U.S. patent application number 16/481928 was filed with the patent office on 2020-02-06 for thermally adhesive sheath-core conjugate fiber and tricot fabric.
The applicant listed for this patent is Toray Industries, Inc.. Invention is credited to Minoru Fujimori, Junji Sato, Yuta Watanabe.
Application Number | 20200040484 16/481928 |
Document ID | / |
Family ID | 63107478 |
Filed Date | 2020-02-06 |
![](/patent/app/20200040484/US20200040484A1-20200206-D00000.png)
![](/patent/app/20200040484/US20200040484A1-20200206-D00001.png)
United States Patent
Application |
20200040484 |
Kind Code |
A1 |
Watanabe; Yuta ; et
al. |
February 6, 2020 |
THERMALLY ADHESIVE SHEATH-CORE CONJUGATE FIBER AND TRICOT
FABRIC
Abstract
A thermally adhesive sheath-core conjugate fiber has, as a core
part, a polyester having a melting point of at least 250.degree.
C., and has, as a sheath part, a polyester having a melting point
which is at least 215.degree. C. and is 20-35.degree. C. lower than
the melting point of the polyester constituting the core part. The
thermally adhesive sheath-core conjugate fiber is characterized by
having a strength of 3.8 cN/dtex or higher and an elongation of 35%
or higher.
Inventors: |
Watanabe; Yuta;
(Mishima-shi, JP) ; Sato; Junji; (Mishima-shi,
JP) ; Fujimori; Minoru; (Mishima-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Toray Industries, Inc. |
Tokyo |
|
JP |
|
|
Family ID: |
63107478 |
Appl. No.: |
16/481928 |
Filed: |
February 6, 2018 |
PCT Filed: |
February 6, 2018 |
PCT NO: |
PCT/JP2018/003927 |
371 Date: |
July 30, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01D 5/16 20130101; D01F
8/14 20130101; D04B 21/08 20130101 |
International
Class: |
D01F 8/14 20060101
D01F008/14; D04B 21/08 20060101 D04B021/08 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 9, 2017 |
JP |
2017-022048 |
Claims
1-3. (canceled)
4. A thermally adhesive sheath-core conjugate fiber comprising: a
core part including a polyester having a melting point of
250.degree. C. or higher; and a sheath part including a polyester
having a melting point of 215.degree. C. or higher and lower by 20
to 35.degree. C. than that of the polyester constituting the core
part, wherein the thermally adhesive sheath-core conjugate fiber
has a strength of 3.8 cN/dtex or more and an elongation of 35% or
more.
5. The thermally adhesive sheath-core conjugate fiber according to
claim 4, wherein the sheath-core conjugate fiber has a total
fineness of 30 dtex or more and a single yarn fineness of 3.0 dtex
or less.
6. A tricot fabric comprising the thermally adhesive sheath-core
conjugate fiber according to claim 4.
7. A tricot fabric comprising the thermally adhesive sheath-core
conjugate fiber according to claim 5.
Description
TECHNICAL FIELD
[0001] This disclosure relates to a thermally adhesive sheath-core
conjugate fiber having low fuzz generation in a high-order process,
exhibits excellent high-order passability even in uses such as
tricot use and the like, requiring a high quality level, enables a
woven or knitted fabric having excellent strength, dimensional
stability, and durability after thermal adhesion, and having an
excellent quality level as a flow path material of a liquid
filtration membrane.
BACKGROUND
[0002] A polyester fiber is suitable as a raw material fiber for
clothing and industrial materials and the like due to its excellent
dimensional stability, weather resistance, mechanical properties,
durability, and productivity that can be mass-produced relatively
inexpensively and the like, and used in various fields and
uses.
[0003] In recent years, in material uses such as a flow path
material for a water treatment membrane and a filter, interior uses
such as a chair and a partition, and other various clothing uses,
utilization of a thermally adhesive polyester fiber capable of
improving the form retention and rigidity of a fabric proceeds. The
thermally adhesive polyester fiber is obtained by forming a
polyester fiber into a woven or knitted fabric, and then subjecting
the fabric to a heat treatment such as calendering to partially
melting fibers, thereby thermally adhering the fibers. Above all,
the demand for a water treatment membrane increases year by year to
mainly solve serious water shortage caused by a population increase
in the Middle East and Africa regions. In a member serving as a
flow path of permeation water filtered in a water treatment device,
the demand for a polyester tricot flow path material obtained by
thermally adhering a polyester tricot fabric rapidly increases.
[0004] As the thermally adhesive polyester fiber, a yarn composed
of 2 or more types of polyesters having different melting points or
softening points is suitable. Examples include a mixed fiber
including a filament yarn, and a sheath-core type or side-by-side
type conjugate fiber. A conjugate fiber in which a filament single
yarn includes polymers having different melting points has an
excellent quality level after thermal adhesion compared to a mixed
yarn in which filaments having different melting points are mixed
at a single yarn level. In particular, a thermally adhesive
sheath-core conjugate fiber is actively used. The thermally
adhesive sheath-core conjugate fiber is a sheath-core conjugate
yarn having an excellent quality level such as productivity of an
original yarn or surface smoothness of a fabric after a heat
treatment, wherein a sheath component has a melting point or a
softening point lower than that of a core component.
[0005] A sheath-core conjugate fiber including a core part
including a polyester whose main repeating unit includes ethylene
terephthalate and a sheath part including a polymer having a
softening temperature of 130 to 200.degree. C. has been proposed as
the thermally adhesive sheath-core conjugate fiber in Japanese
Patent Laid-Open Publication No. 62-184119.
[0006] The above-mentioned sheath-core conjugate fiber makes it
possible to provide a high-quality thermally adhesive woven or
knitted fabric having predetermined strength and elongation
characteristics without causing occurrence of yarn slippage and
embossing due to slippage at a thermal adhesion intersection.
