiber scattered a
large quantity of light, appeared whitish and exhibited poor color
property, since the area ratio of coarse pores each having a
diameter of 200 nm or more was as large as 2.4%.
Comparative Example 5
[0387] A total of 77% by weight of the N6 used in Comparative
Example 3, 20% by weight of a homo-PET, and 3% by weight of a block
polyether polyamide as a compatibilizer containing 45% by weight of
a polyethylene glycol segment and 55% by weight of a
poly-.epsilon.-caprolactam segment were subjected to simple chip
blending, and the blend was subjected to melt spinning by the
procedure of Example 1, except for using a device shown in FIG. 28.
However, the polymers could not be stably discharged during
spinning, the spinnability was poor and yarn breakings often
occurred during spinning. Thus, a yarn could not be stably wound.
The resulting nominal undrawn yarn was subjected to draw thermal
treatment by the procedure of Example 1 to obtain a 77 dtex,
24-filament polymer alloy fiber. The cross section of the fiber was
observed under a TEM to find that the fiber showed significant
uneven blending and contained some coarsely aggregated polymer
particles, and the area ratio of islands each having a diameter of
200 nm or more to the total islands was 14%.
[0388] Then, 99% or more of the PET was dissolved off and removed
by an alkali treatment. The diameter of the fiber did not
substantially change during this procedure, in contrast to Example
10. The color property of the article was determined, to find that
the fiber scattered a large quantity of light, appeared whitish and
exhibited poor color property, since the area ratio of coarse pores
each having a diameter of 200 nm or more was as large as 4.6%.
Comparative Example 6
[0389] The N6 and the copolymerized PET were subjected to melt
spinning by the procedure of Comparative Example 4, except for
using 25% by weight of N6 and 75% by weight of the copolymerized
PET. However, the polymers could not be stably discharged during
spinning, the spinnability was poor and yarn breakings often
occurred during spinning. Thus, a yarn could not be stably wound.
The resulting nominal undrawn yarn was drawn using a hot plate at
120.degree. C. at a draw ratio of 2.7, to obtain a 85 dtex,
24-filament polymer alloy fiber. The cross section of the fiber was
observed under a TEM to find that N6 lower soluble in an alkali
constituted islands, and the copolymerized PET easily soluble in an
alkaline solution constituted a sea, in contrast to Comparative
Example 4. The fiber showed significant uneven blending and
contained some coarsely aggregated polymer particles, and the area
ratio of islands each having a diameter of 200 nm or more to the
total islands was 10%.
[0390] The article was subjected to alkali treatment by the
procedure of Example 10 to remove the sea part copolymerized PET,
to thereby obtain a fiber comprising ultrafine N6 fibers firmly
bonded. The resulting fiber, however, could not be handled in
practice and its strength could not be determined.
[0391] The polymer alloy fiber was treated with formic acid to
dissolve off the islands parts N6. However, the copolymerized PET
became markedly fragile, the resulting fiber fell into pieces and
could not be handled in practice. The polymer alloy fiber did not
substantially yield a porous fiber and could not achieve the
objects of the present invention.
Comparative Example 7
[0392] A copolymerized PET having an intrinsic viscosity of 0.60
and being copolymerized with ethylene naphthalate in an amount of
10% by mole to the total acid component, and 70% by weight of a
copolymerized PET copolymerized with a polyether imide
("ULTEM"-1000 available from General Electric Company) were kneaded
using a twin screw extrusion-kneader having a diameter of 30 mm at
320.degree. C. The resulting polymer alloy chip was fully dried and
was subjected to melt spinning at a number of spinneret orifices of
6, a discharge rate per single orifice of 0.6 g per minute, a
spinning temperature of 315.degree. C. and a spinning rate of 500
meters per minute. The spinning temperature was excessively higher
than the melting point of the sea part copolymerized PET, which
invited unstable spinning and poor spinnability with ten yarn
breakings during spinning for twelve hours. The resulting nominal
undrawn yarn was drawn at a temperature of a preheating roller of
90.degree. C., a temperature of a hot plate of 120.degree. C. and a
draw ratio of 3.0, resulted in frequent yarn breakings. The
resulting drawn yarn had a strength as low as 1.3 cN/dtex. This is
probably because the kneading temperature and the spinning
temperature were excessively high for the copolymerized PET serving
as a major component, and the polymer was deteriorated due to
thermal decomposition. This article showed a very insufficient U %
of 16%.
[0393] A plain fabric was prepared by using the copolymerized PET
alloy fiber as a warp and a weft, which caused frequent yarn
breakings and fluffing and resulted in a woven fabric exhibiting
very poor processability and inferior appearance quality. The woven
fabric was treated with a 6% by weight aqueous sodium hydroxide
solution at 90.degree. C. for 2 hours, to obtain a spongy fiber.
This fiber, however, had a markedly low strength of 0.3 cN/dtex.
This is probably because the copolymerized PET underwent thermal
degradation and, in addition, fell into pieces due to the long-term
treatment with a high concentration alkali.
[0394] As is described above, yarns having a high strength and
exhibiting less yarn unevenness cannot be obtained satisfactorily
unless suitable kneading and spinning conditions for the used
polymers are set. In addition, a small different in solubility
between the higher soluble polymer and the lower soluble polymer
invites low strength.
[0395] Thus, practically usable fibers can be obtained only by
optimizing the kneading, spinning and dissolving conditions for
individual polymers. TABLE-US-00005 TABLE 5 Area ratio Area ratio
Average pore of coarse of coarse Strength .DELTA.MR Color diameter
(nm) pores 1 (%) pores 2 (%) (cN/dtex) (%) property Example 14 20
or less 0 0 2.5 5.8 Excellent Example 15 20 or less 0 0 2.0 4.8
Excellent Example 16 45 0.5 -- 2.0 5.1 Good Example 17 30 0 0 2.0
5.3 Excellent Example 18 30 0 0 3.3 5.0 Excellent Comparative
Example 3 -- 5.0 -- 1.4 2.4 Failure Comparative Example 4 -- 2.4 --
1.3 2.3 Failure Comparative Example 5 -- 4.6 -- 1.3 2.3 Failure
Comparative Example 6 -- -- -- -- -- -- Average pore diameter:
Average pore diameter estimated based on TEM observation Area ratio
of coarse pores 1: Area ratio of pores having a diameter of 200 nm
or more to the total fiber Area ratio of coarse pores 2: Area ratio
of pores having a diameter of 50 nm or more to the total fiber
[0396] TABLE-US-00006 TABLE 6 Ratio in Average Sea-part Islands-
viscosity Area diameter Thermal polymer part between sea Kneading
ratio of islands Strength U % shrinkage Type wt % polymer and
islands procedure (%) (nm) Spinnability (cN/dtex) (%) (%) Example
14 N6 80 PET1 1.1 EXT 0.1 or less 18 Good 4.1 1.2 12 Example 15 N6
50 PET2 0.2 EXT 0.1 or less 25 Good 3.1 1.8 12 Example 16 N6 50
PET3 0.3 EXT 5 143 Fair 3.3 2.5 10 Example 17 N6 80 PAO 0.3 EXT 1.3
80 Good 3.5 1.5 12 Example 18 N6 80 PLA 0.7 EXT 0.1 or less 80 Good
4.0 1.3 12 Comparative Example 3 N6 50 PET4 0.9 chip 10 150 Failure
-- 10 -- Comparative Example 4 N6 70 PET5 0.9 chip 8 125 Failure --
9.1 -- Comparative Example 5 N6 77 PET6 0.9 chip 14 80 Failure 2.7
9.3 -- Comparative Example 6 PET4 75 N6 1.1 chip 10 -- Failure --
11 -- Area ratio: Area ratio of coarsely aggregated polymer
particles having a diameter of 200 nm or more to the total islands
PET1: PET copolymerized with 5% by mole of 5-sodiosulfoisophthalic
acid PET2: PET copolymerized with 12% by mole of
5-sodiosulfoisophthalic acid and 26% by mole of isophthalic acid
PET3: PET copolymerized with 7% by mole of isophthalic acid and 4%
by mole of an ethylene oxide adduct of bisphenol A PET4: PET
copolymerized with 2.5% by mole of 5-sodiosulfoisophthalic acid and
3.5% by mole of an ethylene oxide adduct of bisphenol A PET5: PET
copolymerized with 4.5% by mole of 5-sodiosulfoisophthalic acid and
8.5% by weight of PEG 4000 PET6: Homopolyethylene terephthalate
PAO: Polyalkylene oxide modified product (polymer soluble in hot
water) EXT: Twin-screw extrusion-kneader Chip: Chip blending
Example 19
[0397] The melt spinning and draw thermal treatment procedure of
Example 8 was repeated, except for using N66 instead of N6, setting
the spinning temperature at 280.degree. C., and using 80% by weight
of N66 and 20% by weight of the copolymerized PET. The yarn could
be satisfactorily spun without any yarn breaking during continuous
spinning for 24 hours. The cross section of the polymer alloy fiber
was observed under a TEM, to find that the fiber was free from
coarsely aggregated polymer particles, the area ratio of islands
each having a diameter of 200 nm or more to the total islands was
0.1% or less, and the area ratio of islands each having a diameter
of 100 nm or more was 1% or less. The TEM observation of the
longitudinal section of the fiber shows that the islands has a
lined structure. The yarn had excellent physical properties as
shown in Table 8.
