Note: Descriptions are shown in the official language in which they were submitted.
CA 02668002 2013-12-19
DESCRIPTION
ANTISTATIC CORE-SHEATH TYPE POLYESTER ULTRAFINE FALSE-TWIST
TEXTURED YARN, USES OF AND METHOD FOR PRODUCING THE SAME
Technical Field
The present invention relates to a core-sheath type
polyester ultrafine false-twist textured yarn having antistatic
property and method for producing the same, and an antistatic
woven fabric containing the antistatic core-sheath type
polyester ultrafine false-twist textured yarn.
More
specifically, the invention relates to a production method that
can give stably a polyester ultrafine false-twist textured yarn
of a core-sheath structure having antistatic property with
excellent durability.
Background Art
Polyester fiber is widely used for clothing application
and the like due to excellent grade and stable physical
properties thereof.
However, since polyester is originally
hydrophobic, in such a field that requires antistatic property,
many attempts have been proposed to give hydrophilic property
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CA 02668002 2013-12-19
to polyester to allow it to express antistatic property.
As examples thereof, there are known, for example, a
method of blending a polyoxyalkylene-based polyether compound
to polyester (Japanese Patent Publication No JP-B-39-5214), a
method of blending a substantially
incompatible
polyoxyalkylene-based polyether compound and organic/inorganic
compound to polyester (Japanese Patent Publication No JP-B-44-
31828, Japanese Patent Publication No JP-B-60-11944, Japanese
Patent Publication No JP-A-53-80497, Japanese Patent
Publication No JP-A-53-149247, Japanese Patent Publication No
JP-A-60-39413, Japanese Patent Publication No JP-A-3-139556 and
the like), and the like.
However, there is such a problem in the above method that,
although good antistatic property is expressed in the case of
usual drawn yarns (BOY), good antistatic property can not be
obtained in the case of a false-twist textured yarn, because
fluff occurs due to the deformation of false-twist.
Further, recently in particular, demand for feeling, skin
contact feeling, appearance and the like of a woven or knit
fabric is heightening more and more, and a textile having soft
feeling is produced by using a polyester false-twist textured
yarn of ultrafine fineness having a single filament fineness of
1.6 dtex or less.
But, in the case of a polyester false-twist
textured yarn, along with the proceeding of the ultrafine
fineness, it becomes extremely difficult to inhibit
sufficiently the generation of static charge.
Thus, in such
applications as sportswear, uniform, dustproof wear, or even in
such applications as blouses and shirts that often contact
directly to skin, it is not much to say that there is almost
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no textile that has sufficient antistatic property under the
present circumstances.
Disclosure of the Invention
Purposes of the present invention are to provide a
core-sheath type polyester ultrafine false-twist textured
yarn that can give a polyester textile that is excellent also
in antistatic performance, while maintaining such
performances as soft feeling, warmth-retaining property,
water-absorbing property, hygroscopic property that belong to
an ultrafine polyester false-twist textured yarn; and to
provide a method for producing a core-sheath type polyester
ultrafine false-twist textured yarn capable of producing
stably the same.
As the result of hard studies for achieving the
aforementioned purposes, the present inventors found that the
purpose of the invention could be achieved by melt spinning
a core-sheath type polyester ultrafine composite filament,
which was formed by covering a core component composed of
polyester incorporated with a polyoxyalkylene-based polyether
compound and organic ionic compound that are substantially
incompatible with polyester with a sheath component, under a
specified condition, and then drawing and false-twist
texturing the resulting product.
Namely, according to the invention, there are provided
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following 1) to 3) .
1) An antistatic core-sheath type polyester ultrafine
false-twist textured yarn characterized by being a false-twist
textured core-sheath type composite filament, wherein:
the core part of the core-sheath type composite filament
is formed from an antistatic polyester composition A containing
the following (a) and (b) , as an antistatic agent, relative
to 100 parts by weight of aromatic polyester,
(a) from 0.2 to 30 parts by weight of
polyoxyalkylene-based polyether, and
(b) from 0.05 to 10 parts by weight of an organic ionic
compound that is substantially nonreactive with the polyester;
and
the sheath part is formed from an aromatic polyester
composition B, and
the core-sheath type composite filament satisfies
simultaneously the following (1) to (3) conditions:
(1) a single filament fineness of the false-twist
textured yarn is 1.6 dtex or less,
(2) a crimp percentage of the false-twist textured yarn
is form 3 to 30%, and
(3) a ratio SA:SB of a core part area SA and a sheath
part area SB is in the range of from 5:95 to 80:20.
