U.S. patent application number 14/853180 was filed with the patent office on 2016-08-04 for bicomponent conjugate fibers, complex yarns and fabrics having high crimping property.
This patent application is currently assigned to SHINKONG SYNTHETIC FIBERS CORPORATION. The applicant listed for this patent is SHINKONG SYNTHETIC FIBERS CORPORATION. Invention is credited to CHIH-LUNG HSIEH, CANG-JIE LIN, YI JEN TU, KUO CHUNG WU, HSIANG YU.
Application Number | 20160222549 14/853180 |
Document ID | / |
Family ID | 53938198 |
Filed Date | 2016-08-04 |
United States Patent
Application |
20160222549 |
Kind Code |
A1 |
TU; YI JEN ; et al. |
August 4, 2016 |
BICOMPONENT CONJUGATE FIBERS, COMPLEX YARNS AND FABRICS HAVING HIGH
CRIMPING PROPERTY
Abstract
The present invention relates to bicomponent conjugate fibers
having excellent crimping property, comprising: (A) a thermoplastic
polyester elastomer (TPEE) as a first component, and (B) a
polyester polymer as a second component. The present invention also
relates to yarns and fabrics comprising said bicomponent conjugate
fibers.
Inventors: |
TU; YI JEN; (TAIPEI, TW)
; WU; KUO CHUNG; (TAIPEI, TW) ; HSIEH;
CHIH-LUNG; (TAIPEI, TW) ; LIN; CANG-JIE;
(TAIPEI, TW) ; YU; HSIANG; (TAIPEI, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHINKONG SYNTHETIC FIBERS CORPORATION |
TAIPEI |
|
TW |
|
|
Assignee: |
SHINKONG SYNTHETIC FIBERS
CORPORATION
TAIPEI
TW
|
Family ID: |
53938198 |
Appl. No.: |
14/853180 |
Filed: |
September 14, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 3/34 20130101; D01F
8/16 20130101; D01F 8/14 20130101 |
International
Class: |
D01F 8/14 20060101
D01F008/14; D02G 3/34 20060101 D02G003/34; D01F 8/16 20060101
D01F008/16 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 2, 2015 |
TW |
104103375 |
Mar 26, 2015 |
TW |
104109667 |
Claims
1. A bicomponent conjugate fiber comprising: a thermoplastic
polyester elastomer (TPEE) as a first component; and a polyester
polymer as a second component.
2. The bicomponent conjugate fiber according to claim 1, wherein
the thermoplastic polyester elastomer is a polybutylene
terephthalate (PBT) type thermoplastic elastomer.
3. The bicomponent conjugate fiber according to claim 1, wherein
the thermoplastic polyester elastomer is a poly(ethylene
terephthalate) (PET) type thermoplastic elastomer.
4. The bicomponent conjugate fiber according to claim 1, wherein
the thermoplastic polyester elastomer has an intrinsic viscosity in
the range of 0.5 dl/g to 2.4 dl/g.
5. The bicomponent conjugate fiber according to claim 2, wherein
the thermoplastic polyester elastomer has an intrinsic viscosity in
the range of 0.5 dl/g to 2.4 dl/g.
6. The bicomponent conjugate fiber according to claim 3, wherein
the thermoplastic polyester elastomer has an intrinsic viscosity in
the range of 0.5 dl/g to 2.4 dl/g.
7. The bicomponent conjugate fiber according to claim 1, wherein
the polyester polymer is selected from the group consisting of
polyethylene terephthalate, polyethylene isoterephthalate, a
copolymer of polyethylene terephthalate/polyethylene
isoterephthalate, polybutylene terephthalate, cationic dyeable
polyester, polybutylene succinate, environmentally recycled
polyesters, biomass polyesters, and thermoplastic polyester
elastomer.
8. The bicomponent conjugate fiber according to claim 1, wherein
the polyester polymer has an intrinsic viscosity in the range of
0.45.about.1.2 dl/g.
