U.S. patent number 3,607,611 [Application Number 04/783,585] was granted by the patent office on 1971-09-21 for composite filament having crimpability and latent adhesivity.
This patent grant is currently assigned to Kanegafuchi Boseki Kabushiki Kaisha. Invention is credited to Masao Matsui, Susumu Tokura, Masahiro Yamabe.
United States Patent |
3,607,611 |
Matsui , et al. |
September 21, 1971 |
COMPOSITE FILAMENT HAVING CRIMPABILITY AND LATENT ADHESIVITY
Abstract
A composite filament suitable for manufacturing ladies'
stockings having a crimpability comprising at least two
fiber-forming components differing in shrinkability, which has such
a particular cross section that one component is interposed into
the other component, for example, in a wedge-shape and occupies
only 5 to 30 percent of the peripheral surface of the filament, is
manufactured by flowing two independent same or different spinning
materials in opposite directions to each other in two ducts each
connecting to a common conduit and combining them and interposing a
thin layerlike flow of another spinning material different from the
above-described spinning materials between the two spinning
material flows at the combined portion in the above-described
particular cross-sectional shape and then extruding the thus
combined spinning materials through the conduit from a common
orifice.
Inventors: |
Matsui; Masao (Takatsuki,
JA), Tokura; Susumu (Osaka, JA), Yamabe;
Masahiro (Neyagawa, JA) |
Assignee: |
Kanegafuchi Boseki Kabushiki
Kaisha (Sumida-Ku, Tokyo, JA)
|
Family
ID: |
27301310 |
Appl.
No.: |
04/783,585 |
Filed: |
December 13, 1968 |
Foreign Application Priority Data
|
|
|
|
|
Oct 9, 1968 [JA] |
|
|
43/73752 |
|
Current U.S.
Class: |
428/374; 428/394;
428/395; 428/397 |
Current CPC
Class: |
D01D
5/30 (20130101); Y10T 428/2973 (20150115); Y10T
428/2931 (20150115); Y10T 428/2967 (20150115); Y10T
428/2969 (20150115) |
Current International
Class: |
D01D
5/30 (20060101); D02g 003/00 () |
Field of
Search: |
;161/177,173
;264/171-174 ;18/8SC |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
969,110 |
|
Sep 1964 |
|
GB |
|
1,105,575 |
|
Jun 1968 |
|
GB |
|
744,112 |
|
Jun 1946 |
|
DT |
|
Other References
"Mixed-stream Spinning of Bicomponent Fibers" By Fitzgerald et al.,
Textile Research Journal 37 (6); 447-453. June, 1967; 264-Bicomp.
Dig..
|
Primary Examiner: Woo; Jay H.
Claims
What is claimed is:
1. A crimpable composite filament comprising at least two synthetic
mutually melt spinnable thermoplastic components of different
shrinkability, said components selected from the group consisting
of polyamides, polyesters, polyesteramides, polyacrylonitriles,
polyolefins, polystyrenes, polycarbonates, polyesterethers,
polyvinyl chloride, polyvinylidene chloride, and mixtures thereof,
each of which extends uniformly and continuously along the filament
longitudinal axis, each component occupying the peripheral surface
of the filament, the smallest surface area occupied by either
component being between 5 and 30 percent of the total surface area,
the main body of the component of the smallest surface area lying
within the other component and taking the form of a wedgelike
structure as viewed in filament cross section, the inwardly
extending length of said structure being at least equal to its
greatest length.
2. The filament as claimed in claim 1 , wherein the length of said
wedge is more than 1.5 times of the width of said wedge.
3. The filament as claimed in claim 1, wherein the surface area
occupied by said wedge is 5- 20 percent of the total surface of the
filament.
4. The filament as claimed in claim 1, wherein the volume occupied
by the wedge-forming component is 5- 50 percent of the total volume
of the filament.
5. The filament as claimed in claim 1, wherein said wedge-forming
component has a softening and adhesion-beginning temperature of at
least 5.degree. C. lower than that of the other component.
6. The filament as claimed in claim 1, wherein each of said
components is a polymer selected from the group consisting of
polyamides, polyesters, polyacrylonitriles, polyolefins,
polystyrenes, polycarbonates, polyesterethers, polyvinyl chloride,
polyvinylidene chloride, and polymer blends thereof.
7. The filament as claimed in claim 1, wherein wedge-forming
component and another component are nylon-6 and a mixture of
nylon-6 with polyhexamethyleneisophthalamide respectively.
8. The filament as claimed in claim 1, wherein wedge-forming
component and another component are mixture of nylon-6 with
polyhexamethyleneadipamide and nylon-6 respectively.
9. The filament as claimed in claim 1, wherein the cross section of
the filament is circular.
10. The filament as claimed in claim 1, wherein the cross section
of the filament is noncircular.
11. The filament as claimed in claim 1, wherein the length of said
wedge is more than 1.5 times of the width of said wedge.
12. The filament as claimed in claim 1, wherein the surface area
occupied by said wedge is 5- 20 percent of the total surface of the
filament.
13. The filament as claimed in claim 1, wherein the volume occupied
by the wedge-forming component is 5- 50 percent of the total volume
of the filament.
14. The filament as claimed in claim 1, wherein said wedge-forming
component has a softening and adhesion-beginning temperature of at
least 5.degree. C. lower than that of the other components.
15. The filament as claimed in claim 14, wherein said wedge-forming
component has a softening and adhesion-beginning temperature of at
least 10.degree. C. lower than that of the other components.
16. The filament as claimed in claim 14, wherein said wedge-forming
component has a softening and adhesion-beginning temperature of at
least 10.degree. C. lower than that of the other components.
17. A filament as defined in claim 1, wherein the body of said
filament other than said wedgelike component is composed of two
components of different shrinkability, and said wedgelike component
possesses the property of latent adhesivity relative to the other
two components which adhesive property begins to exhibit itself at
a temperature at least 5.degree. C. lower than that of the other
two components.
18. The filament as claimed in claim 17, wherein each of said
components is a polymer selected from the group consisting of
polyamides, polyesters, polyacrylonitriles, polyolefins,
polystyrenes, polycarbonates, polyesterethers, polyvinyl chloride,
polyvinylidene chloride, copolymers thereof and polymer blends
thereof.
19. The filament as claimed in claim 17, wherein wedge-forming
component and another component are nylon-6 and a copolymer of
nylon-6 with polyhexamethyleneisophthalamide respectively.
20. The filament as claimed in claim 17, wherein wedge-forming
component and another component are copolymer of nylon-6 with
polyhexamethyleneadipamide and nylon-6 respectively.