[0398] The polymer alloy fiber was subjected to circular knitting
and alkali treatment by the procedure of Example 10, to remove 99%
or more of the copolymerized PET, to thereby obtain a round braid
comprising a nanoporous N66 fiber.
[0399] The cross section of the nanoporous N66 fiber was observed
under a TEM, to find that the pores were unconnected pores, the
average diameter of the pores was 10 to 20 nm and were free from
coarse pores each having a diameter of 50 nm or more.
[0400] The round braid comprising the nanoporous N66 fiber was dyed
and was found to have excellent color property. The nanoporous N66
fiber had excellent physical properties as shown in Table 7.
Example 20
[0401] A total of 80% by weight of a homopolyethylene terephthalate
having a melting point of 255.degree. C., an intrinsic viscosity of
0.63 and a melt viscosity of 830 poises (280.degree. C., 2432
sec.sup.-1) and 20% by weight of the polymer soluble in hot water
used in Example 17 were subjected to melt kneading at 275.degree.
C. using a twin-screw extrusion-kneader by the procedure of Example
1, to thereby obtain polymer alloy pellets having b* of 3.2. The
kneaded product was subjected to melt spinning by the procedure of
Example 10, except for setting the temperature of the melting
section 2 at 280.degree. C. and the spinning temperature at
280.degree. C. and changing the discharge rate per orifice and the
number of spinneret orifices. The fiber showed good spinnability
and did not cause yarn breaking during continuous spinning for 24
hours. The article was then subjected to draw thermal treatment by
the procedure of Example 10, except for setting the temperature of
the first hot roller 24 at 90.degree. C., to obtain a 90 dtex,
36-filament polymer alloy fiber having a strength of 3.3 cN/dtex,
an elongation percentage of 40%, a U % of 1.5% and a thermal
shrinkage of 7%. The cross section of the polymer alloy fiber was
observed under a TEM (FIG. 25), to find that the fiber was free
from coarsely aggregated polymer particles, the area ratio of
islands each having a diameter of 200 nm or more to the total
islands was 0.1% or less, and the area ratio of islands each having
a diameter of 100 nm or more was 0.1% or less. The dark region
corresponds to the PET, and the bright regions correspond to the
polymer soluble in hot water. The TEM observation of the
longitudinal section of the fiber shows that the islands has a
lined structure. The yarn had excellent physical properties as
shown in Table 8.
[0402] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 8 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain a round braid comprising a
nanoporous PET fiber.
[0403] The cross section of the nanoporous PET fiber was observed
under a TEM (FIG. 26), to find that the average diameter of the
pores was 20 nm and were free from coarse pores each having a
diameter of 50 nm or more. In the figure, the dark region
corresponds to the PET, and the bright regions correspond to pores,
and the pores are unconnected pores. The physical properties of the
nanoporous fiber are shown in Table 7.
[0404] The round braid comprising the nanoporous PET fiber was dyed
and was found to have excellent color property.
Example 21
[0405] The melt kneading procedure of Example 20 was repeated,
except for changing the temperature at 255.degree. C. and using,
instead of the homopolyethylene terephthalate, a copolymerized PET
being copolymerized with 8% by weight of PEG 1000 and 7% by mole of
isophthalic acid and having a melting point of 235.degree. C., an
intrinsic viscosity of 0.65 and a melt viscosity of 920 poises
(280.degree. C., 2432 sec.sup.-1)). The resulting polymer alloy
pellets had b* of 3.8. The pellets were subjected to melt spinning
by the procedure of Example 19, except for setting the temperature
of the melting section 2 at 255.degree. C., the spinning
temperature at 255.degree. C., and using a spinneret having
orifices with a Y-shaped profile. The pellets showed good
spinnability and did not cause yarn breaking during continuous
spinning for 24 hours. The kneaded product was subjected to draw
thermal treatment by the procedure of Example 20 to thereby obtain
a polymer alloy fiber having a trefoil profile. The cross section
of the polymer alloy fiber was observed under a TEM, to find that
the fiber was free from coarsely aggregated polymer particles, the
area ratio of islands each having a diameter of 200 nm or more to
the total islands was 0.1% or less, and the area ratio of islands
each having a diameter of 100 nm or more was 1% or less. The TEM
observation of the longitudinal section of the fiber shows that the
islands has a lined structure. The yarn had excellent physical
properties as shown in Table 8.
[0406] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 20 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain a round braid comprising a
nanoporous PET fiber.
[0407] The cross section of the nanoporous PET fiber was observed
under a TEM, to find that the average diameter of the pores was 20
nm and were free from coarse pores each having a diameter of 50 nm
or more. The TEM observation shows that the pores are unconnected
pores. The physical properties of the nanoporous fiber are shown in
Table 7.
[0408] The round braid comprising the nanoporous PET fiber was dyed
and was found to have excellent color property.
Examples 22 and 23
[0409] Materials were subjected to melt kneading, melt spinning and
draw thermal treatment by the procedure of Example 20, except for
using, instead of the copolymerized PET, a polytrimethylene
terephthalate (PTT) having a melting point of 220.degree. C. and a
melt viscosity of 1290 poises (280.degree. C., 2432 sec.sup.-1) or
a polybutylene terephthalate (PBT) having a melting point of
220.degree. C. and a melt viscosity of 550 poises (280.degree. C.,
2432 sec.sup.1). The cross sections of the polymer alloy fibers
were observed under a TEM, to find that the fibers were free from
coarsely aggregated polymer particles, the area ratio of islands
each having a diameter of 200 nm or more to the total islands was
0.1% or less, and the area ratio of islands each having a diameter
of 100 nm or more was 1% or less. The TEM observation of the
longitudinal sections of the fibers shows that the islands has a
lined structure. The yarns had excellent physical properties as
shown in Table 8.