However, as exemplified by a polyester obtained by copolymerizing
isophthalic acid as a preferred composition of a polymer used for a
sheath component, the polymer of the sheath part has low
crystallinity which does not have a clear melting point. For this
reason, when the woven or knitted fabric made of the sheath-core
conjugate fiber is subjected to a thermal adhesion treatment,
unevenness occurs in adhesion between the conjugate fibers. This
causes dimensional stability and variation in the strength and
elongation of the fabric, which disadvantageously causes a poor
quality level when used as a flow path material of a liquid
filtration membrane.
[0007] Meanwhile, a sheath-core conjugate fiber has been proposed
in Japanese Patent Laid-Open Publication No. 2000-119918. The
sheath-core conjugate fiber includes a core part including a
polymer whose 90% by mole or more of repeating units include
ethylene terephthalate and a sheath part including copolymerized
polybutylene terephthalate whose 60 to 90% by mole of repeating
units include butylene terephthalate.
[0008] In the above-mentioned sheath-core conjugate fiber,
appropriate crystallinity is imparted to the sheath component, and
the sheath-core conjugate fiber has good fiber physical properties
such as a boiling water contraction ratio and a peak temperature of
heat contraction stress, whereby a thermally adhered woven or
knitted fabric product having a good quality level can be
obtained.
[0009] A tricot fabric using a thermally adhesive sheath-core
conjugate fiber described in Japanese Patent Laid-Open Publication
Nos. 2011-245454 or 2014-070279 has also been reported. In those
techniques, a polyester is used, which includes a sheath component
having a melting point significantly lower than that of a high
melting point polyester of a core component. When a spinning
temperature is set based only on the melting point of the core
component polyester, the heat deterioration of the sheath component
is apt to proceed. Meanwhile, when the spinning temperature is
lowered in consideration of the melting point of the sheath
component polyester, the strength and elongation characteristics of
the core component cannot be maximized so that the conjugate fiber
has a poor strength and elongation.
[0010] Since the sheath-core conjugate fiber described in JP '918
has a poor strength and elongation, the sheath-core conjugate fiber
is processed at a high tension and a high speed, which
disadvantageously makes it difficult to develop the sheath-core
conjugate fiber into a tricot use in which quality defects of an
original yarn such as fuzz notably appear as defects of a fabric.
Since the melting point of the sheath component is low, a thermal
adhesion temperature after weaving cannot be increased so that the
contraction of the conjugate fiber constituting the fabric becomes
insufficient. In uses such as a water treatment membrane flow path
material in which high dimensional accuracy is required in
designing the fabric, there is a problem in dimensional stability
when used for a long time under a high pressure. The thermally
adhesive sheath-core conjugate fibers described in JP '454 and JP
'279 have a poor strength and elongation so that the thermally
adhesive sheath-core conjugate fibers disadvantageously have not
only low high-order passability, but also an insufficient strength
and elongation of the fabric to be formed, which disadvantageously
causes poor durability when used as the flow path material for a
long time. For the same reason as that in JP '918, the thermal
adhesion temperature after weaving cannot be increased so that the
contraction of the fibers constituting the fabric becomes
insufficient. In uses such as a water treatment membrane flow path
material in which high dimensional accuracy is required in
designing the fabric, there remains a problem in dimensional
stability when used for a long time under a high pressure.
[0011] It could therefore be helpful to provide a thermally
adhesive sheath-core conjugate fiber having low fuzz generation in
a high-order process, exhibits excellent high-order passability
even in uses such as tricot use and the like, requiring a high
quality level, enables a woven or knitted fabric having excellent
strength, dimensional stability, and durability after thermal
adhesion, and having an excellent quality level as a flow path
material of a liquid filtration membrane.
SUMMARY
[0012] We thus provide: [0013] (1) A thermally adhesive sheath-core
conjugate fiber including: a core part which includes a polyester
having a melting point of 250.degree. C. or higher; and a sheath
part which includes a polyester having a melting point of
215.degree. C. or higher and lower by 20 to 35.degree. C. than that
of the polyester constituting the core part, wherein the thermally
adhesive sheath-core conjugate fiber has a strength of 3.8 cN/dtex
or more and an elongation of 35% or more. [0014] (2) The thermally
adhesive sheath-core conjugate fiber according to (1), wherein the
sheath-core conjugate fiber has a total fineness of 30 dtex or more
and a single yarn fineness of 3.0 dtex or less. [0015] (3) A tricot
fabric including the thermally adhesive sheath-core conjugate fiber
according to (1) or (2).
[0016] We provide a thermally adhesive sheath-core conjugate fiber
having low fuzz generation in a high-order process, exhibits
excellent high-order passability even in uses such as tricot use
and the like, requiring a high quality level, enables a woven or
knitted fabric having excellent strength, dimensional stability,
and durability after thermal adhesion, and having an excellent
quality level as a flow path material of a liquid filtration
membrane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows an example of the cross-sectional shape of a
single yarn of a thermally adhesive sheath-core conjugate
fiber.
[0018] FIG. 2 shows an example of the cross-sectional shape of a
single yarn of a thermally adhesive sheath-core conjugate fiber,
and is a diagram for describing a cross-sectional eccentricity
ratio.
DESCRIPTION OF REFERENCE SIGNS
[0019] 1: Core component [0020] 2: Sheath component [0021] 3:
Position of center of gravity of core component [0022] 4: Position
of center of gravity of conjugate fiber [0023] 5: Radius of
conjugate fiber [0024] 10: Thermally adhesive sheath-core conjugate
fiber
DETAILED DESCRIPTION
[0025] Hereinafter, a thermally adhesive sheath-core conjugate
fiber will be described in detail.