9. The bicomponent conjugate fiber according to claim 1, wherein
the weight ratio of the first component to the second component is
in the range of 20:80.about.80:20.
10. The bicomponent conjugate fiber according to claim 1, wherein
the fibers have a side-by-side cross section.
11. The bicomponent conjugate fiber according to claim 1, wherein
the fibers are fibers of drawn textured yarns (DTY), air textured
yarns (ATY), high oriented yarns (HOY), or fully drawn yarns
(FDY).
12. The bicomponent conjugate fiber according to claim 1, wherein
the fibers are long filaments or short filaments.
13. Complex yarns which are composed of the fibers according to
claim 1 alone, or are formed by said bicomponent conjugate fibers
in complex with the other fibers.
14. Fabrics produced from the bicomponent conjugate fibers
according to claim 1.
15. Fabrics produced by the complex yarns according to claim 13.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to bicomponent conjugate
fibers having excellent crimping property, comprising: (A) a
thermoplastic polyester elastomer (TPEE) as a first component, and
(B) a polyester polymer as a second component. The present
invention also relates to yarns and fabrics comprising said
bicomponent conjugate fibers.
BACKGROUND OF THE INVENTION
[0002] Self-crimping properties of conjugate fibers can mainly be
generated from the manufacturing process of side-by-side
bicomponent fibers. Due to different intrinsic viscosity (IV)
between two polymers for forming the conjugate fibers, said two
polymers have different shrinkages which lead to three-dimensional
crimp of the fibers. Self-crimping property is a crimping potential
inevitably created by differences in the amount of shrinkage, the
degree of shrinkage and the module of elasticity of the two
polymers. In addition to shrinkage differences as a prerequisite
for self-crimping property, good adherence must be present between
said two polymers. However, it is not absolutely necessary to
utilize different polymers, since a shrinkage difference can also
be caused by differences in orientation, crystallinity or relative
viscosity. In general, the shrinkage difference of polymers
produced by the same materials is smaller and therefore, it is not
easy to produce high shrinkage required by the demand of high
elasticity. For example, Japanese Patent Laid-Open Application No.
2001-226832 utilizes materials of polyethylene terephthalate (PET)
having different intrinsic viscosities (PET having the intrinsic
viscosity of 0.76 dl/g in combination with PET having the intrinsic
viscosity of 0.53 dl/g are utilized in the examples of the patent
application) for the production of high crimping bicomponent
conjugate fibers. However, the CI (Crimp Index, i.e., a flexibility
index) of the fibers produced by said method is not
satisfactory.
SUMMARY OF THE INVENTION
[0003] The main object of the present invention is to provide
bicomponent conjugate fibers having high crimping property and
excellent resilience.
[0004] In one aspect of the present invention, the present
invention relates to bicomponent conjugate fibers having excellent
crimping property, which comprises (A) a thermoplastic polyester
elastomer (TPEE) as a first component, and (B) a polyester polymer
as a second component, wherein the weight ratio of the
thermoplastic polyester elastomer (TPEE) as the first component to
the polyester polymer as the second component is in the range of
20:80.about.80:20, preferably 30:70.about.70:30, and most
preferably 40:60.about.60:40.
[0005] The molecular structure of the thermoplastic polyester
elastomer consists of two parts, hard segments and soft segments,
wherein the hard segments are aromatic polyesters, such as
poly(ethylene terephthalate) (PET) or polybutylene terephthalate
(PBT), and the soft segments are polyether esters.
[0006] In one embodiment of the present invention, the (A)
thermoplastic polyester elastomer as the first component may be
those in which the hard segments are polyesters (such as PET or
PBT), and the soft segments are polyether esters, such as
polytetramethylene ether glycol (PTMEG), wherein the weight ratio
of the hard segments to the soft segments is in the range of
80:20.about.20:80, and the number average molecular weight of the
polyether glycol is in the range of 500.about.5000.
[0007] When the viscosity of the thermoplastic polyester elastomer
is less than 0.5 dl/g, the production yield of fibers is not good
and the physical properties thereof are poor.
