U.S. patent application number 14/910895 was filed with the patent office on 2016-07-07 for elastic monofilament.
The applicant listed for this patent is TORAY INDUSTRIES, INC., TORAY MONOFILAMENT CO., LTD.. Invention is credited to Kota Nakamura, Takuya Ryomoto, Hidetoshi Sakai, Nobuaki Tanaka, Hiroshi Tsuchikura.
Application Number | 20160194788 14/910895 |
Document ID | / |
Family ID | 52461491 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160194788 |
Kind Code |
A1 |
Tanaka; Nobuaki ; et
al. |
July 7, 2016 |
ELASTIC MONOFILAMENT
Abstract
An elastic monofilament includes a core-sheath composite
structure, wherein a ratio of a core component is 2 to 40% by
volume, the core component is a thermoplastic polyester having, in
a polymer, 95 to 100% by mass of a thermoplastic polyester unit,
and a sheath component is a copolymeric thermoplastic elastomer
having a hard segment and a soft segment, and wherein the
monofilament has a diameter of 0.1 to 1.0 mm, and a tensile
strength of 0.3 to 3.0 cN/dtex.
Inventors: |
Tanaka; Nobuaki; (Otsu,
JP) ; Tsuchikura; Hiroshi; (Otsu, JP) ;
Nakamura; Kota; (Okazaki, JP) ; Sakai; Hidetoshi;
(Nagoya, JP) ; Ryomoto; Takuya; (Tokyo,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TORAY INDUSTRIES, INC.
TORAY MONOFILAMENT CO., LTD. |
Tokyo
Okazaki, Aichi |
|
JP
JP |
|
|
Family ID: |
52461491 |
Appl. No.: |
14/910895 |
Filed: |
August 7, 2014 |
PCT Filed: |
August 7, 2014 |
PCT NO: |
PCT/JP2014/070923 |
371 Date: |
February 8, 2016 |
Current U.S.
Class: |
428/373 |
Current CPC
Class: |
D01F 8/14 20130101; D01D
5/34 20130101; D01F 8/16 20130101 |
International
Class: |
D01F 8/14 20060101
D01F008/14 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 9, 2013 |
JP |
2013-166304 |
Claims
1.-7. (canceled)
8. An elastic monofilament comprising a core-sheath composite
structure, wherein a ratio of a core component is 2 to 40% by
volume, the core component is a thermoplastic polyester having, in
a polymer, 95 to 100% by mass of a thermoplastic polyester unit,
and a sheath component is a copolymeric thermoplastic elastomer
having a hard segment and a soft segment, and wherein the
monofilament has a diameter of 0.1 to 1.0 mm, and a tensile
strength of 0.3 to 3.0 cN/dtex.
9. The elastic monofilament according to claim 8, wherein intrinsic
viscosity (IV) of the thermoplastic polyester used in the core
component is 0.7 or higher.
10. The elastic monofilament according to claim 9, wherein the hard
segment contains, as a main constituent unit, an aromatic polyester
unit, and the soft segment contains, as a main constituent unit, an
aliphatic polyether unit and/or an aliphatic polyester unit.
11. The elastic monofilament according to claim 10, wherein the
aromatic polyester unit is a polybutylene terephthalate unit, and
the aliphatic polyether unit and/or the aliphatic polyester unit is
a poly(tetramethylene oxide)glycol unit.
12. The elastic monofilament according to claim 8, wherein a ratio
of the hard segment to the soft segment is 35:65 to 75:25 (ratio by
mass).
13. The elastic monofilament according to claim 8, having a bending
stiffness of 2.0 to 10 cN.
14. The elastic monofilament according to claim 8, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
15. The elastic monofilament according to claim 9, wherein a ratio
of the hard segment to the soft segment is 35:65 to 75:25 (ratio by
mass).
16. The elastic monofilament according to claim 10, wherein a ratio
of the hard segment to the soft segment is 35:65 to 75:25 (ratio by
mass).
17. The elastic monofilament according to claim 11, wherein a ratio
of the hard segment to the soft segment is 35:65 to 75:25 (ratio by
mass).
18. The elastic monofilament according to claim 9, having a bending
stiffness of 2.0 to 10 cN.
19. The elastic monofilament according to claim 10, having a
bending stiffness of 2.0 to 10 cN.
20. The elastic monofilament according to claim 11, having a
bending stiffness of 2.0 to 10 cN.
21. The elastic monofilament according to claim 12, having a
bending stiffness of 2.0 to 10 cN.
22. The elastic monofilament according to claim 9, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
23. The elastic monofilament according to claim 10, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
24. The elastic monofilament according to claim 11, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
25. The elastic monofilament according to claim 12, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
26. The elastic monofilament according to claim 13, wherein a rate
of dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex is 0 to 5%.
Description
TECHNICAL FIELD
[0001] This disclosure relates to an elastic monofilament excellent
in fatigue resistance to repeated deformation in a bending
direction, and suitable for use in various industrial uses such as
marine materials, construction materials, safety materials,
clothing materials, civil engineering materials, agricultural
materials, vehicle materials and sport materials, particularly,
suitable for use in woven or knitted structures having
elasticity.
BACKGROUND
[0002] A monofilament made of a thermoplastic elastomer is known to
have excellent rubber elasticity. Since a woven or knitted fabric
made from such a monofilament made of the thermoplastic elastomer
has excellent elasticity, development for use in clothing materials
such as stockings, medical materials such as supporters, sport
materials such as trampolines, bedding materials such as beds, and
sitting materials such as office chairs/car seats is progressing.
For example, Japanese Translation of PCT International Application
Publication JP-T-1997-507782, Japanese Patent Laid-open Publication
No. 1999-152625 and Japanese Patent Laid-open Publication No.
1999-172532 propose that a woven or knitted fabric made from the
thermoplastic elastomer can be suitably used in application to
office chairs and automobile chairs.
[0003] As one example of the monofilament constituting the woven or
knitted fabric applied to such uses, a monofilament made of a
thermoplastic elastomer containing, as its main component, a
polyester or a polyether is known. A woven or knitted fabric made
from the conventional monofilament made of the thermoplastic
elastomer, however, has a problem of reduction in elastic recovery
after repeated deformation, that is, so-called permanent set in
fatigue at the time of long-term use. Regarding this problem, for
the purpose of obtaining a woven or knitted fabric excellent in
mechanical properties and elastic recovery after repeated
deformation, an elastic monofilament is proposed (see Japanese
Patent Laid-open Publication No. 1999-152625 and Japanese Patent
Laid-open Publication No. 1999-172532).
[0004] Specifically, Japanese Patent Laid-open Publication No.