[0410] The polymer alloy fibers were subjected to circular knitting
by the procedure of Example 20 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain round braid each comprising
a nanoporous polyester fiber.
[0411] The cross sections of the nanoporous polyester fibers were
observed under a TEM, to find that the average diameter of the
pores was 20 nm and were free from coarse pores each having a
diameter of 50 nm or more. The TEM observation shows that the pores
are unconnected pores. The physical properties of the nanoporous
fibers are shown in Table 7.
[0412] The round braids comprising the nanoporous polyester fibers
were dyed and were found to have excellent color property.
Example 24
[0413] Materials were subjected to melt kneading by the procedure
of Example 20, except for using, instead of the PET, the polylactic
acid (PLA) used in Example 18 and setting the melting temperature
at 220.degree. C. The kneaded product was subjected to melt
spinning by the procedure of Example 20, except for setting the
temperature of the melting section 2 at 220.degree. C. and the
spinning temperature at 220.degree. C. In this procedure, the
article could be spun satisfactorily without any yarn breaking
during continuous spinning for 24 hours. The resulting article was
subjected to drawing and thermal treatment by the procedure of
Example 10, except for setting the temperature of the first hot
roller 16 at 90.degree. C. The cross section of the polymer alloy
fiber was observed under a TEM, to find that the fiber was free
from coarsely aggregated polymer particles, the area ratio of
islands each having a diameter of 200 nm or more to the total
islands was 0.1% or less, and the area ratio of islands each having
a diameter of 100 nm or more was 1% or less. The TEM observation of
the longitudinal section of the fiber shows that the islands has a
lined structure. The yarn had excellent physical properties as
shown in Table 8.
[0414] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 20 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain a round braid comprising a
nanoporous PLA fiber.
[0415] The cross section of the nanoporous PLA fiber was observed
under a TEM, to find that the pores were unconnected pores, have an
average diameter of 20 nm and were free from coarse pores each
having a diameter of 50 nm or more. The physical properties of the
nanoporous fiber are shown in Table 7.
[0416] The round braid comprising the nanoporous PLA fiber was dyed
and was found to have excellent color property. Regular PLAs do not
satisfactorily take up dyes, but the nonporous PLA fiber exhibits
an improved uptake of dyes and shows higher color property than
regular PLA fibers. In addition, the nanoporous PLA fiber has an
increased surface area and thereby shows an increased rate of
biodegradation as compared with regular PLA fibers and is optimal
for medical applications in which rapid bioabsorptivity is
required.
Examples 25 and 26
[0417] Materials were subjected to melt kneading, melt spinning,
draw thermal treatment by the procedure of Example 20, except for
using, instead of the PLA, a polypropylene (PP) or a polymethyl
methacrylate (hereinafter may be referred to as "PMMA"). The cross
sections of the resulting polymer alloy fibers were observed under
a TEM, to find that the fibers were free from coarsely aggregated
polymer particles, and the area ratios of islands each having a
diameter of 200 nm or more to the total islands were 1.2% and 0.8%,
respectively. The TEM observation of the longitudinal section of
the fiber shows that the islands has a lined structure. The yarn
had excellent physical properties as shown in Table 8.
[0418] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 20 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain round braids comprising a
nanoporous PP fiber or a nanoporous PMMA fiber. The pores in these
fibers were connected pores. The physical properties of the
nanoporous fibers are shown in Table 7.
Example 27
[0419] Materials were subjected to melt kneading by the procedure
of Example 20, except for using, instead of the PET, a
polymethylpentene (hereinafter may be referred to as "PMP") and
setting the melting temperature at 255.degree. C. The kneaded
product was subjected to melt spinning by the procedure of Example
20, except for setting the temperature of the melting section 2 at
255.degree. C. and the spinning temperature at 255.degree. C. In
this procedure, the article could be spun satisfactorily without
any yarn breaking during continuous spinning for 24 hours. The
resulting article was subjected to drawing and thermal treatment by
the procedure of Example 10, except for setting the temperature of
the first hot roller 24 at 90.degree. C. The cross section of the
polymer alloy fiber was observed under a TEM, to find that the
fiber was free from coarsely aggregated polymer particles, and the
area ratio of islands each having a diameter of 200 nm or more to
the total islands was 1.0%. The TEM observation of the longitudinal
section of the fiber shows that the islands has a lined structure.
The yarn had excellent physical properties as shown in Table 8.
[0420] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 20 and treated with hot water at
100.degree. C. for one hour to remove 99% or more of the polymer
soluble in hot water, to thereby obtain a round braid comprising a
nanoporous PMP fiber.
[0421] The cross section of the nanoporous PMP fiber was observed
under a TEM, to find that the pores were unconnected pores, had an
average diameter of 35 nm, and the area ratio of coarse pores each
having a diameter of 50 nm or more to the total pores was 0.6%. The
physical properties of the nanoporous fiber are shown in Table
7.
Example 28
[0422] Materials were subjected to melt kneading by the procedure
of Example 20, except for using, instead of the PET and the polymer
soluble in hot water, a polyphenylene sulfide (hereinafter may be
referred to as "PPS") and the N6 used in Example 1, respectively,
using PPS in an amount of 90% by weight, and setting the
temperature at 305.degree. C. The kneaded product was subjected to
melt spinning by the procedure of Example 20, except for setting
the temperature of the melting section 2 at 305.degree. C. and the
spinning temperature at 305.degree. C. and changing the discharge
rate per one orifice and the number of spinneret orifices. Broken
end occurred twice during continuous spinning for 24 hours. The
resulting article was subjected to drawing and thermal treatment by
the procedure of Example 10, except for setting the temperature of
the first hot roller 24 at 90.degree. C., to obtain a 150 dtex,
48-filament polymer alloy fiber. The cross section of the polymer
alloy fiber was observed under a TEM, to find that the fiber was
free from coarsely aggregated polymer particles, and the area ratio
of islands each having a diameter of 200 nm or more to the total
islands was 1.5%. The TEM observation of the longitudinal section
of the fiber shows that the islands has a lined structure. The yarn
had excellent physical properties as shown in Table 8.