21. The filament as claimed in claim 17, wherein the cross section
of the filament is circular.
22. The filament as claimed in claim 17, wherein the cross section
of the filament is noncircular.
Description
The present invention relates to composite filaments wherein at
least two thermoplastic linear polymers are uniformly bonded along
the longitudinal direction of the unitary filament and the method
and apparatus for producing thereof.
It has been well known that composite filaments, in which a
plurality of fiber-forming components consisting of thermoplastic
synthetic linear polymers and having different heat shrinkabilities
and swelling properties are eccentrically bonded extending along
the longitudinal direction of the unitary filament uniformly, have
latent crimps, which are developed by a heat or swelling treatment,
and further such composite filaments are useful for the production
of stretchable knit goods, especially sheer circular knit goods
(e.g. ladies' stockings). Moreover, the Japanese Pat. application
No. 32,738/64 by the inventors and in U.S. Pat. No. 3,286,490 by B.
E. Martin have already disclosed that self-bonding composite
filaments, one component of which is a polymer having a selective
sensitivity against tack-inducing agents, such as heat and a
reagent (This polymer being referred to as a latent adhesive
component hereinafter.) are formed into fibrous structures, such as
knit wear, nonwoven fabrics, substrate for synthetic leather, etc.,
and the filament crossover contacts in the resulting structure are
bonded with the tack-inducing agent to stabilize the configuration
of the structure.
For a better understanding of the invention reference is taken to
the accompanying drawings, wherein
FIGS. 1-3 are cross-sectional views of conventional two-component
composite filaments respectively;
FIGS. 4 and 5 are cross-sectional views of two-component composite
filaments according to the invention;
FIG. 6 is a vertical sectional view of one embodiment of a
spinneret according to the invention;
FIGS. 7-11 are diagrammatic views for showing shapes of
apertures;
FIGS. 12-14 are diagrammatic views for showing relative positions
between the aperture and the conduit respectively;
FIGS. 15 and 16 are diagrammatic views for showing various shapes
of the ducts respectively;
FIGS. 18-23 are diagrammatic views for showing modified shapes of
apertures respectively;
FIG. 24 is a vertical sectional view of a spinneret according to
the invention;
FIG. 25 is a cross-sectional view the spinneret shown in FIG. 24
taken on line X--X';
FIGS. 26 and 27 are cross-sectional views of two-component
composite filaments according to the invention respectively;
FIGS. 28 and 29 are cross-sectional views of three-component
composite filaments according to the invention respectively;
FIGS. 30-32 are cross-sectional views of conventional
three-component composite filaments respectively;
FIG. 33 is a diagrammatic view illustrating a contact point of
filaments;
FIGS. 34 and 35 are diagrammatic views for showing a method for the
determination of adhesive strength between filaments; and
FIG. 36 is a graph for showing a relation between adhering
temperature and adhesive strength.
First of all, in order to manufacture uniform sheer circular knit
goods having beautiful appearance, particularly ladies' stockings
with the use of composite filaments, it is required that filaments
have proper difference in the crimpability and dyeability between
leg portion and welt, heel and toe portions, because the knitting
system of the leg portion is different from that of the welt, heel
and toe portions. That is, when two-component filaments having a
cross section as shown in FIG. 1 in which two polymers having
different dyeabilities (e.g. hompolyamide and copolyamide) are
arranged in the same conjugate ratio in a side-by-side relation,
are knitted into ladies' stocking, for example when multifilaments
of 40-50d/6-15f are used in welt portion and monofilaments of 10-30
deniers are used in leg portion, the width of welt (shape under
tensionless state) in the resulting stockings is often smaller than
the leg portion due to the fact that denier of single filaments
constituting the multifilament in the welt is smaller and the
stitch in the welt is coarser, so that the appearance of the
stockings is often poor. In order to improve such an unbalanced
shape of stockings, it is necessary to use two-component filament
having reduced crimpability in the welt.
According to one of the conventional methods, eccentric sheath-core
relation two-component filaments having a kidney-shaped core as
shown in FIG. 2 (disclosed, for example, in the Belgian Patent No.
621,472 specification) are used in the welt. However, in these
filaments, one component covers the surface of the filament, so
that when the two components are different in the dyeability
(generally, two components having different shrinkabilities are
more or less different in the dyeability), if side-by-side relation
two component filaments composed of the same components with those
used in the welt yarn are used in the leg, the dyeability of the
welt is considerably different from that of the leg.
Generally speaking, even when filaments composed of the same
polymers are used in the welt portion and in the leg portion, the
color of the welt portion is apt to be light. This is due to the
difference in the reflection of light between monofilament and
multifilament. Therefore, it is most desirable that the dyeability
of filaments for welt is somewhat higher than that of filaments for
leg. That is to say, it is necessary that the dyeability of
composite filaments for welt is moderately higher than that of
composite filaments for leg and that the crimpability is properly
reduced.
Second, in order to manufacture acceptable run-resisting fabrics by
using the above-described self-bonding composite filaments, a
limited amount of the filament crossovers should be bonded in the
fabrics and if the bonded crossovers are too many, the fabrics are
not adequate because of poor stretch conformability or fit.
Accordingly, in order to accomplish the required bonds, the latent
adhesive component should occupy a limited area of the periphery of
the filament. Namely, even the filament as shown in FIG. 1, wherein
latent adhesive component occupies about 50 percent of the
periphery of the filament, gives too much bonding to the fabric and
the above-described defect appears and further uneven crimps are
developed and the surface of fabric is not uniform.
For the purpose of obviating such defects, if it is intended to
spin filaments, in which the amount ratio of the latent adhesive
component in the composite filament is decreased and the ratio of
said component occupying on the surface of filament is decreased,
for example two-component filament having a cross section as shown
in FIG. 3 the amount ratio of both the component is too different
and it is difficult to effect the spinning smoothly and the ratio
of surface area varies highly by a slight variation of extrusion
ratio of two components, so that it is difficult to obtain
filaments having an excellent uniformity. Accordingly, it is very
desirable to obtain self-bonding two-component filaments having a
reduced latent adhesivity, wherein the amount ratio of two
components occupying in filament, namely, each extrusion rate of
two components is balanced to an acceptable extent and only the
area ratio of latent adhesive component occupying the surface area
of the filament is decreased.
The inventors have found that the above-mentioned two problems can
be advantageously solved by novel two-component filaments having
cross sections as shown in FIGS. 4 and 5, in which a polymer having
a high dyeability or latent adhesivity is used in the hatched
wedge-shaped or keyhole-shaped component, and the present invention
has been accomplished.