[0008] When the viscosity of the thermoplastic polyester elastomer
is higher than 2.4 dl/g, the flowability of polymers is poor and
the melt temperature has to be elevated during the manufacturing
period, and thus the polymers are liable to be degraded, resulting
in a poor production yield. Therefore, in one embodiment of the
present invention, the thermoplastic polyester elastomer as the
first component has an intrinsic viscosity in the range of
0.5.about.2.4 dl/g, preferably 0.8.about.2.2 dl/g, and most
preferably 1.1.about.1.9 dl/g.
[0009] When the viscosity of the polyester polymer is less than
0.45 dl/g, the production yield of fibers is not good and the
physical properties thereof are poor. When the viscosity of the
polyester polymer is higher than 1.2 dl/g, the flowability of
polymers is poor and the melt temperature has to be elevated during
the manufacturing period, and thus the polymers are liable to be
degraded, resulting in a poor production yield. Therefore, in one
embodiment of the present invention, the polyester polymer as the
second component has an intrinsic viscosity in the range of
0.45.about.1.2 dl/g, preferably 0.45.about.0.85 dl/g, and most
preferably 0.45.about.0.70 dl/g.
[0010] In another aspect of the present invention, the present
invention relates to a process for the production of bicomponent
conjugate fibers, which can be performed by utilization of a
single-stage direct spin-drawing process. Said process comprises
heating the first component and the second component as spinning
materials in a screw extruder at a temperature of
220.about.300.degree. C., respectively, depending on the kinds of
materials as the first component and the second component (for
example, a temperature of 220.about.290.degree. C. may be selected
if a PBT-type TPEE is employed; and a temperature of
280.about.300.degree. C. may be selected if a PET-type TPEE is
employed), so that they become a melt and are then spun from a
side-by-side spinneret. After cooling and oiling, spinning and
drawing are carried out at a spinning rate of 1000.about.6000
m/min, a drawing ratio of 1.0.about.10, a drawing temperature of
20.about.100.degree. C. and a heat setting temperature of
20.about.200.degree. C., to produce high crimping bicomponent fully
drawn yarns (FDY) or high oriented yarns (HOY).
[0011] In a further aspect, the bicomponent conjugate fibers of the
present invention can also be produced by utilization of a
multi-stage process of spinning followed by drawing or false-twist
texturing. Said process comprises heating the first component and
the second component as spinning materials in a screw extruder at a
temperature of 220.about.300.degree. C., respectively, depending on
the kinds of materials as the first component and the second
component (for example, a temperature of 220.about.290.degree. C.
may be selected if a PBT-type TPEE is employed; and a temperature
of 280.about.300.degree. C. may be selected if a PET-type TPEE is
employed), so that they become a melt and are then quantitatively
spun from a side-by-side spinneret. After cooling and oiling,
winding is carried out at a spinning rate of 500.about.6000 m/min,
followed by a drawing process, a false-twist texturing process for
draw textured yarns (DTY) or an air false-twist texturing process
for air textured yarns (ATY) at a processing rate of 100.about.1200
m/min, a hot plate temperature of 70.about.220.degree. C. and a
drawing ratio of 1.about.10, to produce high crimping bicomponent
fully drawn yarns (FDY) or textured yarns (such as DTY or ATY).
DETAIL DESCRIPTION OF THE INVENTION
[0012] In one embodiment, the thermoplastic polyester elastomer as
the first component includes PET-type TPEE and PBT-type TPEE, which
are formed respectively in the schemes as shown below:
##STR00001##
[0013] In said schemes, the above mentioned abbreviations have
meanings as below:
TPA: terephthalic acid; EG: ethylene glycol; PTMEG:
polytetramethylene ether glycol; PET: polyethylene terephthalate;
TPEE: thermoplastic polyester elastomer; and BDO: butanediol.
[0014] The thermoplastic polyester elastomer (TPEE) used in the
present invention has an intrinsic viscosity in the range of
0.5.about.2.4 dl/g, preferably 0.8.about.2.2 dl/g, and most
preferably 1.1.about.1.9 dl/g.