[0026] A sheath-core conjugate fiber includes a core component
including a polyester having a melting point of 250.degree. C. or
higher, and a sheath component including a polyester having a
melting point of 215.degree. C. or higher and lower by 20 to
35.degree. C. than the melting point of the polyester constituting
a core part.
[0027] By setting the melting point of the core component polyester
to 250.degree. C. or higher, a spinning temperature can be
increased to such an extent that the strength and elongation
characteristics of the polyester can be maximized, which provides
an excellent strength and durability of a fabric to be formed. The
melting point of the core component polyester is preferably
270.degree. C. or lower from the practical upper limit. When the
melting point of the core component polyester is 270.degree. C. or
lower, the need for extremely high temperature spinning is avoided
to enable spinning to be performed using a general-purpose melt
spinning device, which is preferable. More preferably, the melting
point is 253.degree. C. or higher and 260.degree. C. or lower.
[0028] The melting point of the sheath component polyester is
215.degree. C. or higher, and preferably 250.degree. C. or lower.
When the sheath component polyester has a melting point of
250.degree. C. or lower, a versatile device can be used to
thermally adhere the fabric, and smoking caused by an oil agent
component in a thermal adhesion treatment can be suppressed, which
is preferable. More preferably, the melting point is 220.degree. C.
or higher and 235.degree. C. or lower. By setting a melting point
difference between the sheath component polyester and the core
component polyester to 20.degree. C. or higher, the thermal
adhesion temperature of the fabric can be made sufficiently lower
than the melting point of the core component polyester, whereby a
highly durable fabric utilizing the strength of an original yarn
can be provided. By setting the melting point difference to
35.degree. C. or lower, the spinning temperature can be set to a
temperature that maximizes the strength and elongation of the core
component polyester and suppresses the thermal deterioration of the
sheath component polyester as much as possible, whereby a conjugate
fiber having an excellent strength and elongation, less original
yarn fuzz, and an excellent quality level is provided. The melting
point difference between the sheath component polyester and the
core component polyester is preferably 23.degree. C. or higher and
30.degree. C. or lower.
[0029] The softening temperature of the core component polyester is
preferably 245.degree. C. or higher, and the softening temperature
of the sheath component polyester is preferably 205.degree. C. or
higher. The softening temperature of the core component polyester
is 245.degree. C. or higher, whereby the dimensional change of the
fabric is less, and the form of the fabric is stable when the
fabric is subjected to a thermal adhesion treatment at a
temperature equal to or higher than the melting point of the sheath
component polyester, which is preferable. The softening temperature
of the core component polyester is more preferably 250.degree. C.
or higher. The upper limit of the softening temperature of the core
component polyester is practically 270.degree. C.
[0030] When the softening temperature of the sheath component
polyester is 205.degree. C. or higher, high-speed passability is
stabilized without causing fusion of the conjugate fiber to a
heater during thermal setting in a processing step, which is
preferable. The softening temperature of the sheath component
polyester is more preferably 215.degree. C. or higher. By setting
the melting point of the sheath component polyester to 215.degree.
C. or higher, and setting the softening point to 205.degree. C. or
higher, the thermal adhesion temperature of the fabric to be formed
can be sufficiently increased, whereby the thermal adhesion
treatment causes the thermal contraction of the sheath-core
conjugate fiber to proceed to improve the dimensional stability of
a final product, which is preferable. The upper limit temperature
of the softening temperature of the sheath component polyester is
practically 250.degree. C.
[0031] As the core component polyester, optional polyesters can be
selected as long as the melting point is within the above range,
but the core component polyester is preferably polyethylene
terephthalate (hereinafter, referred to as PET) from the viewpoint
of dimensional stability and strength and elongation
characteristics. The PET is a polyester obtained by using
terephthalic acid as a main acid component and ethylene glycol as a
main glycol component. The core component polyester may
appropriately include a copolymerization component as long as the
melting point is within the range described above. Examples of
compounds copolymerizable with, for example, PET include
dicarboxylic acids such as isophthalic acid, succinic acid,
cyclohexanedicarboxylic acid, adipic acid, dimeric acid, sebacic
acid, and 5-sodium sulfoisophthalic acid, and diols such as
ethylene glycol, diethylene glycol, 2,2-dimethyl-1,3-propanediol,
butanediol, neopentyl glycol, cyclohexane dimethanol, polyethylene
glycol, polypropylene glycol, and bisphenol A ethylene oxide
adduct. It is more preferable that 100% of the compound is homo PET
including repeating units of ethylene terephthalate from the
viewpoint of dimension stability and strength and elongation
characteristics. If necessary, inorganic fine particles made of
titanium dioxide and the like as a matting agent, and silica fine
particles and the like as a lubricant may be added.
[0032] As the sheath component polyester, optional polyesters can
be selected as long as the melting point is within the
above-mentioned range. In addition to PET, polytrimethylene
terephthalate and polybutylene terephthalate are preferable. When
the PET is used as the core component polyester, the PET is
particularly preferably used as the sheath component polyester, in
consideration of the peeling suppression of a composite interface.
As the sheath component polyester, an optional copolymerization
component can be added at an optional ratio as long as the melting
point is within the above-mentioned range. When 70% by mole or more
of copolymerized PET includes repeating units of ethylene
terephthalate, moderate crystallinity can be imparted to a polymer,
to provide stabilized spinning operability, which is preferable.
When the fabric is subjected to thermal adhesion, thermal adhesion
unevenness is less likely to occur, which is preferable. It is more
preferable that 80% by mole or more of copolymerized PET includes
repeating units of ethylene terephthalate. When a polymer other
than PET is used as the sheath component polyester, a
copolymerization component can be appropriately added as long as
original yarn productivity and the quality level of the fabric
after a thermal adhesion treatment are not impaired. As the
copolymerization component, optional components such as the
above-mentioned copolymerization component can be copolymerized.