Furthermore, self-bonding two component filaments having the
above-mentioned cross section is reduced in both the latent
adhesivity and the crimpability, but for highly stretchable ladies'
stockings, filaments having both excellent crimpability and reduced
latent adhesivity are often desired.
The inventors succeeded in satisfying the above-mentioned
requirement by the use of three-component filaments having a novel
structure, which consists of two components having different heat
shrinkabilities for providing crimpability and the third component
having a latent adhesivity, and accomplished this invention by
defining a novel method and apparatus for producing these composite
filaments.
The object of the invention is to provide a two-component filament
having a reduced crimpability and a properly biased dyeability.
Another object of the invention is to provide a two-component
filament having a crimpability and a reduced latent adhesivity.
Further object of the invention is to provide a three-component
filament having an excellent crimpability and a reduced latent
adhesivity together.
Another important object of the invention is to provide sheer
circular knit goods, such as ladies' stockings having uniform
appearance and even color in whole in spite of composing of at
least two portions having different knitting systems.
Further an important object is to provide run-resisting knit wears
and highly stretchable run-resisting knit wears.
These and other objects of the invention will be more apparent from
the following description.
The above-mentioned objects can be firstly attained by spinning
composite filaments with the use of a spinneret of the present
invention having a novel structure.
That is, the spinneret according to the invention comprises a
spinneret plate provided with at least one conduit and at least one
orifice each connecting to the conduit, a distributing block
superposed at the rear of the spinneret plate and provided with two
side reservoirs and a central reservoir located between the side
reservoirs; ducts lying along the abutting surface of the spinneret
plate against the distributing block and connecting the two side
reservoirs to an inlet of each conduit respectively; and a feed
nozzle, one end of which opens to the central reservoir and the
other end of which opens to the upper portion of the duct opposite
to the conduit and traversing the longitudinal direction of the
duct, the latter opening being an aperture having a length smaller
than the width of the duct and being transmitted at one sidewall of
the duct; said spinneret being provided with further means for
supplying spinning materials into both the side reservoirs
respectively; and means for supplying another spinning material
into the central reservoir.
For a better understanding of the spinneret according to the
invention, reference is taken to the accompanying drawings.
Referring to FIG. 6, a spinneret plate 1 provided with a conduit 2
and an orifice 3 connecting to the conduit 2 through a tapered
portion. A distributing block 4 is superposed at the rear of the
spinneret plate 1. The distributing block 4 has two side reservoirs
5 and 6 and a central reservoir 7 located between the reservoirs 5
and 6. Ducts 8 and 9 are arranged at the abutting surface of the
spinneret plate 1 against the distributing block 4, and they are
connected to the side reservoirs 5 and 6 respectively and to the
inlet of the conduit 2. These two ducts 8 and 9 may be formed
either in the upper surface of the spinneret plate 1, in the lower
surface of the distributing block 4, or cross the both plates.
Furthermore, the ducts 8 and 9 may be provided in a certain angle
on the both side of the inlet of the conduit 2, but most preferably
they are substantially aligned.
The above-described central reservoir 7 is connected to a joined
portion of the two ducts 8 and 9 through the feed nozzle 10.
Namely, one end of the feed nozzle 10 opens in the central
reservoir 7 and the other end connects to the joined portion of the
ducts through an aperture.
The shape and arrangement of the above-described aperture, which
constitute an essential portion for the spinneret of the invention,
will be explained in more details.
Firstly, according to the purpose, the aperture may be a single
rectangular slit as shown in FIG. 7, or may be composed of a
plurality of small holes aligned closely to one another as shown in
FIG. 8, or may be a combination of these apertures. Alternatively,
the aperture may be either a single keyhole-shaped slit, a T-shaped
slit as shown in FIG. 9, a plurality of small holes having
different diameters as shown in FIG. 10, or a plurality of small
holes arranged in T-shape as shown in FIG. 11. In some case, the
aperture may be a single small hole. However, in any case the
length L of the aperture 11 should be smaller than the width W of
the ducts 8 and 9 as shown in FIGS. 12-14. When the aperture 11 is
composed of a plurality of small holes, the length L means a length
between both ends of these small holes and the width W of the ducts
8 and 9 means a width of the ducts lying in the abutting surface of
the spinneret plate 1 and the distributing block 4.
Furthermore, the cross section of the ducts 8 and 9 may be
circular, quadrilateral, triangular and any other shape, but in
order to attain the object of the invention the width of the ducts
8 and 9 should be maximum at the abutting surface of the spinneret
plate against the distributing block. Accordingly, in the present
invention, the width W of the ducts 8 and 9 means the width of the
ducts in the abutting surface. Embodiments of the cross-sectional
shape and the width W of the ducts 8 and 9 are shown in FIGS. 15,
16 and 17, which represent circle, quadrilateral and triangle,
respectively.
FIG. 12 shows a fundamental relative portion between these
apertures and the conduit 2. These apertures open in such a manner
that the longitudinal direction of the opening traverses the ducts
8 and 9 and aligns with a joined line P--P' of these ducts, namely
on a center line of the inlet of conduit 2. As shown in FIGS.
15-17, one end of the total length of the aperture 11 makes contact
with one end of the total width of the ducts 8 and 9 and
consequently, as mentioned above, the length of the aperture is
smaller than the width of the ducts, so that the other end of the
aperture does not make contact with the other end of the width of
the ducts.
The relative positions between various embodiments of the aperture
having modified shapes and the conduit are further shown in FIGS.
18-23.
FIGS. 24 and 25 show a useful modified embodiment of the spinneret
of this invention. In this embodiment, eight orifices 3 are
arranged along a concentric circle having an axis located on the
spinneret center on the spinneret plate. Furthermore, in the
distributing block 4, there are provided with an annular central
reservoir 7 such that the reservoir corresponds to the annular
arrangement of the orifices 3, an annular side reservoir 5
surrounding the outside of the central reservoir 7 concentrically,
and a side reservoir 6 located in the center portion of the
spinneret.
In an abutting surface of the spinneret plate 1 against the
distributing block 4, ducts 8 and 9 extend radially which connect
conduits 2 of the orifices to two side reservoirs 5 and 6
respectively. Pins 12 serve to adjust the relative position of the
apertures 11 and the orifices 3.
Next, a practical operation of spinning for attaining the object of
the present invention will be explained with respect to the case
where the spinneret according to the present invention is used.