[0423] The polymer alloy fiber was subjected to circular knitting
by the procedure of Example 20 and treated with formic acid for 2
hours to remove 99% or more of the N6, to thereby obtain a round
braid comprising a nanoporous PPS fiber. The pores were unconnected
pores. The physical properties of the nanoporous fiber are shown in
Table 7. TABLE-US-00007 TABLE 7 Area Area Average ratio of ratio of
pore coarse coarse diameter pores 1 pores 2 Strength Color (nm) (%)
(%) (cN/dtex) property Example 19 20 or less 0 0 2.2 Excellent
Example 20 20 0 0 2.0 Excellent Example 21 20 0 0 2.0 Excellent
Example 22 20 0 0 2.0 Excellent Example 23 20 0 0 2.0 Excellent
Example 24 20 0 0 2.0 Excellent Example 25 38 0 0.8 1.8 -- Example
26 32 0 0.6 1.5 -- Example 27 35 0 0.6 1.7 -- Example 28 50 1.4 --
3.6 -- Average pore diameter: Average pore diameter estimated based
on TEM observation Area ratio of coarse pores 1: Area ratio of
pores having a diameter of 200 nm or more to the total fiber Area
ratio of coarse pores 2: Area ratio of pores having a diameter of
50 nm or more to the total fiber
[0424] TABLE-US-00008 TABLE 8 Ratio in Average Sea-part Islands-
viscosity Area diameter Thermal polymer part between sea Kneading
ratio of islands Strength U % shrinkage Type wt % polymer and
islands procedure (%) (nm) Spinnability (cN/dtex) (%) (%) Example
19 N66 80 PET1 0.9 Static 0.1 or less 33 Good 4.1 1.2 13 Example 20
PET7 80 PAO 0.9 EXT 0.1 or less 40 Good 3.3 1.5 7 Example 21 PET8
80 PAO 1.0 EXT 0.1 or less 38 Good 3.4 1.5 9 Example 22 PTT 80 PAO
1.4 EXT 0.1 or less 34 Good 3.1 1.7 10 Example 23 PBT 80 PAO 0.6
EXT 0.1 or less 45 Good 3.1 1.8 9 Example 24 PLA 80 PAO 0.6 EXT 0.1
or less 35 Good 2.9 1.8 9 Example 25 PP 80 PAO 1.0 EXT 1.2 40 Good
2.7 2.2 6 Example 26 PMMA 80 PAO 1.0 EXT 0.8 35 Good 2.5 2.4 --
Example 27 PMP 80 PAO 1.0 EXT 1.0 38 Good 2.6 2.3 9 Example 28 PPS
90 N6 1.0 EXT 1.5 52 Fair 5.3 2.1 -- Area ratio: Area ratio of
coarsely aggregated polymer particles having a diameter of 200 nm
or more to the total islands PET7: Homopolyethylene terephthalate
(.eta. = 0.63) PET8: PET copolymerized with 8% by weight of PEG
1000 and 7% by mole of isophthalic acid PAO: Polyalkylene oxide
modified product (polymer soluble in hot water) EXT: Twin-screw
extrusion-kneader Static: Static mixer (104 .times. 10.sup.4
splits)
Example 29
[0425] Materials were subjected to melt spinning and draw
false-twisting by the procedure of Example 1, except for changing
the number of spinneret orifices and the discharge rate, to thereby
obtain a 95 dtex, 68-filament false-twisted yarn of
N6/copolymerized PET alloy. This yarn had excellent physical
properties of a strength of 2.7 cN/dtex, an elongation percentage
of 22%, a thermal shrinkage of 8%, a U % of 1.0% and a CR of 38%,
and was free from not-untwisted portions and had good crimping
quality. The cross section of the crimped polymer alloy yarn was
observed under a TEM to find that the yarn had an islands-in-sea
structure comprising N6 as a sea (dark region) and the
copolymerized PET as islands (bright region). The islands had an
average diameter of 25 nm, showing that the polymer alloy fiber
comprised the copolymerized PET ultrafinely dispersed. The area
ratio of islands each having a diameter of 200 nm or more to the
total islands was 0.1% or less, and the area ratio of islands each
having a diameter of 100 nm or more was 0.9%. The islands were
dispersed as lines. A polyurethane fiber yarn "LYCRA" (registered
trademark) available from OPELONTEX CO., LTD. was covered with this
as a sheath yarn. The covered yarn was formed into a knit fabric
for tights and was subjected to alkali treatment by the procedure
of Example 1, to thereby obtain a knit fabric for tights comprising
a nanoporous N6 fiber. The knit fabric for tights had a METSUKE
(mass per unit area) of 100 g/m.sup.2 and contained 95% by weight
of the nanoporous N6 fiber and 5% by weight of the polyurethane
fiber yarn. This was subjected to treatment with silicone and
fabric massaging. The knit fabric for tights was sawn to obtain
tights. The TEM observation of the nanoporous N6 fiber sampled from
the tights shows that the fiber was free from coarse pores having a
diameter of 50 nm or more, and the average diameter of the pores
was 25 nm. The pores were unconnected pores. The yarn strength was
2.5 cN/dtex. The tights had good color property and a high
.DELTA.MR of 5.6%, exhibited a delicate touch and fresh hands like
a skin and felt good to wear. The combination use of the
polyurethane fiber yarn imparts high stretchability and improves
dimensional stability of the tights upon washing.
Example 30
[0426] "LYCRA" was covered by the procedure of Example 28 with the
polymer alloy fiber prepared according to Example 6. The resulting
yarn was formed into a short panty. The TEM observation of the
nanoporous N6 fiber sampled from the short panty shows that the
fiber was free from coarse pores having a diameter of 50 nm or
more, and the average diameter of the pores was 25 nm. The pores
were unconnected pores. The yarn strength was 2.5 cN/dtex. The
short panty had good color property and a high .DELTA.MR of 5.6%,
exhibited a delicate touch and fresh hands like a skin and felt
good to wear. The short panty had an ammonia adsorbing rate of 55%.
The combination use of the polyurethane fiber yarn imparts high
stretchability and improves dimensional stability of the short
panty upon washing.
Example 31
[0427] Materials were subjected to melt spinning by the procedure
of Example 1, except for changing the discharge rate per orifice
and the number of orifices, to obtain a 400 dtex, 96-filament fiber
of a N6/copolymerized PET polymer alloy. The polymer alloy fiber
had a strength of 2.5 cN/dtex, an elongation percentage of 100% and
a U % of 1.2%. The cross section of the highly oriented undrawn
polymer alloy yarn was observed under a TEM, to find that the fiber
was free from coarsely aggregated polymer particles, the area ratio
of islands each having a diameter of 200 nm or more to the total
islands was 0.1% or less, the area ratio of islands each having a
diameter of 100 nm or more to the total islands was 1% or less, and
the islands had an average diameter of 33 nm. This article was
subjected to draw false-twisting using a device shown in FIG. 29 by
the procedure of Example 6, to obtain a 333 dtex, 96-filament
false-twisted yarn. The resulting false-twisted yarn had a strength
of 3.0 cN/dtex, an elongation percentage of 30%, a U % of 1.5% and
a CR of 33%. The cross section of the fiber of the crimped polymer
alloy yarn was observed under a TEM, to find that the fiber was
free from coarsely aggregated polymer particles, the area ratio of
islands each having a diameter of 200 nm or more to the total
islands was 0.1% or less, and the area ratio of islands each having
a diameter of 100 nm or more was 0.1% or less. The islands had an
average diameter of 27 nm and had a lined structure.
[0428] The false-twisted yarn was subjected to soft twisting of 300
turns per meter and used as warp and weft in an S-twist/Z-twist two
ply yarn to thereby obtain a 2/2 twill woven fabric. The twill
woven fabric was subjected to an alkali treatment by the procedure
of Example 6, to thereby obtain a drapery fabric comprising a
nanoporous N6 fiber and having a METSUKE (mass per unit area) of
150 g/m.sup.2. The TEM observation of the nanoporous N6 fiber
sampled from the drapery fabric shows that the fiber was free from
coarse pores having a diameter of 50 nm or more, and the average
diameter of the pores was 25 nm. The pores were unconnected pores.
The yarn strength was 2.5 cN/dtex.
[0429] The resulting curtain had good color property and a high
ratio of moisture adsorption (.DELTA.MR) of 5.5%, indicating
sufficient hygroscopicity. A curtain was prepared from this fabric
and was hanged in a six-mat tatami room. The curtain served to make
a fresh indoor environment by preventing dewing due to its high
hygroscopicity and adsorbing malodor gases. Thus, the nanoporous
fibers of the present invention are suitable for products for
interior with better responsibility to environments than that of
conventional equivalents. The curtain was washed and dewatered in a
washing net using a domestic washer but did not lose its shape,
showing that the curtain had good dimensional stability in spite of
its high hygroscopicity and high water adsorptivity, in contrast to
rayon curtains.
Example 32
[0430] Materials were subjected to melt spinning by the procedure
of Example 10, except for changing the discharge rate per orifice
and the number of orifices and using Y-shaped discharge orifices.