2) A method for producing an antistatic core-sheath type
polyester ultrafine false-twist textured yarn characterized
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in that, when melt-spinning a core-sheath type composite
filament having a core part that is formed from an antistatic
polyester composition A containing the following (a) and (b),
as an antistatic agent, relative to 100 parts by weight of
aromatic polyester,
(a) from 0.2 to 30 parts by weight of
polyoxyalkylene-based polyether, and
(b) from 0.05 to 10 parts by weight of an organic ionic
compound that is substantially nonreactive with the polyester;
and a sheath part that is formed from an aromatic polyester
composition B,
a filament is drawn at a ratio of discharge velocity and drawing
velocity at spinning (drawing velocity/discharge velocity,
hereinafter it is sometimes abbreviated as draft
magnification) in the range of from 150 to less than 800, and
is then subjected to false-twist texturing.
3) An antistatic woven fabric characterized in that the
antistatic woven fabric is a woven fabric containing a
core-sheath type polyester false-twist textured yarn, wherein
the core-sheath type polyester false-twist textured yarn is
the antistatic core-sheath type polyester ultrafine
false-twist textured yarn as described in the above 1).
Brief Description of the Drawings
Fig. 1 is an outline view of a simultaneous drawing and
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false-twist texturing machine for producing a false-twist
textured yarn, which is used in the present invention, wherein
1 is an undrawn core-sheath type polyester yarn, 2 is a yarn
guide, 3, 3' are feed rollers, 4, are interlace nozzles, 5 is
a first stage heater, 6 is a cooling plate, 7 is a false-twisting
tool (three-axis friction disc unit) , 8 is first delivery
rollers, 9 is a second stage heater, 10 is second delivery
rollers, 11 is winding rollers, and 12 is a polyester
false-twist textured yarn cheese.
Fig. 2 is a front view showing an embodiment of a
false-twisting disc unit for use in the invention, wherein 13
is a false-twisting disc, 14 is a guide disc, 15 is a rotation
axis, 16 is a timing belt, and 17 is a driving belt.
Best Mode for Carrying Out the Invention
Hereinafter, embodiments of the present invention are
described in detail.
A polyester in the invention is intended to be an aromatic
polyester having an aromatic ring in a chain unit in the polymer,
which is a polymer obtained by the reaction of a bifunctional
aromatic carboxylic acid or an ester-formable derivative
thereof with a diol or an ester-formable derivative thereof.
Examples of the bifunctional aromatic carboxylic acid
as mentioned here include terephthalic acid, isophthalic acid,
orthophthalic acid, 1, 5-naphthalenedicarboxylic
acid,
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2,5-naphthalenedicarboxylic acid,
2,6-naphthalenedicarboxylic acid, 4,4'-biphenyldicarboxylic
acid, 3,3'-biphenyldicarboxylic acid,
4,4'-biphenyletherdicarboxylic acid,
4,4'-biphenylmethanedicarboxylic acid,
4,4'-biphenylsulfonedicarboxylic acid,
4,4'-biphenylisopropylidenedicarboxylic acid,
1,2-bis(phenoxy)ethane-4,4'-dicarboxylic acid,
2,5-anthracenedicarboxylic acid, 2,6-anthracenedicarboxylic
acid, 4,4'-p-phenylenedicarboxylic acid,
2,5-pyridinedicarboxylic acid, (3-hydroxyethoxybenzoic acid,
p-oxybenzoic acid, and the like. In particular, terephthalic
acid is preferable.
These bifunctional aromatic carboxylic acids maybe used
in combination of two or more kinds. Further, if only a small
amount, one kind or two or more kinds in combination of a
bifunctional aliphatic carboxylic acid such as adipic acid,
azelaic acid, sebacic acid and dodecanedionic acid, a
bifunctional alicyclic carboxylic acid such as
cyclohexanedicarboxylic acid and 5-sodiumsulfoisophthalic
acid may be used with these bifunctional aromatic carboxylic
acids.
Preferable examples of the diol compound include
aliphatic dials such as ethylene glycol, propylene glycol,
butylene glycol, hexylene glycol, neopentyl glycol,
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2-methyl-1,3-propane dial, diethylene glycol, trimethylene
glycol, alicyclic dials such as 1,4-cyclohexane dimethanol,
and mixtures thereof, and the like. Further, if only a small
amount, a polyoxyalkylene glycol, of which both ends or one
end has not been blocked, maybe copolymerized with these dial
compounds.