In the spinneret shown in FIG. 6, when the side reservoirs 5 and 6
are charged with a melt spinning material A and the central
reservoir 7 is charged with a different spinning material B, the
spinning material A is passed from the reservoirs 5 and 6 into the
ducts 8 and 9 respectively, and joined at the conduit 2 and then
extruded through the orifice 3. On the other hand, the spinning
material B in the central reservoir 7 is extruded through the feed
nozzle 10 and the aperture 11 into the flow of the above spinning
material A in a form of a thin layer and joined with the spinning
material A and then extruded through the orifice 3 to form a
composite filament. In this case, since the one end of the aperture
11 is in contact with the one sidewall of the ducts 8 and 9
extending along the width thereof as mentioned above, the spinning
material B is extruded in the form of thin layer on the abutting
line of the two flows of the spinning material A such that one end
of the spinning material B makes contact with one of the sidewalls
of the ducts 8 and 9 and that the other end of the spinning
material B does not make contact with the other sidewall of the
ducts 8 and 9. Thus, the spinning material B can occupy a part of
the surface of the composite filament. The above-mentioned abutting
line means a line where two flows of the spinning material A
supplied from two side reservoirs 5 and 6 are considered to be abut
together. The abutting line is in alignment with a line P--P' where
the above-mentioned two ducts 8 and 9 are communicated each
other.
In the arrangement shown in FIG. 12, a line P--P' crossing
perpendicularly to the ducts 8 and 9 and passing the center of the
conduit 2 is called the abutting line.
The above-mentioned spinning material B corresponds to a
wedge-shaped component of the composite filament as shown in FIG. 4
or a keyhole-shaped component of the composite filament as shown in
FIG. 5.
If the configuration of the aperture 11 is varied, it is possible
to obtain a composite filament whose components are different in
shape.
In order to obtain two-component composite filaments, one component
of which forms a wedge-shape, as the aperture a plurality of
closely aligned small holes as shown in FIG. 8 or a linear slit as
shown in FIG. 7 are used. For the production of two-component
composite filaments, one of which forms a keyhole-shape, apertures
composed of keyhole-shaped slit as shown in FIGS. 18 and 19,
T-shaped slit as shown in FIG. 9, a plurality of small holes having
different diameters as shown in FIG. 10 or a plurality of small
holes arranged in T-shape as shown in FIG. 11 are used. Similarly,
the composite filament as shown in FIG. 26 can be obtained by using
apertures composed of Y-shaped slit as shown in FIG. 20, a
plurality of small holes and a slit as shown in FIG. 21 or a
plurality of small holes arranged in Y-shape closely as shown in
FIG. 22.
Furthermore, the composite filament as shown in FIG. 27 can be
obtained by using a crossed slit as shown in FIG. 23 as the
aperture.
Other variously modified apertures can be used depending upon the
object.
As one embodiment of the composite filaments obtained in the
present invention, ones having a circular cross section are shown
in FIGS. 4 and 5, which can be obtained by using a circular orifice
3, but of course, it is possible to obtain composite filaments
having various cross sections by varying the shape of the
orifice.
Another important spinning process for attaining the object of the
present invention consists in that to the two side reservoirs 5 and
6 of the above-described spinneret, for example, spinning materials
A and B having different heat shrinkabilities, swelling properties
and the like are fed separately, and a spinning material C which is
different from both spinning materials A and B and has a selective
sensitivity to a tack-inducing agent, such as heat or a reagent, is
fed to the central reservoir 7. The fundamental cross section of
the three-component filament thus obtained is as shown in FIGS. 28
and 29 and the latent adhesive component C having the selective
sensitivity to the tack-inducing agent interposes partially in a
wedge-shape or keyhole-shape in the abutting surface of the two
components A and B bonded in a side-by-side relation.
The above-mentioned characteristics of the spinning method of the
present invention are as follows:
Namely, this spinning process comprises flowing two independent
spinning materials in opposite directions to each other in two
ducts each connecting to a common conduit and combining them and
interposing a thin layerlike flow of another spinning material
different from the above-mentioned spinning materials between the
two spinning material flows at the combined portion in such a
manner that the longitudinal direction of the cross section of the
thin layer is perpendicular to the direction of the above-mentioned
two opposite flows and that the thin layer is so shifted that one
end of the layerlike flow is in contact with one sidewall of the
above-mentioned duct, but the other end thereof is not in contact
with the other sidewall of the duct and then extruding the thus
combined spinning materials through the conduit from the orifice.
When the above-mentioned independent flows are same, a
two-component composite filament can be obtained, while when they
are different, a three-component composite filament can be
obtained. In this case, when a latent adhesive component is used as
the thin layerlike flow, the two-component or the three-component
filament having latent adhesivity can be obtained.
As seen from the above-described explanation, the composite
filament obtained by the method of the present invention consists
in a composite filament having a crimpability comprising at least
two components differing in shrinkability which extend uniformly
and continuously along the longitudinal axis, said components
bonding directly to each other and occupying a part of the
peripheral surface of the filament continuously, the smallest
surface area occupied by one component being 5 to 30 percent,
preferably 5 to 20 percent, of the total surface area of the
filament.
In the cross section of such a filament, it is preferable that the
above-described component occupying the minimum surface area is
interposed in a wedge-shape into the other component as shown in
FIG. 4 or in a keyhole-shape into the other component as shown in
FIG. 5.
The term "wedge-shape" used herein means one in which as shown in
FIG. 4, 1 w and w is the maximum value of the width of the wedge
and the term "keyhole-shape" means one in which as shown in FIG. 5,
1 w'>w.
If in two-component filament having such a cross section that one
component is interposed into and bonded with the other component,
the component which is not the wedge-shaped component as shown in
FIG. 4 or the component which is not the keyhole-shaped component
as shown in FIG. 5 has a higher dyeability, composite filament
having a reduced crimpability and a dyeability biased property to a
higher dyeability can be obtained. Such a bonding configuration is
useful for two-component composite filament having self-adhesivity
and it is possible to reduce surface area of the adhesive component
without biasing the conjugate ratio (volume ratio) of two component
extremely. Such a two-component filament is useful for yarn for
producing sheer circular knit fabric, particularly, welt, toe and
heel portions of ladies' stockings.
Moreover, a desirable structure of the filament of this invention
is composed of three-components.
The present invention consists in a three-component filament having
crimpability and latent adhesivity, which consists of two
components A and B having different shrinkabilities and another
component C having a latent adhesivity against said two components,
(1) said three components being bonded to each other uniformly
along the entire length of the filament, (2) every component being
directly to each other, (3) every component occupying a part of the
peripheral surface of the filament continuously, (4) the surface
area occupied by the adhesive component C being 5 to 30 percent,
preferably 5 to 20 percent, of the total surface area of the
filament and (5) a temperature at which the adhesive component C
begins to exhibit adhesivity, being at least 5.degree. C.,
preferably 10.degree. C., lower than those temperatures of the
other components A and B.