The spun yarn was wound at a rate of 900 meters per minute,
subjected to two-step drawing at a draw ratio in the first step of
1.3 and a total draw ratio of 3.5, crimped by using jet nozzles and
wound as a 500 dtex, 90-filament bulked yarn having 9 crimps per 25
mm. The bulked yarn had a strength of 5.0 cN/dtex and an elongation
percentage of 25%. The cross section of the fiber of the crimped
polymer alloy yarn was observed under a TEM, to find that the fiber
was free from coarsely aggregated polymer particles, the area ratio
of islands each having a diameter of 200 nm or more to the total
islands was 0.1% or less, and the area ratio of islands each having
a diameter of 100 nm or more was 1% or less. The islands had an
average diameter of 30 nm and had a lined structure.
[0431] Two plies of the resulting bulked yarn were doubled and
subjected to first twisting (200 T/m), and two plies of the
first-twisted yarn were secondarily twisted (200 T/m), subjected to
twist setting by dry heating at 170.degree. C. and tufted into a
cut-pile carpet according to a conventional procedure.
[0432] The tufting herein was carried out according to a regular
level cut by controlling the stitch so as to have a gauge of 1/10
and a METSUKE (mass per unit area) of 1500 g/m.sup.2. The tufted
article was then subjected to backing. In the tufting, a woven base
fabric using a blended yarn of an acrylic fiber and a polyester
fiber was used as the base fabric. Only the cut-pile portion was
subjected to alkali treatment, to allow the cut-pile portion to be
a nanoporous N6 fiber. This was observed under a TEM and was found
to be free from coarse pores having a diameter of 50 nm or more, in
which the average diameter of the pores was 30 nm. The pores were
unconnected pores. The cut pile drawn therefrom had a strength of
2.0 cN/dtex. The cut-pile portion had good color property and a
high .DELTA.MR of 5.3%, i.e., sufficient hygroscopicity and could
yield a fresh indoor environment as the curtain according to
Example 31.
Example 33
[0433] Materials were spun by the procedure of Example 10, except
for changing the spinneret and the discharge rate per orifice, the
resulting yarn was wound by the first take-up roller 8, doubled and
received by a bunker. The yarns in the bunker were subjected to
gathering to obtain a tow of 15.times.10.sup.4 dtex. The tow was
drawn in a water tank at 90.degree. C. at a draw ratio of 3.2. The
drawn tow was passed through a crimper, to which an oil was fed,
and was cut. The resulting cut fiber had a single yarn fineness of
4 dtex, number of crimp of 10 per 25 mm and a fiber length of 51
mm. The cut fiber had a strength of 3.3 cN/dtex and an elongation
percentage of 40%. The cross section of the fiber was observed
under a TEM, to find that the fiber was free from coarsely
aggregated polymer particles, the area ratio of islands each having
a diameter of 200 nm or more to the total islands was 0.1% or less,
the area ratio of islands each having a diameter of 100 nm or more
was 1% or less. The islands had an average diameter of 33 nm and
had a lined structure.
[0434] The cut fiber was separated using a carding machine and was
formed into a web using a cross lap weaver. The article was then
subjected to needle punching (1500/cm.sup.2) to obtain a fiber
entangled nonwoven fabric of 150 g/m.sup.2. The nonwoven fabric was
subjected to alkali treatment by the procedure of Example 10, to
thereby obtain a nonwoven fabric comprising a nanoporous N6 fiber.
The nanoporous fiber sampled from the nonwoven fabric was observed
under a TEM and was found that the fiber was free from coarse pores
having a diameter of 50 nm or more, and the average diameter of the
pores was 30 nm. The pores were unconnected pores. The cut fiber
itself was subjected to alkali treatment and was converted into a
nanoporous fiber. The resulting nanoporous fiber had a strength of
2 cN/dtex. The nonwoven fabric had good color property and high
hygroscopicity in terms of .DELTA.MR of 5.8%.
Example 34
[0435] The cut fiber comprising the polymer alloy prepared
according to Example 33 was spun to obtain a spun polymer alloy
yarn. By using this as a warp and weft, a plain fabric having a
METSUKE (mass per unit area) of 150 g/m.sup.2 was prepared. The
plain fabric was subjected to alkali treatment by the procedure of
Example 10, to obtain a fabric comprising a nanoporous N6 fiber.
The TEM observation of the nanoporous fiber sampled from the fabric
shows that the fiber was free from coarse pores having a diameter
of 50 nm or more, and the average diameter of the pores was 30 nm.
The pores were unconnected pores. The spun yarn of the nanoporous
fiber sampled from the fabric had a strength of 2.0 cN/dtex. The
fabric had good color property, exhibited sufficient hygroscopicity
in terms of .DELTA.MR of 5.8% and good color property.
Example 35
[0436] A nonwoven fabric comprising a polymer alloy fiber and
having a METSUKE (mass per unit area) of 35 g/m.sup.2 was prepared
by spinning in the same manner as in Example 25, taking a yarn by
an air sucker, separating fibers and collecting on a net, and
subjecting the collected yarn to calendar rolling. The fiber taken
by the air sucker had a single yarn fineness of 2 dtex. The
spinning rate determined based on the fineness was 4500 meters per
minute. The cross section of the polymer alloy fiber sampled from
the nonwoven fabric was observed under a TEM, to find that the
fiber was free from coarsely aggregated polymer particles, the area
ratio of islands each having a diameter of 200 nm or more to the
total islands was 0.1% or less, and the area ratio of islands each
having a diameter of 100 nm or more was 1% or less. The islands had
an average diameter of 31 nm and had a lined structure.
[0437] The nonwoven fabric was subjected to treatment with hot
water to thereby obtain a nonwoven fabric comprising a nanoporous
PP fiber and having excellent water adsorptivity. The nanoporous
fiber was sampled from the nonwoven fabric and was observed under a
TEM to find that the fiber was free from coarse pores having a
diameter of 50 nm or more had unconnected pores as pores having an
average diameter of 30 nm. As is described above, the nanoporous
fibers of the present invention are optimal for yielding
unprecedented high-performance nonwoven fabrics.
Example 36
[0438] Materials were subjected to melt spinning by the procedure
of Example 1, except for changing the discharge rate and the number
of spinneret orifices. Thus, 10 kg of a highly oriented undrawn
yarn was wound. The yarn comprised a polymer alloy of 90 dtex, 68
filaments having a strength of 2.7 cN/dtex, an elongation
percentage of 100% and a U % of 1.3%. The cross section of the
polymer alloy fiber was observed under a TEM to find that a
copolymerized PET was homogeneously dispersed with size on the
order of nanometers as particles having an average diameter of 20
nm, the area ratio of coarse islands each having a diameter of 200
nm or more was 0.1% or less, and the area ratio of islands each
having a diameter of 100 nm or more was 1% or less (FIG. 27). The
observation of the longitudinal section shows that the
copolymerized PET had a lined structure.
[0439] The package had a good shape without saddle or yarns
dropping at a side of a cheese package. The package showed less
water swelling than articles comprising regular nylon fibers, and
was free from package deformation with time and had good
dimensional stability. A highly oriented undrawn yarn comprising a
regular nylon undergoes water swelling during winding, cannot be
stably wound and fails to obtain a package comprising a highly
oriented undrawn yarn and having an elongation percentage of 70% to
200%. The nylon yarn cannot be subjected to combined false twisting
as in PET. In contrast, the nylon polymer alloy fibers of the
present invention can stably yield a wound highly oriented undrawn
yarn having an elongation percentage of 70% to 200% and can thereby
be subjected to various yarn processing.