Regardless of the type of a polymer selected, if necessary,
inorganic fine particles made of titanium dioxide and the like as a
matting agent, and silica fine particles and the like as a
lubricant may be added.
[0033] Next, the intrinsic viscosity (hereinafter, referred to as
IV) of the conjugate fiber is preferably 0.55 to 0.75. When IV is
0.55 or more, the toughness of the conjugate fiber sufficient for
withstanding practical use can be achieved without a degree of
polymerization being too low, which is preferable. Meanwhile, when
IV is 0.75 or less, IV is not too high during spinning. This makes
it possible to suppress an increase in the amount of COOH during
melt spinning without making it necessary to perform extreme high
temperature spinning, and provide a uniform conjugate fiber without
causing melt fracture, and causes no decrease in the toughness,
which is preferable. More preferably, IV is 0.60 to 0.70.
[0034] FIG. 1 is a schematic cross-sectional view of a sheath-core
conjugate fiber. In a sheath-core conjugate fiber 10, a core
component 1 is surrounded by a sheath component 2.
[0035] The cross-sectional shape of the conjugate fiber is not
particularly limited as long as a high melting point component is
disposed in a core part and a low melting point component is
disposed in a sheath form to cover the core part, but it is
preferable that the sheath component completely covers the core
component without exposing the core component. The eccentricity
ratio of the center of gravity of the core component with respect
to the center of gravity of the entire conjugate fiber is
preferably 5% or less in the cross section of the conjugate fiber
because of the productivity of the original yarn and the stability
of physical properties such as Uster unevenness U %. When the
eccentricity ratio is 5% or less, coiled crimp is not expressed
even if the combination of the polymers of the core component and
the sheath component is a combination which causes a difference in
contraction, which preferably provides an excellent quality level
of the fabric. More preferably, the eccentricity ratio is 1% or
less.
[0036] The cross-sectional outer peripheral shape of the conjugate
fiber is preferably a substantially circular shape with a flat
ratio represented by AB and being 1.1 or less, where A is a major
axis of an outer peripheral shape and B is a minor axis thereof.
Such a shape can uniformly disperse and receive a force when an
external tension is applied, and provides also less variation in
strength and elongation in the S-S curve of the conjugate fiber,
which is preferable. More preferably, the flat ratio is 1.0.
[0037] The composite ratio of the core component and the sheath
component in the sheath-core conjugate fiber is set such that the
cross-sectional area ratio (core:sheath) is preferably 40:60 to
90:10, and more preferably 55:45 to 75:25. By setting the composite
ratio to be within the above range, the conjugate fiber can be
stably produced, has an excellent strength and elongation, has low
fuzz generation, and can maintain a strength and an elongation even
during thermal adhesion of the fabric, which is preferable.
[0038] The content of inorganic particles included in the core
component is 3.0% by weight or less, to improve the toughness,
which is preferable. The content is more preferably 0.5% by weight
or less. The content of inorganic fine particles included in the
sheath component is 0.05% by weight or more, to improve the process
passability, which is preferable. More preferably, the content of
the inorganic fine particles included in the sheath component is
0.05% by weight or more and 0.5% by weight or less because a guide
is not excessively abraded during process passing, and unnecessary
falling of the inorganic particles when the conjugate fiber is used
as a flow path material is not caused. The inorganic fine particles
are preferably made of titanium oxide from the viewpoint of the
process passability as the conjugate fiber.
[0039] The conjugate fiber preferably has a total fineness of 30
dtex or more. By setting the total fineness to 30 dtex or more, a
sufficient strength and rigidity can be ensured by a thermal
adhesion treatment. When the conjugate fiber is used as the flow
path material, a sufficient passing amount of a permeation liquid
can be secured even if a water pressure acts. The total fineness is
preferably 90 dtex or less, and more preferably 40 dtex or more. By
setting the total fineness to 90 dtex or less, the thinning of the
fabric can be achieved. When the conjugate fiber is used as the
flow path material, the number of laminated layers per unit formed
by bonding the filtration membrane and the flow path material can
be increased, which is preferable.
[0040] The single yarn fineness of the conjugate fiber is
preferably 3.0 dtex or less. By setting the single yarn fineness to
3.0 dtex or less, the specific surface area is increased. This can
cause even a short time thermal adhesion treatment to provide
uniform thermal adhesion, and provide a suppressed decrease in the
strength of the fabric due to the thermal adhesion treatment,
whereby the fabric having high durability can be obtained. The
single yarn fineness is preferably 0.7 dtex or more, and more
preferably 1.5 dtex or more and 2.5 dtex or less. By setting the
single yarn fineness to 0.7 dtex or more, less yarn unevenness and
original yarn fuzz are provided, which enables stable production,
and knitting yarn breakage is less, which provides excellent
high-order passability, and appropriate rigidity of the fabric to
be formed, which is preferable.
[0041] The conjugate fiber has a strength of 3.8 cN/dtex or more
and an elongation of 35% or more. By setting the strength to 3.8
cN/dtex or more, a fabric to be formed has a high strength. The
fabric has excellent durability when the fabric is used as a flow
path material. The practical upper limit of the strength is 7.0
cN/dtex. By setting the elongation to 35% or more, the fuzz of the
original yarn can be prevented, and the fabric has less warping
fuzz during weaving, and less yarn breakage during knitting,
excellent high-order passability, and an excellent quality level
with few defects. The elongation is more preferably 35 to 50%. A
woven or knitted fabric obtained by setting the elongation to 50%
or less has excellent dimensional stability, which is
preferable.
[0042] To obtain a highly uniform fabric, Uster unevenness U %
which is an index of thickness unevenness in the fiber longitudinal
direction of the conjugate fiber is preferably set to 1.4% or less.
When the Uster unevenness U % is 1.4% or less, the surface of the
fabric after thermal adhesion becomes smooth, and a uniform flow
path can be formed when the fabric is used as the flow path
material, which is preferable. More preferably, the Uster
unevenness U % is 1.0% or less.