One of the features of the filament of the present invention lies
in a relative arrangement of the three components. FIG. 28 is a
cross-sectional view of a three-component filament according to the
invention. The adhesive component C is positioned between the
components A and B, but does not separate the components A and B
from each other. The three components are directly bonded to each
other. In FIGS. 30-32 showing conventional filaments the components
C and B of the filament shown in FIG. 30 do not directly adhere to
each other. In FIG. 31 the components A and C are separated and in
FIG. 32 the components B and A are separated.
FIG. 33 is a diagrammatic view illustrating a contact point of
filaments in the knit goods. Two filaments X and Y make contact
each other at a point J. The adhered point density in the products
depends upon which component faces to the contacting surface at the
contact point J. That is, in FIG. 33, the component facing to the
contact point J is the component B in the filament X and the
component A in the filament Y. Microscopical examination of a
contact point in plain-stitched stretchable stockings composed of
conventional two-component filaments under tension with respect to
the component at the contact surface shows that the component A or
the component B faces to the contact point in many cases (60 to 80
percent), and the boundary line of both components A and B faces to
the contact point in a relatively low probability (30 to 50
percent). This is based on the fact that as the filaments are bent
at the contact point, they have a tendency to be in the most stable
state in the condition. Because, it is an unstable state that the
boundary line faces to the contact point. Therefore, it can be
expected that if the adhesive component C is arranged at one side
of the boundary line, the adhesive component C faces to the
contacted point in a probability of 15 to 25 percent. Actual
determination of the adhered point density in stockings, which are
obtained by knitting with the use of filaments as shown in FIG. 28
and being subjected to crimp-developing and adhering treatments,
showed 5 to 30 percent of adhered point density in many cases.
The adhesive component C will be explained hereinafter. Of course,
all thermoplastic polymers are softened by heating, and
thermoplastic polymers having a softening temperature lower than
the thermal decomposition temperature have latent adhesivity.
Therefore, all the three components constituting the filament of
the present invention have latent adhesivity practically. However,
among them only the component C serves as an adhesive component in
the present invention. It is necessary that the components A and B
do not exhibit adhesivity under such a condition that the component
C adheres sufficiently, i.e. the component C has a selective
sensitivity for tack-inducing agents. Furthermore, care must be
taken such that the strength and the crimpability are not lost by
the adhering treatment of the component C in the practical
treatment. As the tack-inducing agents, use may be made of heating
or solvents, but heating is practically advantageous. The use of
saturated steam is particularly advantageous. It is common to use
steam in the finishing process of fiber. In the production of
run-resisting stockings by self-adhesion of filaments, it is
advantageous that the stockings are dyed and then the filaments are
adhered at the same time with the post boarding of the stockings.
During the post boarding, filaments are heated for 10 to 60 seconds
with saturated steam under tension caused by the shrinking force of
the filaments themselves. The steam is usually used at a
temperature of 110.degree.to 130.degree. C. As the adhesive
components C, one showing adhesivity by the above-mentioned steam
is preferably used.
Determination of the adhesive strength is carried out as
follows:
Two filaments composed only of a sample polymer to be determined
were firstly fixed so as to form a crossover contact point as shown
in FIG. 34. These entangled filaments are heated at a predetermined
temperature, cooled, taken out and cut so as to leave the contact
point J as shown in FIG. 35. The points P and Q are pulled by means
of a fiber tensile tester, for example, Instron universal tester,
to determine the tension when the filaments at the contact point J
are separated. A monofilament of 15 to 20 deniers usually has an
adhesive strength of less than 30 g. This adhesive strength varies
depending upon the adhering treatment conditions. It is heating
velocity, heating time, heating temperature and pressing force
(tension of filament) at the contact point that have the strongest
influence upon the adhesive strength.
FIG. 36 is a graph showing a relation between adhering (steaming)
temperature and adhesive strength. Adhesive or sticking strength
varies depending upon not only the kinds of polymers themselves but
also the kinds of partner polymers to be adhered. Now, three
components are called as A, B and C. The adhesive strength when the
component C is adhered with the component C, that when the
component C is adhered with the component B and that when the
component C is adhered with the component A are different from each
other. FIG. 36 shows relations between adhesive strength and
temperature in various combinations of the components A, B and C.
In FIG. 36, the curve CC shows the relation when the component C is
adhered with the component C. In FIG. 14 the rising point Tc of the
adhesive strength-temperature curve of the component C with the
component A is called as adhesion-beginning temperature of the
component C. This adhesion-beginning temperature usually varies
depending upon the partner polymer to be adhered. The
adhesion-beginning temperature Tc of the component C includes three
different adhesion-beginning temperatures, which are Tcc
(adhesion-beginning temperature of the component C with the
component C), Tca (adhesion-beginning temperature of the component
C with the component A) and Tcb (adhesion-beginning temperature of
the component C with the component B), but among them the highest
(for example, in this case Tca) is practically used as the
adhesion-beginning temperature of the component C.
In order to reduce the adhered point density and to maintain
sufficient strength in the products, the heating should be carried
out within a temperature range where the adhesive component C
adheres with sufficient adhesion strength but the other components
A and B do not exhibit adhesivity.
Suppose that the component B adheres to the component C at a lower
temperature than the component A does. In this case, if the
component C exhibits sufficient adhesivity at a temperature less
than the adhesion-beginning temperature Tb of the component B, the
object of the present invention can be attained. The
adhesion-beginning temperature Tb of the component B includes Tbb
and Tba, but the lower temperature should be discussed with respect
to the adhesivity in connection with Tc. If the softening or
sticking temperature decreases in the order of A>B>C, Tca and
Tbb can be used as Tc and Tb respectively. When, Tc is sufficiently
apart from Tb, i.e. the difference .DELTA.T between Tb and Tc is
sufficiently large, the object of the present invention can be
attained. In the present invention, .DELTA.T is more than 5.degree.
C., preferably more than 10.degree. C.
As the spinning materials to be used for two-component or
three-component filaments of the present invention, mention may be
made of fiber formable thermoplastic synthetic linear polymers, for
example, polyamide, polyester, polyester-amide, polyester-ether,
polyacrylonitrile, polyolefin, polystyrene, polycarbonate,
polyvinyl chloride, copolymers thereof, mixtures thereof and the
like.
While, as the latent adhesive components, ones having a
lower-softening or sticking temperature than that of the other
components are used, and it is necessary that the
adhesion-beginning temperature Tc is at least 5.degree. C.,
preferably more than 10.degree. C., lower than the
adhesion-beginning temperatures of the other components as
described above. In order to cause adhesion during post boarding in
the production of stockings as described above, adhesive components
which adhere in a saturated steam at 110.degree. C. to 130.degree.