Comparative Example 8
[0440] The N6 used in Example 1 alone was subjected to melt
spinning by the procedure of Example 36. However, the resulting
yarn swelled as a result of water adsorption and elongated during
winding, which invited unstable winding and frequent burst of
yarn.
Example 37
[0441] The highly oriented undrawn yarn prepared according to
Example 36 and a 70 dtex, 34-filament regular drawn N6 yarn being
prepared separately and having a strength of 6 cN/dtex and an
elongation percentage of 45% were subjected to combined
false-twisting at a draw ratio of 1.02 and a heater temperature of
165.degree. C. The resulting combined false-twisted yarn having a
CR of 25% was subjected to the procedure of Example 1 to form a
round braid, and the round braid was subjected to alkali
treatment.
[0442] The nanoporous N6 fiber was sampled from the resulting round
braid was observed under a TEM to find that the fiber was free from
coarse pores having a diameter of 50 nm or more, and the average
diameter of the pores was 10 to 20 nm, the yarn strength was 2.5
cN/dtex, and the pores were unconnected pores. The fabric had good
color property and sufficient hygroscopicity in terms of .DELTA.MR
of 4.5% and showed excellent hands with a soft and delicate touch.
Thus, fabrics having excellent hands and being optimum for clothing
can be obtained by the combination use of the polymer alloy fiber
of the present invention and other fibers.
[0443] In particular, conventional nylons do not yield highly
oriented undrawn yarns having a high elongation to fail to provide
further improved hands. In contrast, fabrics having excellent hands
can be easily obtained according to the present invention, as is
shown in this example.
Example 38
[0444] The polymer alloy fiber prepared according to Example 13 and
a 70 dtex, 96-filament regular N6 fiber were subjected to air yarn
mixing using an interlacing nozzle. A plain fabric having a METSUKE
(mass per unit area) of 150 g/m.sup.2 was prepared by using the
resulting yarn as warp and weft, and subjected to alkali treatment
by the procedure of Example 10 and thereby yielded a fabric
comprising a nanoporous N6 fiber and a regular N6.
[0445] The nanoporous N6 fiber was observed under a TEM to find
that the fiber was free from coarse pores having a diameter of 50
nm or more, the average diameter of the pores was 10 to 20 nm, the
yarn strength was 3.3 cN/dtex, and the pores were unconnected
pores. The fabric had good color property and sufficient
hygroscopicity in terms of .DELTA.MR of 4%. The fabric had
excellent hands with a soft and delicate touch.
Example 39
[0446] A 2/2 twill woven fabric having a METSUKE (mass per unit
area) of 150 g/m.sup.2 by using the crimped polymer alloy yarn
prepared according to Example 1 as a warp and a 72 dtex,
27-filament viscose rayon as a weft. The fabric was then subjected
to alkali treatment by the procedure of Example 1.
[0447] The nanoporous N6 fiber was sampled from the resulting
fabric and was observed under a TEM to find that the fiber was free
from coarse pores having a diameter of 50 nm or more, the average
diameter of the pores was 20 nm or less, and the yarn strength was
2.5 cN/dtex. The pores were unconnected pores. The fabric had good
color property and sufficient hygroscopicity in terms of .DELTA.MR
of 7%. The fabric had excellent hands with a soft and delicate
touch. Thus, the fabrics comprising the nanoporous fiber of the
present invention in combination with other fibers have further
improved hands and/or hygroscopicity and are optimum for fabrics
for use in high-grade clothing.
Example 40
[0448] The polymer alloy cut fiber prepared according to Example 33
and cotton were subjected to spinning of mixed cut fibers in a
weight ratio of 50%/50% to obtain a blended yarn containing a
polymer alloy fiber. A plain fabric was prepared by the procedure
of Example 34, except for using the blended yarn, and was subjected
to alkali treatment by the procedure of Example 1. The fabric had
good color property and sufficient hygroscopicity in terms of
.DELTA.MR of 4.8%.
[0449] The spun yarn comprising a nanoporous N6 fiber sampled from
the fabric had a strength of 2.0 cN/dtex. The nanoporous N6 fiber
was sampled and was observed under a TEM to find that the fiber was
free from coarse pores having a diameter of 50 nm or more, and the
average diameter of the pores was 30 nm. The pores were unconnected
pores.
Example 41
[0450] The fabric comprising the nanoporous PET fiber prepared
according to Example 20 was allowed to adsorb triphenyl phosphate
serving as a flame retardant ("REOFOS TPP" available from Ajinomoto
Fine-Tech Co., Inc.) at 20% owf (based on the weight of the
fabric), a liquor ratio of 1:40, a temperature of 130.degree. C.
for one hour. The resulting article was washed with water,
subjected to soaping with an aqueous sodium carbonate solution at
80.degree. C. and subjected to domestic cleaning ten times. The
resulting fabric had a coverage of 7% by weight and showed good
self-extinguishing in a flammability test. Thus, the nanoporous
fibers of the present invention can take functional materials
therein to form a "capsulated structure", serve to improve washing
resistance and are optimum as raw yarns which are good for treating
with functional materials.
Comparative Example 9
[0451] A regular PET fabric was subjected to flame retardation by
the procedure of Example 41. The resulting fabric had a coverage of
1% by weight after cleaning ten times and showed no
self-extinguishing in a flammability test.
Example 42
[0452] The fabric comprising the nanoporous PET fiber prepared
according to Example 20 was allowed to adsorb a moisture absorbent
"SR1000" (10% water dispersion) available from Takamatsu Oil &
Fat Co., Ltd. at 20% owf of the moisture absorbent in terms of
solid content, a liquor ratio of 1:20, a temperature of 130.degree.
C. for one hour. The resulting PET fabric showed a degree of uptake
of 12% or more and had excellent hygroscopicity in terms of
.DELTA.MR of 4% or more, which is equivalent to or higher than
cotton. Thus, the nanoporous fibers of the present invention easily
take functional materials therein to form a "capsulated structure",
serve to improve the degree of uptake of the functional materials
and are optimum as raw yarns which are good for treating with
functional materials.
Comparative Example 10
[0453] A regular PET fabric was subjected to moisturizing by the
procedure of Example 42. The resulting fabric, however, had a
degree of uptake of the moisture absorbent of about 0% and
exhibited no hygroscopicity.
Example 43
[0454] The fabric comprising the nanoporous PET fiber prepared
according to Example 20 was allowed to adsorb a squalane. Such a
squalane is a naturally-occurring oil component extracted from
shark liver and serves as a substance having skin-care functions by
the action of moisturizing. The treatment was carried out by
dispersing a mixture containing 60% of the squalane and 40% of an
emulsifier in water in a concentration of 7.5 grams per liter and
dipping the fabric therein at a liquor ratio of 1:40, a temperature
of 130.degree. C. for 60 minutes. After the treatment, the fabric
was washed at 80.degree. C. for 2 hours. The coverage of the
squalane was 21% by weight to the resulting fabric. The fabric
after domestic cleaning 20 times had a coverage of the squalane of
12% by weight to the fabric and exhibited sufficient washing
(laundry) durability.
[0455] The round braid comprising the nanoporous PET fiber bearing
the squalane was formed into socks. Ten subjects suffering from dry
ankle were subjected to a wearing test for one week. As a result,
eight subjects were mitigated in dry skin. This is probably because
the squalane trapped by the pores was gradually extracted by the
action of the sweat of the subject and was brought into contact
with the skin.