[0043] The dry-heat contraction ratio of the conjugate fiber is
preferably 20% or less. By setting the dry-heat contraction ratio
to 20% or less, a dimensional change due to a thermal adhesion
treatment can be suppressed, which is preferable. The practical
lower limit of the dry-heat contraction ratio is 2.0%.
[0044] A preferred yarn production method will be described. As a
spinneret used for a melt spinning method of a thermally adhesive
sheath-core conjugate fiber, an existing composite spinning
spinneret can be used.
[0045] Examples of the melting method include a pressure melter
method and an extruder method, but melting provided by an extruder
is preferable from the viewpoint of efficiency and suppression of
decomposition. A melting temperature is preferably set to be higher
by 10 to 40.degree. C. than the melting point of a polymer to be
used.
[0046] The spinning temperature is preferably 280 to 295.degree. C.
More preferably, the spinning temperature is 285.degree. C. to
293.degree. C. By employing such a spinning temperature, a
conjugate fiber having a high toughness and good yarn producing
properties can be obtained. A heater may be provided below a
spinneret to alleviate rapid cooling immediately below the
spinneret.
[0047] By shortening a melting passage time and a heating time from
melting to discharging as much as possible, a decrease in the
molecular weight of each of the core component and the sheath
component can be suppressed, which is preferable. The core
component and the sheath component are separately melt-kneaded,
precisely discharged and measured through a heating zone, passed
through a filter layer for trapping extraneous matters, and
discharged, stringed, and cooled using a composite spinneret to
provide a sheath-core form. When a polymer residence time which is
a passage time from melting to discharging is within 30 minutes,
the thermal deterioration of the polymer can be reduced, and a
decrease in IV is suppressed, whereby a decrease in the toughness
of the yarn can be prevented. An increase in the amount of COOH in
the conjugate fiber can be suppressed, whereby suppressed fuzz,
excellent heat resistance, excellent high-order passability, and
improved durability of the fabric to be formed can be provided,
which is preferable. More preferably, the polymer residence time is
20 minutes or less.
[0048] A spinneret surface temperature is preferably set to
270.degree. C. or higher and 290.degree. C. or lower from the
balance between the strength and elongation and the productivity.
By setting the spinneret surface temperature to 270.degree. C. or
higher, the characteristics of the core component can be maximized,
whereby a yarn having an excellent strength and elongation can be
obtained. By setting the spinneret surface temperature to
290.degree. C. or lower, an increase in yarn breakage due to the
deposition of a polymer hydrolyzate immediately below the spinneret
is suppressed, which provides excellent original yarn productivity,
which is preferable.
[0049] The sheath-core conjugate fiber can be manufactured by any
of a two-step method in which a discharged polymer is once wound up
as an undrawn yarn and then drawn, and a one-step method such as a
direct spinning drawing method in which spinning and drawing steps
are continuously performed, or a high speed yarn producing
method.
[0050] A stretching temperature is preferably 60.degree. C. or
higher and 100.degree. C. or lower, which is near the glass
transition temperature of the undrawn yarn. By setting the
stretching temperature to 60.degree. C. or higher, uniform
stretching can be provided, and by setting the stretching
temperature to 100.degree. C. or lower, deterioration in
productivity due to fusion of fibers to a stretching roll or
spontaneous extension of the fibers can be prevented. More
preferably, the stretching temperature is 75.degree. C. or higher
and 95.degree. C. or lower.
[0051] It is preferable that the fiber is thermally set at a
temperature which the crystallization rate of the undrawn yarn
becomes the largest after stretching. The temperature is preferably
set to 110.degree. C. or higher and 180.degree. C. or lower. The
thermal setting at 110.degree. C. or higher makes it possible not
only to promote the crystallization of the fiber to increase the
strength but also to stabilize various kinds of yarn physical
properties including contraction stress and a dry-heat contraction
ratio, which is preferable. The thermal setting at 180.degree. C.
or lower makes it possible to prevent deterioration in productivity
due to the fusion of the conjugate fiber to a thermal setting
device, which is preferable.
EXAMPLES
[0052] Hereinafter, our fibers and fabrics will be specifically
described by way of Examples. Main measured values of Examples were
measured by the following methods.
(1) Intrinsic Viscosity (IV)
[0053] In the definition formula .eta.r, a relative viscosity
.eta.r is obtained according to the following formula by dissolving
0.8 g of a sample in 10 mL of O-chlorophenol (OCP) having a purity
of 98% or more, and using an Ostwald viscometer at 25.degree. C.,
to calculate an intrinsic viscosity (IV).
.eta.r=.eta./.eta.0=(t.times.d)/(t0.times.d0)
Intrinsic viscosity (IV)=0.0242.eta.r+0.2634
[.eta.: viscosity of polymer solution, .eta.0: viscosity of OCP, t:
drop time of solution (sec), d: density of solution (g/cm.sup.3),
t0: drop time of OCP (sec), d0: density of OCP (g/cm.sup.3)].
(2) Melting Point
[0054] 10 mg of a dried sample was weighed by using a differential
scanning calorimetry (DSC) Q100 manufactured by TA Instruments,
sealed in an aluminum pan, and then measured at a heating rate of
16.degree. C./min from room temperature to 300.degree. C. under a
nitrogen atmosphere. After first measurement (1st run), the sample
was held for 5 minutes and then rapidly cooled to room temperature.
Second measurement (2nd run) was continuously performed, and the
peak top temperature of a melting peak in the 2nd run was taken as
a melting point.
(3) Softening Temperature
[0055] A dried sample was placed on a sample stage by using a
thermal mechanical device (TMA/SS-6000) manufactured by Seiko
Instruments Inc., and measured at a heating rate of 16.degree.