C., preferably 115.degree. C., to 125.degree. C., are preferably
used.
As polyamides suitable for such a latent adhesive component C,
mention may be made of a plenty of copolyamides and mixed
polyamides. Homopolyamides having a low softening or sticking
temperature, for example, polyhexamethylene isophthalamide may be
used. The determination of adhesion-beginning temperature can be
effected in such a manner that the adhesive strength of a filament
is measured as described above, and that a curve showing a relation
between the adhering treatment temperature and the adhesive
strength is plotted, and then the temperature at the rising point
of the curve is read.
Filaments having both latent crimpability and reduced latent
adhesivity according to the invention are very useful for the
production of ladies' stockings. That is to say, when such
filaments are knitted into stockings and the resulting stockings
are subjected to a suitable crimp-developing treatment and adhering
treatment, then novel stockings having stretchability and
run-resisting property can be obtained.
The invention will be explained by the following examples.
EXAMPLE 1
A copolymer, which was composed of nylon-6 (hereinafter abridged as
6) and nylon-66 (hereinafter abridged as 66) in a copolymerization
ratio of 6/66=8/2 (by weight) and had a melting point of
181.degree. C. and an intrinsic viscosity of 1.12 in m-cresol at
25.degree. C., was melt spun and drawn to 4.2 times its original
length at room temperature in a conventional manner to obtain a
filament E of 15 deniers. The filament E was placed as shown in
FIG. 34, relaxed by 10 percent, and treated with saturated steam at
various temperatures for 30 seconds to determine the adhesive
strengths. The results are shown in Table 1. The heating velocity
was controlled so as that the temperature was raised from
80.degree. C. to predetermined temperature within 30 to 60 seconds.
The adhesive strength is shown in an average value of 10 samples.
---------------------------------------------------------------------------
TABLE 1
Treating temperature Adhesive strength (.degree. C.) (g)
__________________________________________________________________________
100 0 105 2.0 110 4.3 115 7.1 120 9.2
__________________________________________________________________________
From table 1, adhesive strength-temperature curves as shown in FIG.
36 were obtained. It was found that the adhesion-beginning
temperature Tee of the filament E with the same filament E was
about 101.degree. C.
In the same manner, a relation between treating temperature and
adhesive strength of the filament E entangled with nylon-6 filament
was determined to obtain a result as shown in Table 2.
---------------------------------------------------------------------------
Table 2
Treating temperature Adhesive strength (.degree. C.) (g)
__________________________________________________________________________
100 0 105 0 110 2.2 115 4.7 120 5.8
__________________________________________________________________________
Table 2 shows that the adhesion-beginning temperature Te.sub.6 of
filament E with nylon-6 filament is 106.degree. C.
The adhesive strength is highly influenced by the pressure and the
tension at the adhering treatment as described above. In this
example, the adhesive strength of filament, when the filament
shrank by 10 percent, was determined. However, the
adhesion-beginning temperature and the adhesive strength are often
varied by the shrinking percentage or relax ratio of the filament
used. A test of adhesivity under a constant load can be effected by
suspending a weight to a sample filament. However, it is most
advantageous that a practical product is subjected to adhering
treatment and then the adhesive strength is determined. For
example, in case of stockings, the adhesive strength can be
determined in such a manner that a stocking knitted with the use of
sample filaments is subjected to a crimp-developing treatment, and
after dyeing, the stocking is further subjected to an adhering
treatment (in this case, it is preferable to effect post boarding
too), then the tension of unknitting is determined. The adhesive
strength between two kinds of filaments can be determined with the
use of a two-feed knitting machine.
Thus, as the result of the determination of adhesive strengths of
various polyamides and copolyamides, it was found that an adhering
treatment at least 5.degree. C. higher than the adhesion
temperature give an adhesive strength (i.e. more 2g) necessary for
practical use.
EXAMPLE 2
As component A, nylon-6 having an intrinsic viscosity of 1.20 in
m-cresol was used. As component B, a copolymer of nylon-6 with
polyhexamethyleneisophthalamide (hereinafter abridged as 6I) in a
copolymerization ratio (by weight) of 6/6I=9/1, which had a melting
point of about 192.degree. C. and an intrinsic viscosity of 1.21 in
m-cresol, was used. As component C, the copolyamide 6/66 used in
example 1 was used.
These three components were melted separately and fed into a
spinneret for conjugate spinning as shown in FIG. 24 in a feed
ratio (i.e. conjugate ratio by volume) of A/B/C=50/40/10 by means
of gear pumps to obtain a three-component filament having a cross
section as shown in FIG. 28, which was filament I. Furthermore,
filaments F, G and H having cross sections as shown in FIGS. 30, 31
and 32 respectively were spun through three conventional
side-by-side type spinnerets. In the spinning procedure, each
filament was spun through a spinneret at 260.degree. C., cooled,
taken up and drawn 4.2 times its original length at room
temperature. Each of the resulting filaments had a fineness of
about 17 deniers.
Each filament was twisted at a rate of 100 T/M, wound on an
aluminum bobbin, heat-set for 15 minutes with saturated steam at
75.degree. C., and then knitted into a plain stitched stocking by
means of a conventional knitting machine for seamless stockings
having 400 needles. In these stockings, low shrinkable nylon-6
filaments of 50 d/16 f were used for the welt, toe and heel, and
the above-mentioned filaments were used for the leg. The resulting
stockings were called as stockings F, G, H and I corresponding to
the filaments used for the legs respectively.
Each stocking was treated with saturated steam at 100.degree. C.
for 30 minutes under tensionless state to develop crimps, packed
and dyed in a Smith drum in a conventional manner. The dyed
stocking was placed in a form, and subjected to post boarding in
such a manner that the temperature was raised from 80.degree. C. to
116.degree. C. in 30 seconds and maintained at 116.degree. C. for
30 seconds by means of saturated steam to effect post boarding.
After dried and cooled, the stocking was taken out from the form
and left to stand for 24 hours in a room maintained at 25.degree.
C. and 65 percent RH. The resulting stocking had adhesive strengths
of 5.8 g. (average value) in the ankle portion and 4.3 g. (average
value) in the leg-top (upper leg) portion. The adhered point
densities of the obtained stockings are shown in table 3. Among
these stockings, the stocking I made of the filaments I has the
most excellent stretchability.