1999-152625 describes that an effect of reducing change in the
knitted or woven structure after repeated deformation of a fabric
and of excellent long-term durability is obtained by using an
elastic composite monofilament in which a two-component
polyester-based elastomer is used as a main raw material, the
monofilament has a sheath (sheath of core-sheath structure)-core
(core of core-sheath structure) shape having an area ratio of a
core part in a fiber cross-sectional area of 50% or more, the
melting point of a core part component is 150.degree. C. or higher
and lower than 200.degree. C., and the melting point of a sheath
part component is lower than the melting point of the core part
component by 20.degree. C. or more and less than 50.degree. C., and
partially melting or fusing a low melting point component used in a
sheath side to form a fusion point at an intersection part of a
knitted or woven texture, thereby improving a force of
constraint.
[0005] In Japanese Patent Laid-open Publication No. 1999-172532, a
single component monofilament made of a polymer of particular
components, and having a creep ratio at 80.degree. C. for 24 hours
under a 15% extension stress at room temperature of 5% or less is
proposed as a monofilament having reduced change in property due to
repeated deformation.
[0006] In those proposals, the elastic monofilament is required to
exhibit high rubber elasticity, and in both of the single component
monofilament made of the thermoplastic elastomer (see Japanese
Patent Laid-open Publication No. 1999-172532) and the core-sheath
composite monofilament made of two polymers (see Japanese Patent
Laid-open Publication No. 1999-152625), the monofilament (both of
core and sheath in the case of core-sheath composite monofilament)
is, as a premise, made of the thermoplastic elastomer, and exhibits
rubber elasticity which is as high as possible.
[0007] However, the proposals concerning improvement in permanent
set in fatigue of the elastic seat, which are disclosed in Japanese
Patent Laid-open Publication No. 1999-152625 and Japanese Patent
Laid-open Publication No. 1999-172532, provide still insufficient
resistance to permanent set in fatigue at the time of practical
use. It could therefore be helpful to provide an elastic
monofilament excellent in resistance to permanent set in fatigue at
practical use of an elastic seat.
SUMMARY
[0008] We studied a cause for failure to obtain desired resistance
to permanent set in fatigue in a woven or knitted fabric obtained
from the conventional monofilament. We then searched for a
configuration to improve fatigue resistance to repeated deformation
in a bending direction of a monofilament based on our idea that
fatigue resistance to repeated deformation in a tensile direction
of the monofilament is improved in the conventional techniques to
improve resistance to permanent set in fatigue of the woven or
knitted fabric, but this is insufficient, and improvement in
fatigue resistance to repeated deformation in a bending direction
of the monofilament would be necessary. As a result, we found that
by adopting the following configuration, resistance to permanent
set in fatigue of the woven or knitted fabric can be considerably
improved as compared to before.
[0009] The elastic monofilament has a core-sheath composite
structure, wherein a ratio of a core component is 2 to 40% by
volume, the core component is a thermoplastic polyester having, in
a polymer, 95 to 100% by mass of a thermoplastic polyester unit,
and a sheath component is a copolymeric thermoplastic elastomer
having a hard segment and a soft segment, and wherein the
monofilament has a diameter of 0.1 to 1.0 mm, and a tensile
strength of 0.3 to 3.0 cN/dtex.
[0010] Preferably, the intrinsic viscosity (IV) of the
thermoplastic polyester used in the core component is 0.7 or
higher.
[0011] Preferably, the hard segment contains, as a main constituent
unit, an aromatic polyester unit, and the soft segment contains, as
a main constituent unit, an aliphatic polyether unit and/or an
aliphatic polyester unit, the aromatic polyester unit is a
polybutylene terephthalate unit, and the aliphatic polyether unit
and/or the aliphatic polyester unit is a poly(tetramethylene
oxide)glycol unit.
[0012] Preferably, a ratio of the hard segment to the soft segment
is 35:65 to 75:25 (ratio by mass).
[0013] Preferably, the elastic monofilament has a bending stiffness
of 2.0 to 10 cN. In this aspect, when the monofilament is
heat-treated for 3 minutes in a temperature condition of
160.degree. C. under fixed length, and then retained for 12 hours
under a tension of 0.1 cN/dtex, a rate of dimensional change is 0
to 5%.
[0014] The elastic monofilament excellent in fatigue resistance in
a bending direction is thus obtained. Thereby, it becomes possible
to considerably improve resistance to permanent set in fatigue at
the time of practical use of a woven or knitted fabric typified by
trampolines, supporters, beds, car seats, and office chairs.
[0015] Since the elastic monofilament has the core component
containing a thermoplastic polyester having, in a polymer, 95 to
100% by mass of a thermoplastic polyester unit unlike the
conventional elastic monofilament made only of the thermoplastic
elastomer, the core component bears part of a stress applied to a
filament when the monofilament is extended and/or bent. For this
reason, in the elastic monofilament, extension deformation and
plastic deformation of the thermoplastic elastomer component are
easily suppressed even when the monofilament is extended and/or
bent. That is, since the elastic monofilament is difficult to be
permanently set even when the monofilament undergoes extension
and/or bending deformation, it also becomes possible to
considerably improve resistance to permanent set in fatigue of a
woven or knitted fabric typified by trampolines, supporters, beds,
car seats, and office chairs, when the monofilament is used in the
woven or knitted fabric.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 is a schematic side view for illustrating a method of
measuring an amount of permanent set in fatigue.
DESCRIPTION OF REFERENCE SIGNS
[0017] 1. Elastic monofilament after bending abrasion property
test
[0018] 2. Load
[0019] a. Line connecting between marks
[0020] A. Distance of perpendicular line drawn from line a
connecting between marks towards deformation maximum point (Amount
of permanent set in fatigue)
DETAILED DESCRIPTION
[0021] The elastic monofilament has a core-sheath composite
structure, wherein a ratio of a core component is 2 to 40% by
volume, the core component is a thermoplastic polyester having, in
a polymer, 95 to 100% by mass of a thermoplastic polyester unit,
and a sheath component is a copolymeric thermoplastic elastomer
having a hard segment and a soft segment, and wherein the
monofilament has a diameter of 0.1 to 1.0 mm, and a tensile
strength of 0.3 to 3.0 cN/dtex.
[0022] That is, the elastic monofilament improves fatigue
resistance to repeated deformation in a bending direction by
combining a thermoplastic elastomer having rubber elasticity with a
thermoplastic polyester resin having no rubber elasticity such as
specified polyethylene terephthalate in a particular constitution.
We found that a remarkable effect regarding resistance to permanent
set in fatigue is obtained while retaining elasticity in the
bending direction by daringly reducing rubber elasticity in the
tensile direction of the monofilament, which is not reduced as a
premise in the conventional techniques.