C./min from room temperature to 300.degree. C. under a nitrogen
atmosphere using a needle probe having a tip diameter of 1.0 mm in
a state where a measurement load was set to 10 g. A temperature at
the start of displacement was taken as a softening temperature.
(4) Cross-Sectional Eccentricity Ratio
[0056] The cross section of a fiber was observed by using a
microscope VHX-2000 manufactured by Keyence Corporation, and each
value was measured with an attached image analysis software. When
the position of center of gravity of a core component was taken as
C1 (numeral number 3 in FIG. 2); the position of center of gravity
of a conjugate fiber was taken as Cf (numeral number 4 in FIG. 2);
and the radius of the conjugate fiber was taken as rf (numeral
number 5 in FIG. 2), the cross-sectional eccentricity ratio was
calculated from the following formula:
Cross-sectional eccentricity ratio (%)={|Cf-C1|/rf}.times.100.
(5) Cross-Sectional Flat Ratio
[0057] In the same manner as in (4), the cross section of the
conjugate fiber was observed. Among diameters passing through the
center of the cross section, the longest diameter was taken as a
major axis A, and the shortest diameter was taken as a minor axis
B. The cross-sectional flat ratio was calculated according to the
following formula:
Cross-sectional flat ratio=major axis A/minor axis B.
(6) Fineness, Strength, Elongation, and Toughness
[0058] The fineness, the strength, the elongation, and the
toughness were measured according to JIS L1013 (2010, chemical
fiber filament yarn test method). The toughness was calculated
according to the following formula:
(Toughness)=(Strength).times.(Elongation).sup.0.5.
(7) Uster Unevenness U %
[0059] The Uster unevenness U % was measured in a normal mode using
USTER TESTER 4-CX manufactured by Zellweger while feeding a yarn at
a speed of 200 m/min for 5 minutes.
(8) Boiling Water Contraction Ratio and Dry-Heat Contraction
Ratio
[0060] Ten skeins were produced using a frame measuring device
having a frame circumference of 1.0 m, and the boiling water
contraction ratio and the dry-heat contraction ratio were
calculated according to the following formula. Both an original
length and a length after treatment were measured in a state where
a load was applied {(notified fineness (dtex).times.2)g}. Regarding
a contraction treatment, the boiling water contraction ratio was
obtained by immersing in boiling water for 15 minutes, and the
dry-heat contraction ratio was obtained by treating at 200.degree.
C. for 5 minutes.
Contraction ratio (%)={(original length (L1)-length after treatment
(L2))/original length (L1)}.times.100.
(9) Number of Fuzz Defects
[0061] Using Fly Counter (MFC-120S) manufactured by Toray
Engineering Co., Ltd., 48 conjugate fibers were measured under
measurement conditions of an unraveling speed of 500 m/min and a
measuring length of 50000 m, and the number of detected fuzzes was
counted. Based on the counted number of fuzzes, the following
scores were made:
[0062] Score 3: The number of fuzzes in all of the 48 fibers: 0
[0063] Score 2: The average number of fuzzes of the 48 fibers: less
than 0.1, and the maximum number of fuzzes in the 48 fibers: 1
[0064] Score 1: The average number of fuzzes of the 48 fibers: 0.1
or more and less than 0.3, and the maximum number of fuzzes in the
48 fibers: 1
[0065] Score 0: The average number of fuzzes in the 48 fibers: 0.3
or more, or the maximum number of fuzzes in the 48 fibers: 2 or
more.
(10) High-Order Passability
[0066] After the conjugate fiber was warped, the following
evaluation scores were made according to the number of warping
fuzzes detected and the number of knitting yarn breakages when
knitting was performed at a double denby structure seam using a
tricot knitting machine (36 gauges) including two guide bars using
the original yarn obtained for both a front yarn and a back
yarn:
[0067] Score 3: The number of warping fuzzes: less than 0.3/10
million m, and the number of knitting yarn breakages: less than
0.5/200 m
[0068] Score 2: The number of warping fuzzes: 0.3/10 million m or
more and less than 0.6/10 million m, and the number of knitting
yarn breakages: less than 0.5/200 m, or the number of warping
fuzzes: less than 0.3/10 million m, and the number of knitting yarn
breakages: 0.5/200 m or more and less than 1.0/200 m
[0069] Score 1: The number of warping fuzzes: 0.3/10 million m or
more and less than 0.6/10 million m, and the number of knitting
yarn breakages: 0.5/200 m or more and less than 1.0/200 m
[0070] Score 0: The number of warping fuzzes: 0.6/10 million m or
more, or the number of knitting yarn breakages: 1.0/200 m or
more.
(11) Strength of Fabric After Thermal Adhesion
[0071] A tricot fabric was produced by the method of (10), and a
heat treatment was performed at a melting point of a sheath
component+10.degree. C. with a pin tenter dryer in a non-loaded
state to produce a thermally adhered fabric. The density of the
fabric after thermal adhesion was adjusted so that 66 yarns/2.54 cm
(=inch) in a wale direction and 53 yarns/2.54 cm (=inch) in a
course direction were set. The strength of the fabric after thermal
adhesion was measured in accordance with JIS 1096: 2010 (testing
methods for woven and knitted fabrics) in a wale (vertical)
direction and a course (horizontal) direction, and the following
scores were made based on the strength values:
[0072] Score 3: 600 N/5 cm or more in vertical direction and 100
N/5 cm or more in horizontal direction
[0073] Score 2: 500 N/5 cm or more and less than 600 N/5 cm in
vertical direction and 100 N/5 cm or more in horizontal direction,
or 600 N/5 cm or more in vertical direction, and 80 N/5 cm or more
and 100 N/5 cm or less in horizontal direction0
[0074] Score 1: 500 N/5 cm or more and less than 600 N/5 cm in
vertical direction, and 80 N/5 cm or more and less than 100 N/5 cm
in horizontal direction
[0075] Score 0: less than 500 N/5 cm in vertical direction or less
than 80 N/5 cm in horizontal direction.