Comparative Example 11
[0456] A regular PET fabric was subjected to exhaustion (uptake) by
the procedure of Example 43. The coverage after washing was 21% by
weight to the fabric, but that after domestic cleaning ten times
was 0% by weight, showing no washing resistance.
Example 44
[0457] The fabric comprising the nanoporous N6 fiber prepared
according to Example 10 was immersed in de-ionized water and was
mixed with 1,2-bis(trimethoxysilyl)ethane, followed by stirring for
3 hours. After standing still at room temperature for 14 hours, the
article was stirred for further 13 hours, left stand for 14 hours
and stirred for further 7 hours for polymerizing silica. The round
braid was washed with de-ionized water and was air-dried. This
procedure yielded N6/silica composite material in the form of a
fabric prepared by using the pores of the N6 nanofiber as a
template. This material was an excellent material having sufficient
rigidity and flexibility and was a hybrid material having excellent
flame retardancy. The composite material contained 30% by weight of
silica.
[0458] Thus, the nanoporous fibers of the present invention can be
easily formed into hybrid materials by adsorbing a polymerizable
monomer or oligomer and polymerizing the monomer or oligomer and
are optimum as precursors for advanced materials including organic
materials having functions of inorganic substances (e.g., flame
retardancy or catalytic activity) or inorganic materials having
flexibility.
Example 45
[0459] The tights comprising the nanoporous N6 fiber prepared
according to Example 29 was immersed in "New Policain Liquid"
available from TAIHO Pharmaceutical Co., Ltd. and was dried. This
yielded tights that can release an agent for dermatophytosis by the
action of the sweat. Patients with dermatophytosis were allowed to
wear the tights one per day. This treatment was continued for one
month to find that the symptom was remedied because of
sustained-released agent for dermatophytosis. Thus, the nanoporous
fibers of the present invention are capable of medicinally
efficacious components and are suitable as medical devices.
Example 46
[0460] The fabric comprising the nanoporous N6 fiber prepared
according to Example 1 was immersed in a 3% aqueous
diethylenetriamine solution at 50.degree. C. for one minute to
allow the nanoporous N6 fiber to support diethylenetriamine. The
acetaldehyde adsorbing capability of the resulting article was
determined in the same way as that for ammonia. As a result, the
article showed excellent elimination capability, since the
concentration was decreased from 30 ppm to 1 ppm within 10 minutes.
Thus, the nanoporous fibers of the present invention are capable of
supporting adsorbents and are suitable as industrial materials
typically for chemical filters and air filters.
Example 47
[0461] A highly oriented undrawn yarn was prepared by melting the
polymer alloy prepared according to Example 1 as a core component,
and the N6 used in Example 1 as a sheath component respectively at
270.degree. C., spinning at a temperature of 275.degree. C. to
obtain core-in-sheath multi-component fiber and taking the yarn at
a rate of 3800 meters per minute. This was subjected to draw
false-twisting by the procedure of Example 1. The compounding ratio
of the polymer alloy was 80% by weight. The resulting crimped yarn
comprising the core-in-sheath conjugated fiber was of 150 dtex and
76 filaments and had a strength of 4.1 cN/dtex, an elongation
percentage of 27%, a U % of 1.0%, a thermal shrinkage of 10% and a
CR of 45%. The islands parts copolymerized PET in the polymer alloy
as the core component had an average diameter of 26 nm and were
homogeneously dispersed with size on the order of nanometers. The
area ratio of coarse islands each having a diameter of 200 nm or
more to the total islands was 0.1% or less, and the area ratio of
coarse islands each having a diameter of 100 nm or more to the
total islands was 1% or less. The islands-part polymer was
dispersed as lines. The crimped yarn comprising the core-in-sheath
conjugated fiber was subjected to circular knitting by the
procedure of Example 1 and was subjected to alkali treatment, to
thereby obtain a round braid comprising a nanoporous N6 fiber.
[0462] The nanoporous fiber was sampled from the round braid and
was observed under a TEM to find that the fiber was free from
coarse pores having a diameter of 50 nm or more, and the average
diameter of the pores was 20 nm. The area ratio of nanopores was
77% of a cross section of the fiber. The nanoporous fiber had a
yarn strength of 3.3 cN/dtex, higher than that in Example 1, and
exhibited superior wear resistance. The pores were unconnected
pores. The fabric exhibited higher color property than that in
Example 1 and had sufficient hygroscopicity in terms of .DELTA.MR
of 4.8%.
Example 48
[0463] The core-in-sheath multi-component fiber spinning and draw
false-twisting procedures of Example 47 were carried out, except
for interchanging the core component and the sheath component and
setting the compounding ratio of the polymer alloy at 50% by
weight, to obtain a crimped yarn comprising a core-in-sheath
conjugated fiber of 150 dtex, 76 filaments having a strength of 4.1
cN/dtex, an elongation percentage of 27%, a U % of 1.0%, a thermal
shrinkage of 10% and a CR of 45%. The islands of the copolymerized
PET in the polymer alloy as the sheath component had an average
diameter of 26 nm and were homogeneously dispersed with size on the
order of nanometers. The area ratio of coarse islands each having a
diameter of 200 nm or more to the total islands was 0.1% or less,
and the area ratio of coarse islands each having a diameter of 100
nm or more to the total islands was 1% or less. The islands-part
polymer was dispersed as lines. The crimped yarn comprising the
core-in-sheath conjugated fiber was subjected to circular knitting
and alkali treatment by the procedure of Example 47, to thereby
obtain a round braid comprising a nanoporous N6 fiber. The
nanoporous fiber sampled from the round braid was observed under a
TEM to find that the fiber was free from coarse pores having a
diameter of 50 nm or more, and the average diameter of the pores
was 20 nm. The area ratio of nanopores to the cross section of the
fiber was 45%. The nanoporous fiber had a higher strength of 3.5
cN/dtex than that in Example 1. The pores were unconnected pores.
The fabric had good color property and sufficient hygroscopicity in
terms of .DELTA.MR of 4%.
Example 49
[0464] The multi-component fiber spinning procedure of Example 48
was carried out, except for using the high-viscosity N6 used in
Example 14 as the N6 alone side, and the polymer alloy prepared in
Example 1 as the polymer alloy side, to obtain a side-by-side yarn
at a compounding ratio of 50% by weight/50% by weight. The
high-viscosity N6 had a viscosity as large as 2 times or more that
of the polymer alloy. The resulting undrawn yarn was subjected to
drawing at a draw ratio of 1.2 and thermal treatment by the
procedure of Example 10, to obtain a 110 dtex, 34-filament crimped
side-by-side yarn having a strength of 4.1 cN/dtex, an elongation
percentage of 27%, a U % of 1.2%, a thermal shrinkage of 10%,
number of crimp of 20 per 25 mm. The islands of the copolymerized
PET in the polymer alloy as the outside component of the crimp had
an average diameter of 26 nm and were homogeneously dispersed with
size on the order of nanometers. The area ratio of coarse islands
each having a diameter of 200 nm or more to the total islands was
0.1% or less, and the area ratio of coarse islands each having a
diameter of 100 nm or more to the total islands was 1% or less. The
islands-part polymer was dispersed as lines. The resulting crimped
side-by-side yarn was subjected to circular knitting and alkali
treatment by the procedure of Example 48, to thereby obtain a round
braid comprising a nanoporous N6 fiber. The nanoporous fiber was
sampled from the round braid and was observed under a TEM to find
that the fiber was free from coarse pores having a diameter of 50
nm or more, and the average diameter of the pores was 20 nm. The
area ratio of nanopores to the cross section of the fiber was 44%.