[0023] The reason why such a remarkable effect is obtained is
presumed as follows.
[0024] As a typical example of a usage mode of the elastic
monofilament, an example will be described where an elastic woven
fabric made from an elastic monofilament as a weft, and a
polyethylene terephthalate monofilament as a warp is used in office
chairs or car seats. In such a usage mode, a load at the time of
sitting is imparted to the elastic woven fabric from a
substantially vertical direction. When attention is paid to
deformation behavior of one elastic monofilament, the elastic
monofilament, movement of which due to a load on the elastic woven
fabric in a vertical direction is suppressed by a warp, is greatly
deformed in a bending direction. Furthermore, when microscopic
attention is paid to a bent part of the elastic monofilament, the
elastic monofilament is compressed inside the bent part, and the
elastic monofilament is greatly extended outside the bent part.
[0025] In such a situation, in the conventional elastic
monofilament made only of the thermoplastic elastomer, we believe
that large extension outside a bent part generates deformation more
than the elastically deformable elongation originally possessed by
the thermoplastic elastomer to cause plastic deformation and, as a
result, permanent set in fatigue is generated in the woven or
knitted fabric.
[0026] Whereas, in a similar situation, in a core-sheath composite
monofilament in which a thermoplastic polyester such as
polyethylene terephthalate is used in a core component, and a
thermoplastic elastomer is used in a sheath component in a
particular constitution as in our monofilaments, the core component
bears a prescribed stress. As a result, extension and deformation
of a thermoplastic elastomer component and plastic deformation
outside a bent part are suppressed, and excellent stretch back
property of the thermoplastic elastomer used in the sheath
component is hardly deteriorated. Furthermore, by using the
thermoplastic polyester such as polyethylene terephthalate in the
core component, creep elongation when the monofilament is exposed
to bending deformation for a long period of time is also
suppressed. For this reason, we believe that a woven or knitted
fabric made from our elastic monofilament is hardly set permanently
over a long term, and can continuously exhibit excellent
elasticity.
[0027] In the elastic monofilament, from the viewpoint of achieving
both of improvement in heat-resistant creep property and elasticity
in the bending direction, a ratio of the core component is required
to be 2 to 40% by volume. When the ratio of the core component is
less than 2% by volume, excessive extension outside a bent part due
to the core component described above cannot be suppressed. On the
other hand, when the ratio of the core component exceeds 40% by
volume, since an amount of the thermoplastic elastomer component is
too small, objective elasticity is hardly exhibited. From such a
viewpoint, the ratio of the core component is preferably 3 to 20%
by volume, and more preferably 3 to 13% by volume.
[0028] As a cross-sectional shape of the elastic monofilament, the
monofilament may have a modified cross-sectional shape such as
elliptic, quadrilateral, polygonal and polyphyllous cross sections,
in addition to a circular cross section.
[0029] The elastic monofilament has a diameter of 1.0 mm or less,
preferably 0.7 mm or less. When the diameter is too great, an
absolute amount of extension outside a bent part at the time of
bending deformation is increased to easily cause plastic
deformation, and when the monofilament is made into a woven or
knitted fabric, permanent set in fatigue is easily caused. To
exhibit the function of the elastic monofilament, there is
originally no lower limit of the diameter. However, the diameter is
0.1 mm or more since it becomes difficult to maintain the shape of
a core-sheath composite form when the diameter is too small.
[0030] Herein, letting an average diameter of a cross section of
the elastic monofilament to be L1, letting an average diameter of a
cross section of the core component to be L2, and letting a
thickness of the sheath component along an arbitrary line segment t
drawn on an outer circumference of the elastic monofilament from a
center of gravity of a cross section of the core component to be
Lt, it is preferable that Lt corresponding to the arbitrary line
segment t satisfies the following relation over the entire outer
circumference of the elastic monofilament:
-15(%).ltoreq.(Lt-LT).times.100/LT.ltoreq.15(%)
wherein LT=(L1-L2)/2.
[0031] Average diameters L1 and L2 of cross sections each represent
a diameter of an area equivalent circle. When the above relation is
satisfied, since the sheath component retains a prescribed
thickness over the whole circumference of the elastic monofilament,
a region where an amount of the sheath component is partially small
or a part where the amount is extremely large is not generated.
Therefore, at the time of bending deformation, a problem is hardly
caused that the sheath component is torn by excessive extension, or
elastic recovery becomes uneven.
[0032] Examples of the thermoplastic polyester which can be used in
the core component include polybutylene terephthalate, polyethylene
terephthalate, polypropylene terephthalate, polyethylene
naphthalate, and aromatic polyesters. From the viewpoint of
versatility, heat resistance and high stiffness, polyethylene
terephthalate is preferably used.
[0033] The intrinsic viscosity (IV) of the thermoplastic polyester
used in the core component is preferably 0.7 or higher, and more
preferably 1.0 or higher. When the intrinsic viscosity (IV) is too
low, since a load per molecular chain when the core component bears
a stress becomes great, the resulting elastic monofilament tends to
be permanently set. From the viewpoint of improvement in creep
property of the resulting elastic monofilament, improvement in
mechanical properties of the monofilament, and deformation
controllability when the monofilament is bent, the intrinsic
viscosity originally has no upper limit. However, it is preferable
that the intrinsic viscosity (IV) is 1.4 or lower from the
viewpoint of melting processability.
[0034] The thermoplastic polyester used in the core component is a
polymer in which the thermoplastic polyester unit accounts for 95
to 100% by mass. The thermoplastic polyester unit refers to
components having a polyester skeleton other than components
corresponding to the thermoplastic elastomer described later. As
the component of a structure other than that of the thermoplastic
polyester unit, a copolymer with a component copolymerizable with
the thermoplastic polyester or other thermoplastic polymers that
can be blended with the thermoplastic polyester can be used, as far
as the amount thereof is less than 5% by mass.
[0035] On the other hand, when the amount of the thermoplastic
polyester unit is less than 95% by mass, since mechanical
properties of the thermoplastic polyester are deteriorated due to
copolymerization or blending, this consequently leads to an elastic
monofilament which easily causes permanent set in fatigue when the
monofilament is made into a woven or knitted fabric. Examples of
the copolymerizable component include aromatic dicarboxylic acids
such as isophthalic acid and naphthalenedicarboxylic acid,
aliphatic dicarboxylic acids such as adipic acid, sebacic acid and
azelaic acid, diol compounds such as diethylene glycol and
1,4-butanediol, polyfunctional compounds, 5-sulfoisophthalic acid
metal salts, and phosphorus-containing compounds. It is preferable
that the thermoplastic polyester constituting the core component is
a so-called homopolymer, which is composed of substantially 100% by
mass of the thermoplastic polyester unit.