[0015] In one embodiment, the (B) polyester polymer as the second
component may be selected from the group consisting of polyethylene
terephthalate, polyethylene isoterephthalate, a copolymer of
polyethylene terephthalate/polyethylene isoterephthalate,
polybutylene terephthalate, cationic dyeable polyester,
polybutylene succinate, environmentally recycled polyesters,
biomass polyesters, and thermoplastic polyester elastomer; wherein
the environmentally recycled polyesters and biomass polyesters may
be environmentally recycled PET and biomass PET.
[0016] The polyester used in the present invention has an intrinsic
viscosity in the range of 0.45.about.1.2 dl/g, preferably
0.45.about.0.85 dl/g, and most preferably 0.45.about.0.70 dl/g.
[0017] The bicomponent conjugate fibers of the present invention
may be side-by-side bicomponent conjugate fibers. Namely, from the
cross sectional view of the conjugate fibers, the above mentioned
first component and second component are arranged in a side by side
configuration.
[0018] The bicomponent conjugate fibers of the present invention
may be in the form of continuous long filaments or short
filaments.
[0019] The bicomponent conjugate fibers of the present invention
may be in the form of a circular cross section or non-circular
cross section.
[0020] In another embodiment of the present invention, the process
for the production of the bicomponent conjugate fibers of the
present invention may comprise addition of further functional
additives, such as flame retardants, heat insulating agents,
anti-ultraviolet agents, anti-statistic agents, fluorescent
brighteners, antibacterial agents, matting agents, etc., depending
on the demand.
[0021] The bicomponent conjugate fibers described in the present
invention may be fibers of drawn textured yarns (DTY), air textured
yarns (ATY), high oriented yarns (HOY), or fully drawn yarns
(FDY).
[0022] In another aspect, the present invention relates to yarns
and fabrics produced by the bicomponent conjugate fibers of the
present invention.
[0023] Based on the side-by-side bicomponent conjugate fibers of
the present invention, high crimping long-filament products or
short-filament products may be produced depending on the
demand.
[0024] Based on the bicomponent conjugate fibers of the present
invention, the conjugate fibers may be present alone or further in
complex with the other fibers to form complex yarns.
[0025] The present invention may also utilize the bicomponent
conjugate fibers produced by the above mentioned process of
production or conjugate fiber yarns comprising the bicomponent
conjugate fibers of the present invention to produce fibers by
means of textile manufacturing techniques known in the
industry.
[0026] The physical properties of the side-by-side bicomponent
conjugate fibers of the present invention are determined in the
manners as described in detail below: [0027] 1. Intrinsic Viscosity
(IV) [0028] Intrinsic viscosity is determined by a method in
accordance with ASTM D2857-87. The raw materials in each of the
examples and comparative examples were dissolved to form test
solutions. The flowing time of the test solutions in different
concentrations (0.1%, 0.2%, 0.3%, 0.4%, 0.5%) and pure solvents in
a capillary Ubbelohde viscometer is respectively measured, and the
intrinsic viscosity of each test solution is determined. The
intrinsic viscosity versus the concentration is then plotted. The
intrinsic viscosity in the unit of dl/g is represented by the
viscosity calculated by extrapolation when the concentration
approaches 0%. [0029] 2. Fiber Strength and Elongation [0030] The
breaking strength and elongation of fibers are measured by an
automatic elongation tester, STATIMAT M. [0031] 3. Crimp Index (CI)
[0032] Sample preparation: Fibers with a given fineness are wound
on a winding machine comprising a filament winding section having a
barrel with a perimeter of 1 m or 1.125 m. The crimp number of
fibers is calculated in the following manner:
[0032] Crimp number of fibers=3500/fineness [0033] Experiments are
performed after the oven is set up at 120.degree. C. and maintained
for 30 minutes. [0034] The fibers wound on the winding machine are
taken out, and the fibers are hung on the wall in a vertical state.