---------------------------------------------------------------------------
TABLE 3
Adhered point density of Run-resisting Stocking leg-top
Stretchability property portion (%)
__________________________________________________________________________
F 63 poor excellent G 72 poor excellent H 59 poor excellent I 23
good good
__________________________________________________________________________
In the above table 3, the adhered point density (%) is shown by the
number of adhered points per 100 of contacted points (two per one
stitch) of filaments. The number of the adhered points can be
calculated by the following way. Namely, a variation of tension,
when unknitting the stocking, is measured and from the number of
peaks of tension thus measured and a length of the unknitted
filament, the number of adhered points are calculated. The number
of adhered points can also be calculated by a microscope.
In the nylon-6 stocking used in this example, the
adhesion-beginning temperature Taa of nylon-6 component with the
same nylon-6 component was higher than 125.degree. C., that Tcb of
copolyamide 6/6I with another copolyamide 6/66 was 118.degree. C.
and that Tca of copolyamide 6/66 with nylon-6 was 108.degree. C.,
which shows that .DELTA.T is 10.degree. C.
EXAMPLE 3
As component A, nylon-66 having an intrinsic viscosity of 1.10 in
m-cresol at 30.degree. C. was used. As component B, a copolymer of
nylon-66 with nylon-610 (hereinafter abridged as 610) in a
copolymerization ratio (by weight) of 66/610=2/3, which had a
melting point of about 200.degree. C. and an intrinsic viscosity of
1.15 in m-cresol, was used. As component C, a mixed polyamide
obtained by melting 2 parts of copolymer 66/610 used in the
component B together with 1 part of 6I (melting point: about
170.degree. C.) was used.
These three components were melted separately and spun through a
spinneret as shown in FIG. 24 at 280.degree. C. in a conjugate
ratio (by volume) of A/B/C=5/5/2 to obtain a filament having a
cross section as shown in FIG. 28. The resulting filament was drawn
3.9 times its original length on a draw pin at 90.degree. C. to
obtain three-component filament J of 15 deniers/monofilament.
Furthermore, monocomponent filaments each composed of the component
A, B or C alone were spun in the same manner, and the
adhesion-beginning temperatures (in wet state) were determined to
obtain Taa>125.degree. C., C, Tbb=120.degree. C.,
Tca=105.degree. C. and .DELTA.T=15.degree. C.
A stocking was knitted with the use of the filaments J in the leg
in the same manner as described in Example 2, and subjected to a
crimp-developing treatment. After dyeing, the stocking was
subjected to boarding with saturated steam at 118.degree. C. for 45
seconds to obtain a stocking having excellent stretchability and
run-resisting property.
EXAMPLE 4
As component A, polyethylene terephthalate having an intrinsic
viscosity of 0.65 in o-chlorophenol at 30.degree. C. was used. As
component B, plyethylene-oxybenzoate having an intrinsic viscosity
of 0.61 was used. As component C, a copolyester of polyethylene
terephthalate/polyethylene adipate=70/30 (by weight) having a
melting point of 188.degree. C. was used. These three components
were spun into a three-component filament in a conjugate ratio of
5/5/1 in the same manner as described in example 3 and the
resulting filament was drawn 3.6 times its original length on a
draw pin at 105.degree. C. to obtain filament K of 240 d/80 f.
Furthermore, one-component filaments each composed of the component
A, B or C alone were spun in the same manner, and the
adhesion-beginning temperature in dry state was determined to
obtain Taa>250.degree. C., Tbb>220.degree. C. and
Tca=190.degree. C. A large number of filaments K were arranged
uniformly to form a tow. The tow was subjected to crimp-developing
treatment in a relaxed state, while being passed through boiling
water. The tow was cut and dried to obtain crimped staple fibers of
5 cm. length. Furthermore, when the tow composed of filaments K was
firstly cut and then subjected to crimp-developing treatment,
substantially same crimped staple fibers were obtained.
A web was produced from the above-mentioned staple fibers and
pressed by means of a hot roll at 195.degree. C. to obtain a fairly
stretchable and bulky nonwoven fabric. Test of elongation showed
that the nonwoven fabric had a reversible elongation of 45 percent.
On the contrary, a nonwoven fabric produced from staple fibers
composed only of the components A and C in a conjugate ratio of
10/1 had a reversible elongation of 17 percent.
Furthermore, when a web was produced with the use of staple fibers
of filament K and subjected to crimp-developing treatment with
saturated steam at 100.degree. C. in a relaxed state, then the web
shrank to about 1/3in length (1/9 in area). The shrunk web was
pressed by means of a hot roll at 195.degree. C. to obtain a
nonwoven fabric, which had a reversible elongation of 55
percent.
The determination of reversible elongation was made as follows:
A test piece having a width of 2 cm. and a length of 10 cm. is
determined with respect to the recovering percentages for various
elongations, and then the elongation showing 80 percent recovering
percentage is multiplied by 0.8 In general, as the elongation is
higher, the recovering percentage lowers, so that the elongation
showing 80 percent recovering percentage can be determined by
plotting a relation between elongation and recovering
percentage.
It has been hitherto known that after two-component composite
filaments or staple fibers are formed into a weblike product, the
product is heated to cause adhesion of low softening point
component in the product. However, in this method, nonwoven fabrics
having the above-mentioned highly reversible elongation and
bulkiness cannot be obtained. In the conventional two-component
filament, as the adhesive component is heated up to substantially
the same temperature with the softening temperature, the strength
is substantially lost. As the result, for example, when a
two-component composite filament having a conjugate ratio of 1/1 is
subjected to such a treatment that adhesion of one component
occurs, the total strength of the composite filament lowers to
about a half of its original strength. The decrease of strength
caused by the adhesion can be obviated by the use of small amount
of adhesive component, but the latent crimpability of the resulting
filament is extremely poor, so that fibrous product having
bulkiness and stretchability cannot be obtained. In the filament
according to the invention or the staple fiber obtained by cutting
the filament, the main components A and B show small decrease in
the strength by the adhering treatment and have sufficient latent
crimpability, so that fibrous products, such as knit goods, woven
fabrics, webs and nonwoven fabrics, having excellent properties can
be obtained.
As the component A suitable for polyester three-component
filaments, mention may be made of aromatic polyesters having a
melting point higher than 240.degree. C., for example,
homopolyesters, such as polyethylene terephthalate,
poly-1,4-bis-methylcyclohexane terephthalate and the like, and
copolyesters of said homopolyester with less than 10 percent by
weight of the other copolymeric components. As the component B,
mention may be made of polyesters, copolyesters, polyester-ethers,
copolyester-ethers, and mixtures thereof, each having a melting
point of 210.degree. to 240.degree. C. As the component C, mention
may be made of polyesters having a softening point of 160.degree.
to 210.degree. C. It is necessary that the component C adheres to
the components A and B at conjugate spinning, so that copolymers
containing polyesters, such as polyethylene terephthalate and the
like and polyesterethers, such as polyethylene-oxybenzoate and the
like can be preferably used for the component C.