[0036] The thermoplastic polyester used in the core component can
contain additives such as matting agents such as titanium oxide,
calcium carbonate, kaolin and clay, pigments, dyes, lubricants,
antioxidants, heat-resistant agents, steaming-resistant agents,
light-resistant agents, ultraviolet absorbing agents, antistatic
agents and flame retardants, as far as the amount thereof is within
a range in which the desired effect is not impaired, specifically,
the amount is 5% by mass or less. Among them, from the viewpoint of
suppression of shininess of the resulting elastic monofilament and
generation of premium feel, and improvement in durability of the
elastic monofilament in spite of the unclear detailed mechanism, it
is preferable that the amount of titanium oxide is 0.01 to 1% by
mass.
[0037] The thermoplastic elastomer constituting the sheath
component of the elastic monofilament is required to be a
copolymeric thermoplastic elastomer having a hard segment and a
soft segment such as styrene-based elastomers, polyester-based
elastomers, polyurethane-based elastomers, and polyamide-based
elastomers. The reason therefor is that in a blend-type
thermoplastic elastomer typified by olefin-based elastomers, heat
resistance is deficient, and there are concerns about interface
peeling of a sea-island component and recycle property. From the
viewpoint of heat resistance and mechanical properties, the
thermoplastic elastomer preferably has a melting point of
150.degree. C. or higher, particularly 180.degree. C. or
higher.
[0038] A preferable aspect of the polyester-based elastomer is that
a hard segment has, as a main constituent unit, an aromatic
polyester unit mainly formed of an aromatic dicarboxylic acid or an
ester forming derivative thereof, and a diol or an ester forming
derivative thereof
[0039] Specific examples of the aromatic dicarboxylic acid include
terephthalic acid, isophthalic acid, phthalic acid,
naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic
acid, anthracenedicarboxylic acid, diphenyl-4,4'-dicarboxylic acid,
diphenoxyethanedicarboxylic acid, 4,4'-diphenyl ether dicarboxylic
acid, 5-sulfoisophthalic acid, and sodium 3-sulfoisophthalate.
[0040] The above aromatic dicarboxylic acid is mainly used. If
necessary, part of this aromatic dicarboxylic acid can be replaced
with an alicyclic dicarboxylic acid such as
1,4-cyclohexanedicarboxylic acid, cyclopentanedicarboxylic acid and
4,4'-dicyclohexyldicarboxylic acid, or an aliphatic dicarboxylic
acid such as adipic acid, succinic acid, oxalic acid, sebacic acid,
dodecanedioic acid, and dimer acid. Furthermore, an ester forming
derivative of a dicarboxylic acid, for example, lower alkyl esters,
aryl esters, carbonic acid esters and acid halides can be of course
used equally.
[0041] Then, as a specific example of the diol, diols having a
molecular weight of 400 or less, for example, aliphatic diols such
as 1,4-butanediol, ethylene glycol, trimethylene glycol,
pentamethylene glycol, hexamethylene glycol, neopentyl glycol, and
decamethylene glycol, alicyclic diols such as
1,1-cyclohexanedimethanol, 1,4-dicyclohexanedimethanol, and
tricyclodecanedimethanol, and aromatic diols such as xylylene
glycol, bis(p-hydroxy)diphenyl, bis(p-hydroxy)diphenylpropane,
2,2'-bis[4-(2-hydroxyethoxy)phenyl]propane,
bis[4-(2-hydroxyethoxy)phenyl]sulfone,
1,1-bis[4-(2-hydroxyethoxy)phenyl]cyclohexane,
4,4'-dihydroxy-p-terphenyl, and 4,4'-dihydroxy-p-quarter phenyl are
preferably used. These diols can also be used in a form of an ester
forming derivative, for example, an acetyl derivative and an alkali
metal salt.
[0042] Two or more kinds of these dicarboxylic acids, derivatives
thereof, diol components and derivatives thereof can be used
together.
[0043] A preferable example of such a hard segment is a
polybutylene terephthalate unit derived from terephthalic acid
and/or dimethyl terephthalate and 1,4-butanediol. A hard segment
composed of a polybutylene terephthalate unit derived from
terephthalic acid and/or dimethyl terephthalate, and a polybutylene
isophthalate unit derived from isophthalic acid and/or dimethyl
isophthalate and 1,4-butanediol is also preferably used.
[0044] The soft segment of the polyester-based elastomer has, as a
main constituent unit, an aliphatic polyether unit and/or an
aliphatic polyester unit. Examples of the aliphatic polyether
include poly(ethylene oxide)glycol, poly(propylene oxide)glycol,
poly(tetramethylene oxide)glycol, poly(hexamethylene oxide)glycol,
a copolymer of ethylene oxide and propylene oxide, an ethylene
oxide addition polymer of poly(propylene oxide)glycol, and a
copolymer glycol of ethylene oxide and tetrahydrofuran.
[0045] Examples of the aliphatic polyester include
poly(.epsilon.-caprolactone), polyenantholactone,
polycaprylolactone, polybutylene adipate, and polyethylene adipate.
In view of elastic property of the resulting polyester-based
elastomer, it is preferable to use, among these aliphatic
polyethers and/or aliphatic polyesters, poly(tetramethylene
oxide)glycol, an ethylene oxide adduct of poly(propylene
oxide)glycol, a copolymer glycol of ethylene oxide and
tetrahydrofuran, poly(.epsilon.-caprolactone), polybutylene
adipate, and polyethylene adipate. Among them, poly(tetramethylene
oxide)glycol is a preferable constituent unit. It is preferable
that the number average molecular weight of these soft segments is
around 300 to 6000 in the copolymerized state.
[0046] In the elastic monofilament, it is preferable that the ratio
of the hard segment to the soft segment, that is, the
copolymerization ratio is 35:65 to 75:25 (ratio by mass). By
setting the ratio of the hard segment to the soft segment within
the above range, not only a heat characteristic that thermal
degradation is hardly caused at the time of composite spinning is
obtained, but also the sheath component has moderate elasticity.
Therefore, an elastic monofilament excellent in stretch back
property can be obtained.
[0047] In the elastic monofilament, for the purpose of imparting
heat adhesiveness, a third component can be provided outside the
sheath component composed of the thermoplastic elastomer, or
further inside the core component composed of the thermoplastic
polyester, as far as the desired effect is not impaired.