A weight of 10.5 g is hung on one end of the fibers, and a weight
of 700 g is subsequently hung thereon. After 10 seconds, the
lengths of the fibers are measured and recorded as L1. [0035] The
weight of 700 g was taken out from the fibers, and the fibers still
loaded with the weight of 10.5 g are placed in the oven maintaining
at 120.degree. C. and dried for 5 minutes. [0036] After drying, the
fibers still loaded with the weight of 10.5 g are taken from the
oven and are hung on the wall again for 2 hours to allow for being
cooled down. At this point of time, the lengths of the fibers are
measured and recorded as L2. [0037] The weight of 700 g is further
hung on the fibers. At this point of time, the lengths of the
fibers are measured and recorded as L3. [0038] The crimp index (CI)
is calculated based on the following formula:
[0038] CI %=[(L3-L2)/(L2)].times.100%
EXAMPLES
[0039] The following examples are used to illustrate the technical
content of the present invention and the efficacy to be achieved,
but are not intended to limit the present invention. Any equivalent
changes and modifications made according to the invention are all
within the scope of the claims of the invention.
Example 1
[0040] The bicomponent conjugate fibers of Example 1 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 20:80 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air and then spun and drawn at a
spinning rate of 4000 m/min, a drawing temperature of 80.degree.
C., a heat setting temperature of 140.degree. C. and a drawing
ratio of 2.1 to produce 75/24 bicomponent fully drawn yarns (FDY).
The results of the produced fibers are shown in Table 1.
Example 2
[0041] The bicomponent conjugate fibers of Example 2 were prepared
according to the production method described in Example 1, wherein
the weight ratio of the first component and the second component
was substituted with 50:50. The results of the produced fibers are
shown in Table 1.
Example 3
[0042] The bicomponent conjugate fibers of Example 3 were prepared
according to the production method described in Example 1, wherein
the weight ratio of the first component and the second component
was substituted with 80:20. The results of the produced fibers are
shown in Table 1.
Example 4
[0043] The bicomponent conjugate fibers of Example 4 were prepared
according to the production method described in Example 2, wherein
the second component was substituted with a cationic dyeable
polyester (CD) having the intrinsic viscosity of 0.56 dl/g. The
results of the produced fibers were shown in Table 1.
Comparative Example 1
[0044] The bicomponent conjugate fibers of Comparative Example 1
were prepared according to the production method described in
Example 2, wherein the first component was substituted with PET
having a high intrinsic viscosity (0.75 dl/g), and the second
component was substituted with PET having a low intrinsic viscosity
(0.53 dl/g). The results of the produced fibers were shown in Table
1.
TABLE-US-00001 TABLE 1 First Second Fiber component component Elon-
weight weight Fiber ga- Crimp percentage percentage Strength tion
Index (wt %) (wt %) (g/d) (E %) (CI) Example 1 PBT-TYPE PET/80 wt %
4.2 33.1 66 TPEE/20 wt % Example 2 PBT-TYPE PET/50 wt % 4.3 35.1 80
TPEE/50 wt % Example 3 PBT-TYPE PET/20 wt % 3.5 34.8 80 TPEE/80 wt
% Example 4 PBT-TYPE CD/50 wt % 3.7 36.8 63 TPEE/50 wt %
Comparative PET/50 wt % PET/50 wt % 3.7 33.0 5 Example 1
Example 5
[0045] The bicomponent conjugate fibers of Example 5 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 0.5 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air and then spun and drawn at a
spinning rate of 4000 m/min, a drawing temperature of 80.degree.
C., a heat setting temperature of 140.degree. C. and a drawing
ratio of 2.1 to produce 75/24 bicomponent fully drawn yarns (FDY).
The results of the produced fibers are shown in Table 2.
Example 6
[0046] The bicomponent conjugate fibers of Example 6 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 2.4 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air and then spun and drawn at
the spinning rate of 4000 m/min, the drawing temperature of
80.degree. C., a heat setting temperature of 140.degree. C. and a
drawing ratio of 2.1 to produce 75/24 bicomponent fully drawn yarns
(FDY). The results of the produced fibers are shown in Table 2.