(12) Flow Path Material Water Resistance Test (Salt Removal Rate
(%), Water Production Amount (m.sup.3/day))
[0076] A tricot fabric after thermal adhesion produced in the same
manner as in (11) was sandwiched between two RO separation
membranes each having a thickness of 150 .mu.m, to form a spiral
type unit. The spiral type unit was incorporated into a module
having a diameter of 0.2 m and a length of 1 m. Sea water having a
TDS (soluble evaporation residue) of 3.5% by weight was filtered at
a liquid temperature of 25.degree. C. under a differential pressure
of 4.5 MPa for 5 days. The electrical conductivity of the
permeation liquid was measured after 5 days, and the removal rate
of magnesium sulfate was calculated. The amount of a permeation
liquid after 5 days was measured, and a water production amount per
day was calculated. Based on the results of the test, the following
evaluation scores were made:
[0077] Score 3: The removal rate of magnesium sulfate: 99.8% or
more, and the water production amount: 45 m.sup.3/day or more
[0078] Score 2: The removal rate of magnesium sulfate: 99.8% or
more, and the water production amount: 40 m.sup.3/day or more and
less than 45 m.sup.3/day, or the removal ratio of magnesium
sulfate: 99.0% or more and less than 99.8%, and the water
production amount: 45 m.sup.3/day or more
[0079] Score 1: The removal rate of magnesium sulfate: 99.0% or
more and less than 99.8%, and the water production amount: 40
m.sup.3/day or more and less than 45 m.sup.3/day
[0080] Score 0: The removal rate of magnesium sulfate: less than
99.0%, or the water production amount: less than 40
m.sup.3/day.
(13) Decision to Pass or Fail
[0081] In the evaluation items in (9) to (12), all items having
score 2 or more was taken as pass, and when having at least one
item was score 1 or less was taken as fail.
Example 1
[0082] There were prepared a homo PET polymer of IV 0.67 not
including titanium oxide (high melting point component, melting
point: 255.degree. C.), and a copolymerized PET polymer (low
melting point component, melting point: 230.degree. C.) obtained by
copolymerizing 7.1% by mole of isophthalic acid and 4.4% by mole of
bisphenol A ethylene oxide adduct as copolymerization components
with respect to total acid components and having a titanium oxide
content of 0.05% by weight and IV of 0.65. The high melting point
component was melted at 285.degree. C. in an extruder, and the low
melting point component was melted at 260.degree. C. in the
extruder. A spinning temperature was set to 290.degree. C., and
weighing was performed by a measuring pump. After filtration in a
pack, by a spinneret nozzle, the components were discharged in a
sheath-core conjugate form having a composite area ratio of 65:35
to form a concentric sheath-core cross-sectional shape as shown in
FIG. 1 (cross-sectional eccentricity ratio: 0%, and cross-sectional
plat ratio: 1.0). At this time, the high melting point component
was disposed in a core and the low melting point component was
disposed in a sheath.
[0083] As a take-up device, a direct spinning method (DSD) which
drawing and winding were consistently performed was adopted, and
the discharged polymer was taken up by a take-up roll (1st HR) set
to a surface temperature of 85.degree. C. at a speed of 1728 m/min
through a cooling part and a fueling part. The polymer was
continuously wound around a heat treatment roll (2nd HR) set at
128.degree. C. at 4489 m/min without being wound once, and a
2.6-fold stretching was performed. The tensions of the stretched
and heat-treated yarns were adjusted with a godet roller (3rd GR,
4th GR) set to 4549 m/min and 4584 m/min. A cheese-shaped package
was wound at a speed of 4500 m/min and a tension of 0.20 cN/dtex,
to obtain a sheath-core conjugate fiber having 56 dtex-24
filaments. The evaluation results for the obtained fibers were
shown in Table 1. Uster unevenness U % was 0.4%; a boiling water
contraction ratio was 10.3%; and a dry-heat contraction ratio was
17.2%.
[0084] As shown in Table 1, the fiber had an excellent strength and
elongation, an excellent toughness, and low original yarn fuzz
generation. The obtained original yarn was used for both a front
yarn and a back yarn, and knitting was performed at a double denby
structure seam using a tricot knitting machine (36 gauges)
including two guide bars. The fiber had less warping fuzz
generation, less yarn breakage during knitting, and excellent
high-order passability. Furthermore, a fabric strength after a
thermal adhesion treatment with a pintenter at 240.degree. C. (the
melting point of the sheath component+10.degree. C.) was high. When
the fabric was used as a flow path material of a water treatment
membrane, the high temperature heat treatment caused a tricot flow
path material to have excellent dimensional stability, and could
secure a stable water production amount while maintaining membrane
performance without causing the breakage or clogging of the flow
path material in continuous use.
Examples 2 to 4 and Comparative Examples 1 to 3
[0085] Examples 2 to 4 and Comparative Examples 1 to 3 were the
same as Example 1 except that the melting points of a core
component polyester and a sheath component polyester were adjusted
as shown in Table 1 such that a copolymerization ratio was changed
by using the copolymerization component used in the sheath
component of Example 1, and an appropriate spinning temperature was
adopted according to the adjustment. The evaluation results are as
shown in Table 1.
Example 5
[0086] Example 5 was the same as Example 1 except that a DSD for a
spinning machine was changed to a two-step method, and a spinning
condition and the like was incidentally adjusted. The evaluation
results are as shown in Table 1.
Examples 6 and 7
[0087] Examples 6 to 7 were the same as Example 1 except that the
discharge hole shape of a spinneret was changed, and a
cross-sectional shape and the eccentricity ratio of a core-sheath
were changed as shown in Table 2. The evaluation results are as
shown in Table 2.