[0048] The thermoplastic elastomer constituting the sheath
component preferably has a Shore D hardness of 30 to 65. By setting
the Shore D hardness within the above range, it becomes possible to
suppress excessive extension at the time of bending deformation
while controlling the amount of the hard segment which is easily
deformed plastically.
[0049] The thermoplastic elastomer used in the sheath component can
contain matting agents such as titanium oxide, calcium carbonate,
kaolin, and clay, pigments, dyes, lubricants, antioxidants,
heat-resistant agents, steaming-resistant agents, light-resistant
agents, ultraviolet absorbing agents, antistatic agents and flame
retardants, as far as the amount thereof is within a range in which
the desired effect is not impaired, specifically, the amount is 5%
by mass or less.
[0050] The tensile strength is 0.3 to 3.0 cN/dtex, preferably 0.3
to 2.94 cN/dtex, and further preferably 0.5 to 2.5 cN/dtex. When
the tensile strength is within the above range, in a higher-order
processing step such as a weaving or knitting step, deterioration
of the capability of passing through processes due to yarn breakage
is hardly caused, and an elastic monofilament retaining sufficient
elasticity is obtained. Particularly, when the tensile strength
exceeds 3.0 cN/dtex, rubber elasticity when the monofilament is
made into a woven or knitted structure is easily deteriorated since
stiffness of the core-sheath composite monofilament is too high and
the elasticity in the bending direction is deteriorated.
[0051] The elastic monofilament preferably has a bending stiffness
of 2.0 to 10.0 cN. As a more preferable bending stiffness, 2.5 to
8.0 cN can be mentioned. When the bending stiffness is too low,
there are concerns that the elastic monofilament is excessively
extended outside a bent part at the time of bending, whereas, when
the bending stiffness is too great, there arise concerns that the
filament is hardly bent and deformed, and objective elasticity is
not exhibited. From such a viewpoint, the bending stiffness is
preferably within the above range to obtain a monofilament
excellent in durability and excellent also in elasticity.
[0052] The rate of dimensional change when the monofilament is
heat-treated for 3 minutes in a temperature condition of
160.degree. C. under fixed length, and then retained for 12 hours
under a tension of 0.1 cN/dtex is preferably 0 to 5%. Herein, heat
treatment for 3 minutes at a temperature of 160.degree. C. assumes
that the elastic monofilament is made into a woven or knitted
fabric, and the fabric is subjected to heat setting. When the rate
of dimensional change when the monofilament is heat-treated for 3
minutes at a temperature of 160.degree. C. under fixed length, and
then retained for 12 hours under a tension of 0.1 cN/dtex is within
the above range, even after the monofilament is made into an
article such as a woven or knitted fabric, and the article is
heat-set, it is not excessively extended, and can have excellent
creep property. As a more preferable range of the rate of
dimensional change when the monofilament is heat-treated for 3
minutes in a temperature condition of 160.degree. C. under fixed
length, and then retained for 12 hours under a tension of 0.1
cN/dtex, 0 to 3% can be mentioned.
[0053] The elastic monofilament preferably has a boiling water
shrinkage rate of 3 to 10%. By setting the boiling water shrinkage
rate within the above range, it becomes possible to obtain an
article which is excellent in dimensional stability at the time of
heat impartation, which is more hardly wrinkled when made into a
woven or knitted fabric, and which is excellent in quality.
[0054] The elastic monofilament can be of course used alone.
Moreover, a plurality of the elastic monofilaments can be used, or
our elastic monofilament and a filament of other materials can be
used as a composite yarn.
[0055] Then, a process of manufacturing the elastic monofilament
will be described in more detail, but the process of manufacturing
the elastic monofilament is not limited thereto.
[0056] Since the elastic monofilament can be manufactured by a
core-sheath composite spinning method using a previously known
coextrusion facility, it is possible to produce the elastic
monofilament at high productivity and low cost.
[0057] That is, a thermoplastic polyester polymer constituting a
core component and a thermoplastic elastomer constituting a sheath
component of a core-sheath composite monofilament are melted in
separate extruders, weighed with a gear pump and made to flow into
a composite pack, respectively. Two kinds of polymers of the core
component and the sheath component which have been made to flow
into the composite pack are filtered with a metal non-woven fabric
filter or a metal mesh in the pack, introduced into a composite
spinneret, and spun out in a form where the core component is
surrounded with the sheath component.
[0058] In this case, it is a preferable aspect to reduce the
moisture content of polymers used in spinning to less than 200 ppm
in advance using a vacuum dryer or the like for the purpose of
suppressing hydrolysis in a spinning machine for the thermoplastic
elastomer and the thermoplastic polyester used in spinning. When
the moisture content is within the above range, not only
conjugation abnormality is hardly generated, but also it becomes
easy to obtain an elastic monofilament excellent in durability.
[0059] When function impartation such as spun-dyeing, light
resistance impartation and antibacterial property impartation is
performed on the elastic monofilament, it is possible to prepare a
master chip containing large amounts of a desired pigment, a light
resistant agent and an antibacterial agent in advance, blend a
required amount of them into a thermoplastic polyester resin and/or
a thermoplastic elastomer resin, and spin the blend.
[0060] Particularly, for the elastic monofilament, it is a
preferable aspect that a light-resistant agent is added to the
thermoplastic elastomer resin for the purpose of reducing
deterioration due to ultraviolet rays at the time of practical use.
Examples of a preferable light-resistant agent-added master chip to
impart the light-resistant agent to the elastic monofilament
include "Hytrel" (registered trademark) 21UV manufactured by Du
Pont-Toray Co., Ltd.
[0061] It is a preferable aspect, from the viewpoint of removing a
strain of a molecular structure generated in a spinneret hole, that
the molten monofilament which has been spun out from a composite
spinneret is passed through a heating cylinder and/or a
heat-insulating cylinder arranged beneath the composite spinneret.
The length of the heating cylinder and/or the heat-insulating
cylinder is preferably 10 to 150 mm, from the viewpoint of
reduction in unevenness of fineness in a longitudinal direction of
the resulting elastic monofilament.
[0062] If necessary, the molten monofilament which has passed
through the heating cylinder and/or the heat-insulating cylinder is
cooled in a cooling bath containing water or polyethylene glycol as
a solvent, and is taken up with a take-up roll which rotates at a
desired surface speed. Regarding the temperature of the cooling
bath, the temperature can be changed in consideration of
circularity and unevenness of fineness of the resulting elastic
monofilament. Examples of the cooling temperature to obtain the
elastic monofilament include 20 to 80.degree. C. In addition, the
take-up speed should be a speed by which cooling solidification of
the molten monofilament in a cooling bath is completed. To set the
fiber structure of an unstretched yarn within a range suitable to
obtain the elastic monofilament, 5 to 50 m/min is preferable.