Comparative Example 2
[0047] The bicomponent conjugate fibers of Comparative Example 2
were prepared according to the production method described in
Example 2, wherein the first component was substituted with
PBT-TYPE TPEE having the intrinsic viscosity of 0.45 dl/g. The
results of the produced fibers are shown in Table 2.
Comparative Example 3
[0048] The bicomponent conjugate fibers of Comparative Example 3
were prepared according to the production method described in
Example 2, wherein the first component was substituted with
PBT-TYPE TPEE having the intrinsic viscosity of 2.5 dl/g. The
results of the produced fibers are shown in Table 2.
TABLE-US-00002 TABLE 2 First Second Component Component Intrinsic
Intrinsic Fiber Fiber Crimp Viscosity Viscosity Strength Elongation
Index (dl/g) (dl/g) (g/d) (E %) (CI) Example 2 1.8 0.45 4.3 35.1 80
Example 5 0.5 0.45 2.5 35.1 8 Example 6 2.4 0.45 4.5 35.1 82
Comparative 0.45 0.45 2.1 35.9 2 Example 2** Comparative 2.5 0.45
4.5 37.8 85 Example 3* Note: *poor production yield. **poor
production yield and poor physical property.
Example 7
[0049] The bicomponent conjugate fibers of Example 7 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.76 dl/g was melted at the melt temperature
of 290.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air and then spun and drawn at
the spinning rate of 4000 m/min, the drawing temperature of
80.degree. C., a heat setting temperature of 140.degree. C. and a
drawing ratio of 2.1 to produce bicomponent fully drawn yarns
(FDY). The results of the produced fibers are shown in Table 3.
Example 8
[0050] The bicomponent conjugate fibers of Example 8 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 1.0 dl/g was melted at the melt temperature
of 295.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air and then spun and drawn at
the spinning rate of 4000 m/min, the drawing temperature of
80.degree. C., a heat setting temperature of 140.degree. C. and a
drawing ratio of 2.1 to produce bicomponent fully drawn yarns
(FDY). The results of the produced fibers are shown in Table 3.
Comparative Example 4
[0051] The bicomponent conjugate fibers of Comparative Example 4
were prepared according to the production method described in
Example 2, wherein the second component was substituted with PET
having the intrinsic viscosity of 1.3 dl/g and was melted at a melt
temperature of 300.degree. C. The results of the produced fibers
are shown in Table 3.
TABLE-US-00003 TABLE 3 First Second Component Component Intrinsic
Intrinsic Fiber Fiber Crimp Viscosity Viscosity Strength Enlogation
Index (dl/g) (dl/g) (g/d) (E %) (CI) Example 2 1.8 0.45 4.3 35.1 80
Example 7 1.8 0.76 4.4 33.5 47 Example 8 1.8 1.20 4.4 36.1 31
Comparative 1.8 1.30 4.5 36.9 15 Example 4* Note: *poor production
yield.
Example 9
[0052] The bicomponent conjugate fibers of Example 9 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air, wound at the spinning rate
of 3000 m/min, and then processed by the FDY drawing process at the
processing rate of 500 m/min and a drawing ratio of 1.8 to produce
high crimping bicomponent fully drawn yarns (FDY). The results of
the produced fibers are shown in Table 4.
Example 10
[0053] The bicomponent conjugate fibers of Example 10 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air, wound at the spinning rate
of 3000 m/min, and then processed by the DTY false-twist texturing
process at the processing rate of 500 m/min and a drawing ratio of
1.8 to produce high crimping bicomponent false-twist draw textured
yarns (DTY). The results of the produced fibers are shown in Table
4.