Examples 8 to 11
[0088] Examples 8 to 11 were the same as Example 1 except that the
fineness of a conjugate fiber and the number of filaments were
changed as shown in Table 2. The evaluation results are as shown in
Table 2.
Examples 12 to 14
[0089] Examples 12 to 14 were the same as Example 1 except that the
amounts of titanium oxide added to a core component polyester and a
sheath component polyester were changed as shown in Table 3. The
evaluation results are as shown in Table 3.
Examples 15 to 17
[0090] Examples 15 to 17 were the same as Example 1 except that the
discharge amounts of a core component polyester and a sheath
component polyester were changed, and the ratio of a core-sheath
was as shown in Table 3. The evaluation results are as shown in
Table 3.
TABLE-US-00001 TABLE 1 Unit Example 1 Example 2 Example 3 Example 4
Spinning Production method -- DSD DSD DSD DSD condition Spinning
temperature .degree. C. 290 285 280 295 Spinneret surface
temperature .degree. C. 281 278 273 287 Raw material Core component
melting point .degree. C. 255 250 250 255 polymer Core component
softening .degree. C. 253 247 247 253 temperature Core component
polymer -- PET CoPET CoPET PET Sheath component melting point
.degree. C. 230 220 215 235 Sheath component softening .degree. C.
227 215 208 232 temperature Sheath component polymer -- CoPET CoPET
CoPET CoPET Melting point difference of .degree. C. 25 30 35 20
core and sheath Conjugate fiber IV -- 0.65 0.64 0.63 0.65 Fiber
physical Strength cN/dtex 4.0 3.9 3.8 4.0 properties Elongation %
40 41 38 36 Toughness -- 25 25 23 24 Evaluation Number of fuzz
defects Score 3 3 2 2 Higher-order passability Score 3 3 2 2
Strength of fabric after Score 3 3 3 2 thermal adhesion Flow path
material water Score 3 3 3 2 resistance test Comparative
Comparative Comparative Unit Example 1 Example 2 Example 3 Example
5 Spinning Production method -- DSD DSD DSD Two-step condition
method Spinning temperature .degree. C. 275 290 280 286 Spinneret
surface temperature .degree. C. 267 281 273 285 Raw material Core
component melting point .degree. C. 245 255 255 255 polymer Core
component softening .degree. C. 239 253 253 253 temperature Core
component polymer -- CoPET PET PET PET Sheath component melting
point .degree. C. 215 245 210 230 Sheath component softening
.degree. C. 208 239 200 227 temperature Sheath component polymer --
CoPET CoPET CoPET CoPET Melting point difference of .degree. C. 30
10 45 25 core and sheath Conjugate fiber IV -- 0.53 0.75 0.60 0.66
Fiber physical Strength cN/dtex 3.5 4.1 3.6 4.1 properties
Elongation % 39 40 36 44 Toughness -- 22 26 22 27 Evaluation Number
of fuzz defects Score 1 3 2 3 Higher-order passability Score 1 3 1
3 Strength of fabric after Score 1 0 1 3 thermal adhesion Flow path
material water Score 1 -- 2 3 resistance test
TABLE-US-00002 TABLE 2 Unit Example 6 Example 7 Example 8 Example 9
Example 10 Example 11 Raw material Core component melting point
.degree. C. 255 255 255 255 255 255 polymer Core component
softening .degree. C. 253 253 253 253 253 253 temperature Sheath
component melting point .degree. C. 230 230 230 230 230 230 Sheath
component softening .degree. C. 227 227 227 227 227 227 temperature
Melting point difference of .degree. C. 25 25 25 25 25 25 core and
sheath Conjugate fiber Core-sheath eccentricity ratio % 1.0 5.0 0 0
0 0 Cross-sectional flat ratio -- 1.0 1.1 1.0 1.0 1.0 1.0 Total
fineness dtex 56 56 33 44 84 96 Number of filaments -- 24 24 24 24
36 24 Single yarn fineness dtex 2.3 2.3 1.4 1.8 2.3 4.0 Fiber
physical Strength cN/dtex 4.0 3.9 3.8 4.0 4.1 4.1 properties
Elongation % 39 38 39 38 40 40 Toughness -- 25 24 24 25 26 26
Effect Number of fuzz defects Score 3 2 2 2 3 3 Higher-order
passability Score 3 2 2 2 3 3 Strength of fabric after Score 3 3 2
3 3 3 thermal adhesion Flow path material water Score 3 2 2 2 3 2
resistance test
TABLE-US-00003 TABLE 3 Unit Example 12 Example 13 Example 14
Example 15 Example 16 Example 17 Raw material Core component
melting point .degree. C. 255 255 255 255 255 255 polymer Core
component softening .degree. C. 253 253 253 253 253 253 temperature
Sheath component melting point .degree. C. 230 230 230 230 230 230
Sheath component softening .degree. C. 227 227 227 227 227 227
temperature Melting point difference of .degree. C. 25 25 25 25 25
25 core and sheath Amount of titanium oxide of wt % 0 0.3 2.0 0 0 0
core component Amount of titanium oxide of wt % 0 0.3 2.0 0.05 0.05
0.05 sheath component Conjugate fiber Core-sheath ratio -- 65:35
65:35 65:35 75:25 55:45 80:20 Fiber physical Strength cN/dtex 4.0
4.0 3.8 4.1 4.0 4.1 properties Elongation % 38 39 40 40 40 42
Toughness -- 25 25 24 26 25 27 Evaluation Number of fuzz defects
Score 2 3 2 3 3 3 Higher-order passability Score 2 3 2 3 2 3
Strength of fabric after Score 3 3 2 2 2 2 thermal adhesion Flow
path material water Score 3 3 2 2 2 2 resistance test
* * * * *