[0063] The unstretched monofilament which has been taken up with a
take-up roll is subjected to a stretching step after it is wound up
once, or without being wound up. Regarding the number of stretching
stages in a stretching step, a multi-stage stretching method of two
or more stages is preferably adopted for obtaining the elastic
monofilament. In addition, regarding the heating medium at the time
of stretching, warm water, a PEG bath, steam and a dry heat
stretching machine can be used.
[0064] Regarding the stretching temperature, to obtain the elastic
monofilament, it is a preferable aspect that the second stage
stretching temperature is set within a range of the melting point
of the thermoplastic elastomer used in the sheath component under
50.degree. C. of the melting point to under 10.degree. C. of the
melting point. By setting the second stage stretching temperature
within the above range where molecular mobility of the
thermoplastic elastomer is extremely high, excessive orientation of
the thermoplastic elastomer in a stretching step is suppressed, and
it becomes possible to obtain an elastic monofilament having
excellent elasticity even when deformed in a bending direction.
[0065] The elastic monofilament after stretching is then subjected
to relaxation heat treatment. From the viewpoint of suppression of
filament sway and securement of elasticity recovery when the
monofilament is subjected to repeated bending deformation, the
relaxation ratio is preferably 0.99 to 0.85. The relaxation heat
treatment temperature is preferably set within a range of the
melting point of the thermoplastic elastomer used in the sheath
component under 50.degree. C. of the melting point to under
10.degree. C. of the melting point, and examples of a more
preferable range include the melting point of the thermoplastic
elastomer under 40.degree. C. of the melting point to under
10.degree. C. of the melting point. By setting the relaxation heat
treatment temperature within the above range, it becomes possible
to obtain a monofilament having excellent elasticity even when
deformed in a bending direction, by relaxing excessive orientation
generated in the sheath component in a stretching step while
suppressing heat fusion between elastic monofilaments in a heat
treatment step.
[0066] In the core-sheath resin structure, to satisfy the above
range of the tensile strength, the total stretching ratio obtained
by multiplying the stretching ratio by the relaxation ratio is
preferably set at less than 4.0-fold. Examples of a more preferable
range include less than 3.8-fold.
[0067] The elastic monofilament after relaxation treatment is wound
up with a winding machine. In this case, it is preferable that the
winding tension is 0.10 cN/dtex or less. By setting the winding
tension within the above range, a load applied to the elastic
monofilament at the time of winding is reduced and, consequently,
it becomes possible to obtain an elastic monofilament excellent in
durability. To obtain a winding package which can be applied to
practical use, the lower limit of the winding tension is preferably
0.02 cN/dtex or more.
[0068] Thus, the elastic monofilament can be obtained.
[0069] Since the elastic monofilament is particularly excellent in
resistance to permanent set in fatigue in a bending direction,
elasticity, and creep property after subjected to a high
temperature, it can be suitably utilized of course in various
industrial uses such as marine materials, construction materials,
safety materials, clothing materials, civil engineering materials,
agricultural materials, vehicle materials, and sport materials, and
particularly, in elastic woven or knitted structure uses such as
car seats and office chairs, which easily undergoes deformation in
a bending direction at the time of practical use.
EXAMPLES
[0070] The elastic monofilament will be described in more detail by
way of examples. Definitions and measurement methods of properties
used in the examples are as follows. The measurement number n is 1
unless otherwise described.
Diameter
[0071] The external diameter of the elastic monofilament was
measured at 10 points in a length direction, using a laser external
diameter measuring apparatus manufactured by Anritsu Corporation,
and the mean value of the resulting external diameters was defined
as the diameter. Fineness
[0072] The fineness was measured in accordance with JIS L1013:2010
8.3.1 B Method. Tenacity, elongation and tensile strength
[0073] Using a Tensilon model UTM-4-100 tensile testing machine
manufactured by Orientec Co., Ltd., and in accordance with JIS
L1013:2010 8.5.1, the tenacity of the monofilament was measured at
3 points at a length of specimen between grips of 25 cm in a
constant rate extension manner, and the mean tenacity and mean
elongation of the 3 trials were obtained. The strength was obtained
by dividing the mean tenacity by the fineness.
Diameter of Core Component and Ratio of Core Component
[0074] A cross section obtained by cutting the elastic monofilament
in a direction vertical to a fiber axis was observed with a digital
microscope VHX-100F manufactured by Keyence Corporation. The
diameter of the core component was measured using a length
measuring tool of the digital microscope, and the ratio (% by
volume) of the core component was obtained from the cross-sectional
area of the elastic monofilament and the cross-sectional area of
the core component which had been obtained using an area measuring
tool.
Melting Point
[0075] A temperature giving an extreme value of a melting
endothermic curve obtained by measuring 10 mg of a sample at a
heating rate of 10.degree. C./min using a differential scanning
calorimeter model DSC-7 manufactured by Perkin Elmer was defined as
the melting point.
Bending Stiffness
[0076] The elastic monofilament which had been cut into a length of
about 4 cm was set below two stainless bars having a diameter of 2
mm, which were mounted at an interval of 10 mm in a horizontal
direction, and a J-shaped hook made of stainless steel having a
diameter of 1 mm was hooked on the elastic monofilament at the
central position of two stainless bars. The hook made of stainless
steel was pulled up at a speed of 50 mm/min using a model TCM-200
universal tensile testing/compression testing machine manufactured
by Minebea Co., Ltd., and the maximum stress generated then was
defined as the bending stiffness.
Boiling Water Shrinkage Rate (Boiling Shrinkage)
[0077] The boiling water shrinkage rate was measured in accordance
with JIS L1013:2010 8.18.1 (B Method).
Intrinsic Viscosity
[0078] To 100 mL of orthochlorophenol in a flask, 8 g of a sample
which had been ground with a Wiley grinder (filter hole diameter 1
mm) was added, and the mixture was heat-treated at a temperature of
160.degree. C. for 10 minutes. The flask after heat treatment was
cooled with flowing water for 15 minutes, and then the relative
viscosity .eta. of the resulting solution was measured at a
temperature of 25.degree. C. using an Ostwald viscometer. The
intrinsic viscosity was obtained by an approximate equation of
intrinsic viscosity=(K1.times..eta.)+K2. The constant K1 is 0.0242,
and the constant K2 is 0.2634.