The yarn had a high strength of 3.5 cN/dtex. The pores were
unconnected pores. The fabric had good color property and
sufficient hygroscopicity in terms of .DELTA.MR of 4%. The fabric
showed further higher bulkiness after water adsorption.
Example 50
[0465] The multi-component fiber spinning and draw thermal
treatment procedures of Example 49 were carried out, except for
using the low-viscosity N6 used in Example 1 as the N6 alone side
and the polymer alloy prepared in Example 14 as the polymer alloy
side, to thereby obtain a 110 dtex, 34-filament crimped
side-by-side yarn having a yarn strength of 4.0 cN/dtex, an
elongation percentage of 25%, a U % of 1.2%, a thermal shrinkage of
10% and a number of crimp of 18 per 25 mm.
[0466] The islands of the copolymerized PET in the polymer alloy as
the inside component of the crimp were dispersed with an average
diameter of 18 nm, and the area ratio of coarse islands each having
a diameter of 100 nm or more to the total islands was 0.1% or less.
The resulting crimped side-by-side yarn was subjected to circular
knitting and alkali treatment by the procedure of Example 49, to
thereby obtain a round braid comprising a nanoporous N6 fiber.
[0467] The nanoporous fiber was sampled from the round braid and
was observed under a TEM to find that the fiber was free from
coarse pores each having a diameter of 50 nm or more, and the
average diameter of the pores was 20 nm. The area ratio of
nanopores to the cross section of the fiber was 45%. The nanoporous
fiber had satisfactory bulkiness and a high yarn strength of 3.4
cN/dtex. The pores were unconnected pores. The fabric exhibited
good color property and had sufficient hygroscopicity in terms of
.DELTA.MR of 4%. The fabric exhibited further improved air
permeability after water adsorption, since crimps elongated and
stitches were enlarged.
Example 51
[0468] The round braid comprising the polymer alloy fiber prepared
in Example 10 was treated with a 2% aqueous sodium hydroxide
solution (95.degree. C., liquor ratio of 1:40) for twenty minutes
to decompose and dissolve out 50% of the copolymerized PET in the
polymer alloy fiber with a weight loss as the fiber of 10%. The
dissolution proceeded in the form of a rind from the fiber surface
layer, and the area ratio of nanopores to the cross section of the
fiber was 50%. This portion was observed under a TEM to find that
the pores were unconnected pores having an average diameter of 20
nm, and there was no coarse pores each having a diameter of 50 nm
or more.
[0469] The round braid had a .DELTA.MR of 4.0% and an ammonia
adsorbing rate of 50%, showing excellent hygroscopicity and/or
adsorptivity, and exhibited a sufficient percentage of water
retention of 60%. The nanoporous fiber also showed reversible water
swelling but a higher dimensional stability under wet conditions in
terms of a percentage of swelling of 4% than that in Example 10.
The fiber had a higher yarn strength of 3 cN/dtex than in Example
10.
Example 52
[0470] A high-density plain fabric having a METSUKE of 170
g/m.sup.2 was prepared by using the crimped polymer alloy yarn
prepared in Example 1 as a warp and weft. The article was subjected
to alkali treatment by the procedure of Example 1, to obtain a
plain fabric comprising a nanoporous N6 fiber. The shape and
physical properties of the nanoporous fiber sampled from the plain
fabric were determined and were found to be similar to those in
Example 1. The article was buffed to fibrillate the surface layer
of the nanoporous fiber and to form a multitude of fibrils having a
diameter of about 0.01 to 1 .mu.m which covered the surface of the
woven fabric. The resulting fabric had a soft touch and feeling
like spun, exhibited water repellency although it had not been
coated and was suitable as a sporting fabric.
Comparative Example 12
[0471] A high-density plain fabric was prepared and was subjected
to buffing by the procedure of Example 51, except for using a
false-twisted regular N6 yarn (77 dtex, 34 filaments). The
resulting fabric, however, was not sufficiently fibrillated and
failed to provide fibrils covering the surface of the woven fabric
and to obtain a soft and "spun feel" touch. The fabric was further
buffed to proceed fibrillation but resulted in breakage.
Example 53
[0472] A five-ply back satin of 180 g/m.sup.2 was prepared by using
the crimped polymer alloy yarn prepared in Example 1 as a weft and
a regular N6 fiber (44 dtex, 12 filaments) as a warp. The article
was subjected to alkali treatment by the procedure of Example 1, to
obtain a back satin woven fabric comprising a nanoporous N6 fiber.
The shape and physical properties of the nanoporous fiber sampled
from the fabric were determined and were found to be similar to
those in Example 1. The article was buffed to fibrillate the
surface layer of the nanoporous fiber and to form a multitude of
fibrils having a diameter of about 0.01 to 1 .mu.m which covered
the surface of the woven fabric. The fibrils were further separated
by water punching. The resulting fabric was suitable as a fabric
for wiping cloths.
Example 54
[0473] The nonwoven fabric comprising the nanoporous N6 fiber
prepared in Example 33 was buffed to obtain a multitude of fibrils
having a diameter of about 0.01 to 1 .mu.m, which covered the
surface of the nonwoven fabric. The resulting fabric had a surface
touch near to the skin, unlike conventional nylon nonwoven
fabrics.
Example 55
[0474] The nonwoven fabric comprising the nanoporous PP fiber
prepared in Example 35 was buffed to obtain a multitude of fibrils
having a diameter of about 0.01 to 1 .mu.m, which covered the
surface of the nonwoven fabric. This article was more suitable as a
filter than conventional PP spun bond nonwoven fabrics.
INDUSTRIAL APPLICABILITY
[0475] The porous fibers according to the present invention serve
to dramatically the liquid adsorptivity and/or adsorptivity which
they inherently have, as intact or as fibrous structures such as
yarns, cut fibers, felts, packages or fibrous articles using the
fibers. They can have a variety of functions using the nanoporous
structure, are promising in various fields and are very epoch
making.
[0476] More specifically, the fibers easily take a variety of
functional materials in the nanopores and are easily processed to
have the functions, as compared with conventional fibers.
[0477] The fibers can bear or support, for example, any of moisture
absorbents, flame retardants, water repellents, humectants, cold
insulators, heat insulators and lubricating agents in the form of,
but not limited to, fine particles. In addition, agents for
promoting health and beauty care, such as polyphenols, amino acids,
proteins, capsaicin and vitamins, as well as agents for dermatosis
such as dermatophytosis and medicaments such as disinfectants,
anti-inflammatory agents and analgesics.
[0478] Further, polyamines, photocatalytic nanoparticles and other
agents for adsorbing and/or decomposing harmful substances can be
imparted to the fibers. If desired, hybrid materials can be
arbitrarily obtained therefrom by allowing the fibers to adsorb or
absorb organic or inorganic monomers capable of forming polymers
and polymerizing the monomers.
[0479] The fibers can have selective adsorptivity and/or catalytic
activity by activating the walls of the pores by chemical
processing using their high specific surface areas.
[0480] The fibers can have any of various functions as mentioned
above with adjustable performance according to necessity, can yield
comfortable products for use in clothing such as panty hose,
tights, inner wears, shirts, blousons, trousers and coats and can
also be used in clothing materials such as cups and pads; interior
decoration such as curtains, carpets, mats and furniture;
livingwares such as wiping cloths; industrial materials such as
abrasive cloths; and vehicle interior decoration.
[0481] The fibers, if adsorbing any functional molecule or agent,
can also be used as most advanced materials typically in the fields
of environment, medical or information technology (IT), such as
fibrous structures as health-cosmetic-related goods, base fabrics
for medicaments and medical devices, as well as electrodes of fuel
cells.
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