EXAMPLE 5
Nylon-6 having an intrinsic viscosity of 1.20 in m-cresol at
25.degree. C., and a copolymer having an intrinsic viscosity of
1.25 as in m-cresol at 25.degree. C. and consisting of 90 parts by
weight of nylon-6 and 10 parts by weight of polyhexamethylene
isophthalamide (hereinafter abridged as 6/6I) were used as spinning
materials. A spinneret as shown in FIG. 24, which had an aperture
composed of a T-shaped slit, was used. Temperature of the spinneret
was maintained at 275.degree. C. 50 parts by weight of the melted
copolymer 6/6I and 50 parts by weight of nylon-6 were fed into the
reservoirs 5 and 6, and the reservoirs 7 by means of gear pumps
respectively. The two spinning materials were bonded and extruded
through an orifice 3 into the air, cooled and taken up at a rate of
600 m./min. in a conventional manner, while oiling. The taken up
undrawn filaments were drawn 3.69 times their original length at
room temperature to obtain filament F.sub.1 of 45 d/7 f, the
unitary filament of which had a cross-sectional view as shown in
FIG. 5.
As a control, the same nylon-6 and the same copolymer 6/6I are
conjugate spun in a conventional manner to obtain side-by-side
relation two-component filament F.sub.2 of 45 d/7 f, the unitary
filament of which had a conjugate ratio of 1/1 and a
cross-sectional view as shown in FIG. 1.
The shrinking percentage in hot water and the number of crimps of
Filaments F.sub.1 and F.sub.2 are shown in table 4.
---------------------------------------------------------------------------
TABLE 4
Shrinking Number of percentage crimps in hot water per cm. (%)
__________________________________________________________________________
filament F.sub.1 65 9 Filament F.sub.2 83 16
__________________________________________________________________________
the determination of shrinking percentage in hot water was made as
follows:
A sample having a length of l.sub.0 is dipped in boiling water for
10 minutes under no lead and then airdried to obtain a shrunk
filament having a length of l.sub.1.
The shrinking percentage in hot water is calculated by the
following formula:
EXAMPLE 6
Spinning materials of nylon-6 and the copolyamide 6/6I used in
example 5 were conjugate spun in a conventional manner to obtain an
undrawn two-component filament having a conjugate ratio (by weight)
of 1/1, and the undrawn filament was drawn 3.9 times its original
length at room temperature to obtain filament F.sub.3 of 15
d/monofilament having a cross section as shown in FIG. 1.
Filament F.sub.1 obtained in example 5 was twisted to 200 T/M,
taken up on an aluminum bobbin and treated with saturated steam at
105.degree.C. for 15 minutes to obtain filament F.sub.11. Filament
F.sub.2 obtained in example 5 was twisted and treated in the same
manner as described above to obtain filament F.sub.12. While, the
filament F.sub.3 was twisted to 120 T/M, taken up on an aluminum
bobbin and treated with saturated steam at 75.degree.C. for 15
minutes to obtain filament F.sub.13. A plain stitched seamless
stocking was knitted with the use of filaments F.sub.11 in welt,
toe and heel, and filaments F.sub.13 in the leg by means of a
knitting machine having 400 needles. Then the stocking was treated
with saturated steam at 100.degree.C. for 20 minutes under
tensionless state to develop crimps. After dyed, the stocking was
placed in a form, subjected to boarding with saturated steam at
116.degree.C. for 45 seconds, taken out from the form, and left to
stand for one day in a room at 25.degree.C. and 65 percent RH under
no tension to obtain stretchable stocking H.sub.1. Another stocking
was knitted with the use of filaments F.sub.12 in the welt, toe and
heel, and filaments F.sub.13 in the leg, and subjected to finishing
in the same manner as described in stocking H.sub.1 to obtain
stocking H.sub.2. The width of welt and the width of the upper leg
portion of the resulting stretchable stockings under tensionless
state are shown in table 5.
---------------------------------------------------------------------------
TABLE 5
Width Width of the of welt upper leg (cm.) portion (cm.)
__________________________________________________________________________
Stocking H.sub.1 12.3 11.5 Stocking W.sub.2 10.1 11.5
__________________________________________________________________________
as seen from table 5, in stocking H.sub.2, the width of welt is
smaller than that of the upper leg portion, and they are
unbalanced. On the contrary, in stocking H.sub.1, the width of welt
and the width of the upper leg portion were well-balanced.
Moreover, in stocking H.sub.2, the welt has a color tone somewhat
lighter than the leg, but in stocking H.sub.1, the welt had
substantially the same color tone with the leg.
EXAMPLE 7
An experiment was carried out to produce self-adhesive filaments,
in which surface area occupied by the adhesive component in a
filament is reduced, as raw filaments for the production of
run-resisting stockings.
Nylon-6 used in example 5, and an adhesive component of a copolymer
having an intrinsic viscosity of 1.1 in m-cresol at 25.degree. C.
and consisting of 80 parts by weight of nylon-6 and 20 parts by
weight of polyhexamethylene adipamide (hereinafter abridged as
copolymer 6/66) were used as spinning materials. A spinneret as
shown in FIG. 24, which had inner orifices composed of a linear
slit, was used. Temperature of the spinneret was maintained at
275.degree. C. 80 parts by weight of melted nylon-6 and 20 parts by
weight of the melted copolymer 6/66 were fed into reservoirs 5 and
6, and reservoirs 7 by means of gear pumps respectively. The two
spinning materials were bonded and extruded through an orifice 3
into the air, cooled, and taken up at a rate of 600 m/min in a
conventional manner, while oiling. The taken up undrawn filament
was drawn 3.89 times its original length at room temperature to
obtain filament F.sub.4 of 15 d/monofilament. Filament F.sub.4 had
a cross section as shown in FIG. 4.
As a control, the same nylon-6 and the same copolymer 6/66 were
conjugate spun in a conventional manner to obtain side-by-side
relation two-component filament F.sub.5 having a conjugate ratio of
nylon 6/copolymer 6/66 =92/8. Filament F.sub.5 had a cross section
as shown in FIG. 3. In the resulting filaments F.sub.4 and E.sub.5,
both the average values of surface areas occupied by the adhesive
component (copolymer 6/66 ) were about 20 percent. However, the
unevenness of surface areas in the longitudinal direction of a
filament and between filaments was 18 to 24 percent in filament
F.sub.4, while the unevenness in filament F.sub.5 was as large as 7
to 30 percent.
* * * * *