Rate of Dimensional Change after Heat Treatment
[0079] A raw yarn sample (elastic monofilament) which had been
wound around an iron plate having a length of 30 cm ten times so
that there was neither raw yarn slack nor a gap between raw yarns
was heat-treated for 3 minutes in a dry heat oven at a temperature
of 160.degree. C., taken out from the dry heat oven, and naturally
cooled. Then, the raw yarn sample after heat treatment was mounted
in a Tensilon model UTM-4-100 tensile testing machine manufactured
by Orientec Co., Ltd. at a yarn length of 25 cm, and the elongation
(E.sub.0) (%) when a load of 0.1 cN/dtex was imparted and the
elongation (E.sub.12) (%) when the sample was allowed to stand for
12 hours in the state where a load of 0.1 cN/dtex was imparted were
obtained. E.sub.12-E.sub.0 was defined as the rate of dimensional
change after heat treatment. Letting the measurement number n to be
5, the mean value of them was adopted.
Evaluation of Elasticity
[0080] The elastic monofilament was put up in a commercially
available badminton racket under a load of 0.1 cN/dtex in both of
warp and weft directions. After the elastic monofilament was put
up, subjects were made to perform a repeated loading-unloading
motion five times with a palm from a direction vertical to a ball
shooting face, and the elasticity was scored based on the following
criteria. The number of subjects was 10, and the mean value of the
scores of 10 subjects was used as the result. Score 3 to score 5
were defined as acceptance.
Score 5: The monofilament has excellent rubber elasticity. Score 4:
Between score 3 and score 5 Score 3: The monofilament has rubber
elasticity. Score 2: Between score 3 and score 1 Score 1: The
monofilament is stiff.
Amount of Permanent Set in Fatigue
[0081] Using a bending abrasion property testing machine in
accordance with JIS L1095:2008 9.10. (B Method), one end contacted
on a fixed friction block (hard steel wire SWP-A) having a diameter
of 0.6 mm was grasped, and the elastic monofilament which had been
marked at an interval of 200 mm outside a reciprocating stroke
width of the friction block in advance was hooked under two free
rollers which had been provided so that the elastic monofilament
was bent each at an angle of 55.degree. in left and right of the
friction block. The elastic monofilament was set in the testing
machine in the state where a load of 2.5 kg/mm.sup.2 was imparted
to a yarn end opposite to the grasped yarn end of the monofilament,
and the friction block was reciprocally contacted with the elastic
monofilament 250 times at a reciprocating stroke of 25 mm and a
speed of 120 reciprocations/min. This was retained for 24 hours in
the state where the load was kept imparted.
[0082] The sample (elastic monofilament) after treatment was
removed from the bending abrasion property testing machine, and
immediately suspended in a perpendicular direction in the state
where a load 2 of 6 g/mm.sup.2 was imparted, as shown in FIG. 1.
Regarding the suspended sample (elastic monofilament 1), a distance
A (mm) of a perpendicular line which was drawn from a line a
connecting between marks towards a deformation maximum point was
obtained, and the mean value of five times of measurement was
defined as the amount of permanent set in fatigue.
Manufacture of Copolymeric Thermoplastic Elastomer (A-1)
[0083] A reactor equipped with a helical ribbon-type impeller was
charged with 51.9 parts by mass of terephthalic acid, 39.7 parts by
mass of 1,4-butanediol and 47.6 parts by mass of
poly(tetramethylene oxide)glycol having a number average molecular
weight of about 1400 together with 0.04 part by mass of titanium
tetrabutoxide and 0.02 part by mass of mono-n-butyl-monohydroxytin
oxide. The mixture was gradually heated from a temperature of
190.degree. C. to a temperature of 225.degree. C. over 3 hours to
perform an esterification reaction while flowing reaction water to
the outside of the system. To the reaction mixture was additionally
added 0.2 part by mass of tetra-n-butyl titanate, and added 0.05
part by mass of "Irganox" (registered trademark) 1098 (hindered
phenol-based antioxidant manufactured by Ciba Geigy) and,
thereafter, the temperature was raised to 245.degree. C. Then, the
pressure in the system was reduced to 27 Pa over 50 minutes, and
polymerization was performed for 1 hour and 50 minutes under that
condition. The resulting polymer was discharged into water in a
strand form, and the strand was cut to afford a pellet of a
copolymeric thermoplastic elastomer (A-1) having a hard/soft ratio
of 48/52 (ratio by mass). The resulting pellet had a melting point
of 200.degree. C., and a Shore hardness D of 47.
Manufacture of Copolymeric Thermoplastic Elastomer (A-2)
[0084] A reactor equipped with a helical ribbon-type impeller was
charged with 32.9 parts by mass of terephthalic acid, 9.6 parts by
mass of isophthalic acid, 40.3 parts by mass of 1,4-butanediol and
46.7 parts by mass of poly(tetramethylene oxide)glycol having a
number average molecular weight of about 1400 together with 0.04
part by mass of titanium tetrabutoxide and 0.02 part by mass of
mono-n-butyl-monohydroxytin oxide. The mixture was gradually heated
for 3 hours from a temperature of 190.degree. C. to a temperature
of 225.degree. C. over 3 hours to perform an esterification
reaction while flowing reaction water to the outside of the system.
To the reaction mixture was additionally added 0.15 part by mass of
tetra-n-butyl titanate, and added 0.05 part by mass of "Irganox"
(registered trademark) 1098 (hindered phenol-based antioxidant
manufactured by Ciba Geigy) and, thereafter, the temperature was
raised to 245.degree. C. Then, the pressure in the system was
reduced to 27 Pa for 50 minutes, and polymerization was performed
for 1 hour and 50 minutes under that condition. The resulting
polymer was discharged into water in a strand form, and the strand
was cut to afford a pellet of a copolymeric thermoplastic elastomer
(A-2) having a hard/soft ratio of 49/51 (ratio by mass). The
resulting pellet had a melting point of 160.degree. C., and a Shore
hardness D of 40.
Examples 1 to 6, Comparative Example 2, and Comparative Example
4
[0085] Using a polyethylene terephthalate polymer (T-701T
manufactured by Toray Industries, Inc.) having a melting point of
257.degree. C. and an intrinsic viscosity of 1.21, and containing
0.1% by mass of titanium oxide, which had been dried until the
moisture content became less than 100 ppm as a polymer for a core
component, and using the copolymeric thermoplastic elastomer (A-1)
which had been dried until the moisture content became less than
100 ppm as a polymer for a sheath component, respective polymers
were melted in a .phi.30 mm extruder set at a temperature of
295.degree. C. and a .phi.40 mm extruder set at a temperature of
245.degree. C., weighed using gear pumps retained at a temperature
of 245.degree. C. and 295.degree. C. so that the external diameter
(diameter) and the ratio of a core component would be as described
in Table 1, and introduced into a composite spinning pack retained
at a temperature of 290.degree. C. In the composite spinning pack,
respective molten polymers were filtered with a 200-mesh wire mesh,
and discharged from a core-sheath composite spinneret having a pore
diameter of 1.5 mm and a number of pores of 10. The discharged
filament was passed through a heat-insulating cylinder having a
length of 30 mm, which had been mounted beneath the spinneret,
passed through a cooling water bath at a temperature of 25.degree.