Example 11
[0054] The bicomponent conjugate fibers of Example 11 were prepared
according to the method as described below. By using a screw
extruder, the PBT-TYPE TPEE (the first component) having the
intrinsic viscosity of 1.8 dl/g was melted at the melt temperature
of 250.degree. C., and the PET (the second component) having the
intrinsic viscosity of 0.45 dl/g was melted at the melt temperature
of 280.degree. C., which were then quantitatively discharged,
respectively. The first component and the second component were
mixed in a weight ratio of 50:50 and then placed in a spinning
cabinet at a spinning temperature of 285.degree. C., which were
subsequently extruded through a complex and side-by-side spinneret
assembly, cooled down with cooling air, wound at the spinning rate
of 3000 m/min, and then processed by an air false-twist texturing
process at the processing rate of 500 m/min and a drawing ratio of
1.8 to produce high crimping bicomponent air false-twist air
textured yarns (ATY). The results of the produced fibers are shown
in Table 4.
TABLE-US-00004 TABLE 4 First Second Component Component Intrinsic
Intrinsic Fiber Fiber Crimp Viscosity Viscosity Strength Elongation
Ibdex (dl/g) (dl/g) (g/d) (E %) (CI) Example 9 1.8 0.45 4.0 25.9 72
Example 10 1.8 0.45 3.6 25.0 65 Example 11 1.8 0.45 3.8 25.4 70
Example 12
[0055] The bicomponent conjugate fibers of Example 12 were prepared
according to the production method described in Example 2, wherein
the first component was substituted with PET-TYPE TPEE having the
intrinsic viscosity of 1.1 dl/g. The results of the produced fibers
are shown in Table 5.
Example 13
[0056] The bicomponent conjugate fibers of Example 13 were prepared
according to the production method described in Example 2, wherein
the first component was substituted with PET-TYPE TPEE having the
intrinsic viscosity of 1.5 dl/g. The results of the produced fibers
are shown in Table 5.
Example 14
[0057] The bicomponent conjugate fibers of Example 14 were prepared
according to the production method described in Example 2, wherein
the first component was substituted with PET-TYPE TPEE having the
intrinsic viscosity of 1.8 dl/g. The results of the produced fibers
are shown in Table 5.
TABLE-US-00005 TABLE 5 First Second Component Component Intrinsic
Intrinsic Fiber Fiber Crimp Viscosity Viscosity Strength Elongation
Index (dl/g) (dl/g) (g/d) (E %) (CI) Example 2 1.8 0.45 4.3 35.1 80
Example 12 1.1 0.45 3.8 31.8 38 Example 13 1.5 0.45 4.2 31.1 47
Example 14 1.8 0.45 4.4 30.3 55
Example 15
[0058] According to the production method described in Example 2,
the first component was substituted with PBT-TYPE TPEE having the
intrinsic viscosity of 1.8 dl/g and was melted at the melt
temperature of 250.degree. C., and the PBT-TYPE TPEE (the second
component) having the intrinsic viscosity of 1.2 dl/g was melted at
the melt temperature of 250.degree. C. The produced fibers are
shown in Table 6.
Example 16
[0059] According to the production method described in Example 2,
the first component was substituted with PET-TYPE TPEE having the
intrinsic viscosity of 1.8 dl/g and was melted at the melt
temperature of 270.degree. C., and the PBT-TYPE TPEE (the second
component) having the intrinsic viscosity of 1.2 dl/g was melted at
the melt temperature of 250.degree. C. The produced fibers are
shown in Table 6.
Example 17
[0060] According to the production method described in Example 2,
the first component was substituted with PBT-TYPE TPEE having the
intrinsic viscosity of 1.8 dl/g and was melted at the melt
temperature of 250.degree. C., and the PET-TYPE TPEE (the second
component) having the intrinsic viscosity of 1.2 dl/g was melted at
the melt temperature of 260.degree. C. The produced fibers are
shown in Table 6.
TABLE-US-00006 TABLE 6 First Second Component Component Intrinsic
Intrinsic Fiber Fiber Crimp Viscosity Viscosity Strength Elongation
Index (dl/g) (dl/g) (g/d) (E %) (CI) Example 15 1.8 1.2 3.7 35.1 70
Example 16 1.8 1.2 3.8 31.8 55 Example 17 1.8 1.2 3.7 33.0 65
* * * * *