C., which had been mounted to have an air gap of 30 mm, and was
taken up as an unstretched monofilament with a take-up roll
rotating at a surface speed of 20 m/min. The resulting unstretched
monofilament was subjected to first stage stretching at a
stretching ratio described in Table 1, without being wound once,
using a warm water bath controlled to a temperature of 90.degree.
C., and subjected to second stage stretching at a ratio described
in Table 1 using a dry heat stretching bath controlled to a
temperature described in Table 1. The monofilament after stretching
was subsequently subjected to relaxation heat treatment at a ratio
described in Table 1 using a dry heat bath controlled to a
temperature described in Table 1, and wound at a winding tension
described in Table 1 to obtain an elastic monofilament. Properties
of the resulting monofilament were as shown in Table 1 and Table
2.
[0086] In Comparative Example 2, since the ratio of the core
component was small, excessive extension outside a bent part was
not suppressed, and the amount of permanent set in fatigue was
large. In Comparative Example 4, the tensile strength exceeded 3.05
cN/dtex, and elasticity in the bending direction was
deteriorated.
Example 7
[0087] In the same manner as that of Example 1 except that, as the
polymer for the sheath component, 97% by mass of the copolymeric
thermoplastic elastomer (A-1) and 3% by mass of "Hytrel"
(registered trademark) 21UV were used, the procedure was performed.
Properties of the resulting monofilament were as shown in Table
1.
Example 8, Comparative Example 3, and Comparative Example 5
[0088] In the same manner as that of Example 1 except that, as the
polymer for the core component, a polyethylene terephthalate
polymer (T-301T manufactured by Toray Industries, Inc.) having a
melting point of 257.degree. C. and an intrinsic viscosity of 0.71,
and containing 0.1% by mass of titanium oxide was used, the
procedure was performed. Properties of the resulting monofilament
were as shown in Table 1 and Table 2. In Comparative Example 3 and
Comparative Example 5, the tensile strength exceeded 3.05 cN/dtex,
and elasticity in the bending direction was deteriorated.
Comparative Example 1
[0089] In the same manner as that of Example 1 except that, the
copolymeric thermoplastic elastomer (A-1) which had been dried
until the moisture content became less than 150 ppm, as the polymer
for the core component, and the copolymeric thermoplastic elastomer
(A-2) which had been dried until the moisture content became less
than 150 ppm, as the polymer for the sheath component, were melted
in a .phi.30 mm extruder set at a temperature of 250.degree. C.,
and a .phi.40 mm extruder set at a temperature of 215.degree. C.,
respectively and, thereafter, introduced into a composite spinning
pack retained at a temperature of 250.degree. C. using gear pumps
retained at a temperature of 245.degree. C. and 250.degree. C.,
respectively, the procedure was performed. Properties of the
resulting elastic monofilament were as shown in Table 2.
TABLE-US-00001 TABLE 1 Example 1 Example 2 Example 3 Example 4
Example 5 Example 6 Example 7 Example 8 Manufacturing Core
component resin -- PET PET PET PET PET PET PET PET conditions for
species elastic PET intrinsic viscosity -- 1.21 1.21 1.21 1.21 1.21
1.21 1.21 0.71 monofilament First stage stretching Fold 3.33 3.00
3.33 3.33 3.33 3.33 3.33 3.33 ratio Second stage Fold 1.21 1.33
1.21 1.21 1.21 1.21 1.21 1.21 stretching ratio Second stage
.degree. C. 180 180 180 180 155 180 180 180 stretching temperature
Relaxation ratio Fold 0.90 0.90 0.95 0.95 0.95 0.90 0.90 0.90
Relaxation treatment .degree. C. 180 180 180 180 180 180 180 180
temperature Properties of Diameter .mu.m 490 490 490 490 490 490
490 490 elastic Core ratio % by volume 9.9 4.3 16.8 35.7 16.8 12.1
9.8 9.9 monofilament Fineness dtex 2258 2254 2288 2364 2281 2270
2249 2258 Tensile strength cN/dtex 0.93 0.85 1.22 2.94 2.18 1.17
0.95 0.93 Bending stiffness cN 4.56 2.93 7.76 13.46 8.39 7.34 4.39
4.81 Boiling shrinkage % 6.2 5.9 8.3 14.2 9 7.3 6.2 6.2 Rate of
dimensional % 1.3 1.8 0.7 0.4 0.5 1.1 1.4 3.2 change after heat
treatment Evaluation of elasticity Score 4.1 4.4 3.9 3.1 3.7 4 4.2
4.1 Amount of permanent mm 0.9 1.1 2 2.7 1.7 1.2 1.1 2.5 set in
fatigue
TABLE-US-00002 TABLE 2 Comparative Comparative Comparative
Comparative Comparative Example 1 Example 2 Example 3 Example 4
Example 5 Manufacturing Core component resin species -- Elastomer
PET PET PET PET conditions for PET intrinsic viscosity -- -- 1.21
0.71 1.21 0.71 elastic First stage stretching ratio Fold 3.00 3.00
3.33 3.33 3.33 monofilament Second stage stretching ratio Fold 1.67
1.33 1.60 1.21 1.76 Second stage stretching temperature .degree. C.
130 180 140 140 140 Relaxation ratio Fold 0.85 0.90 1.00 0.90 0.90
Relaxation treatment temperature .degree. C. 145 180 180 140 180.00
Properties of Diameter .mu.m 486 491 490 490 488 elastic Core ratio
% by volume 29.6 1.3 16.8 35.7 16.8 monofilament Fineness dtex 2188
2237 2388 2345 2369 Tensile strength cN/dtex 1.22 0.76 4.23 3.89
4.18 Bending stiffness cN 1.82 2.24 15.14 15.83 13.95 Boiling
shrinkage % 9.4 5.2 15.3 16.6 14.2 Rate of dimensional change after
heat treatment % 13.4 5.1 2.4 0.5 2.7 Evaluation of elasticity
Score 4.7 4.6 2.3 1.9 2.6 Amount of permanent set in fatigue mm 3.2
3 2.6 2.8 2.6
[0090] As shown in Table 1 and Table 2, the elastic monofilament
was excellent in resistance to permanent set in fatigue in the
bending direction, elasticity, and creep property after subjected
to a high temperature.
* * * * *