Furthermore, in such a range that polyester is
substantially linear, polycarboxylic acids such as
trimellitic acid and pyromellitic acid, and polyols such as
glycerin, trimethylolpropane and pentaerythritol may be used.
Specific examples of the preferable aromatic polyester
include polyethylene terephthalate,
polybutylene
terephthalate, polyhexylene terephthalate, polyethylene
naphthalate, polybutylene
naphthalate,
polyethylene-1,2-bis(phenoxy)ethane-4,4'-dicarboxylate and
the like, and in addition, copolymerized polyesters such as
polyethylene isophthalate/terephthalate,
polybutylene
terephthalate/isophthalate and
polybutylene
terephthalate/decanedicarboxylate. Among
these,
polyethylene terephthalate and polybutylene terephthalate
that have balanced mechanical properties, molding properties
and the like are particularly preferable.
Such aromatic polyesters may be synthesized by an
arbitrary method. For example, polyethylene terephthalate
can be easily produced through a first step reaction in which
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terephthalic acid and ethylene glycol are directly subjected
to an esterification reaction, or a lower alkyl ester of
terephthalic acid such as dimethyl terephthalate and ethylene
glycol are subjected to an ester exchange reaction, or
terephthalic acid and ethylene oxide are reacted to generate
glycol ester of terephthalic acid and/or oligomer thereof, and
a subsequent second step reaction in which the resulting
product is heated under a reduced pressure to subject the same
to polycondensation reaction until an intended polymerization
degree is achieved.
Polyoxyalkylene-based polyether (a) to be blended to the
composition for use in the invention may be a polyoxyalkylene
glycol consisting of a single oxyalkylene unit, or a
copolymerized polyoxyalkylene glycol consisting of two kinds
or more of oxyalkylene units, in so far as it is substantially
insoluble in polyester, or may be a polyoxyethylene-based
polyether represented by the following formula (I) :
Z-E-(CH2 CH2 0) 1
(R 0) 2
-R 3 ( I )
=
(wherein, Z represents an organic compound residue having from
1 to 6 active hydrogen atoms; RI- represents an alkylene group
or substituted alkylene group having 6 or more carbon atoms;
R2 represents a hydrogen atom, monovalent hydrocarbon group
having 1 - 40 carbon atoms, monovalent hydroxyhydrocarbon group
having 2 - 40 carbon atoms or monovalent acyl group having 2
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- 40 carbon atoms; k represents an integer of from 1 to 6; n
represents an integer that satisfies n 70/k; and m represents
an integer of 1 or greater) .
Specific examples of such polyoxyalkylene-based
polyether include polyoxyethylene glycol having a molecular
weight of 4000 or more, polyoxypropylene glycol having a
molecular weight of 1000 or more, polyoxytetramethylene glycol,
ethylene oxide having a molecular weight of 2000 or more,
propylene oxide copolymer, trimethylolpropane ethylene oxide
adduct having a molecular weight of 4000 or more, nonylphenol
ethylene oxide adduct having a molecular weight of 3000 or more,
and compounds in which a substituted ethylene oxide having 6
or more carbon atoms is added to an end OH group thereof. Among
these, polyoxyethylene glycol having a molecular weight of from
10000 to 100000, and compounds in which an alkyl
group-substituted ethylene oxide having 8 - 40 carbon atoms
is added to both ends of polyoxyethylene glycol, which has a
molecular weight of from 5000 to 16000.
The blending amount of such a polyoxyalkylene-based
polyether compound is in the range of from 0.2 to 30 parts by
weight relative to 100 parts by weight of the aromatic polyester.
When it is less than 0.2 part by weight, hydrophilicity is
insufficient and satisfactory antistatic property can not be
exerted. On the other hand, when the blending amount is more
than 30 parts by weight, an additional effect of improving
CA 02668002 2009-04-29
antistatic property can not be recognized anymore, but, in
contrast, mechanical properties of an obtained composition
tends to be degraded, and, in addition, since the polyether
tends to bleed out to lower the biting property of the chip
to a ruder upon melting and molding, and also to degrade molding
stability.
In the polyester composition of the invention, in order
to improve antistatic property in particular, an organic ionic
compound is blended. As the organic ionic compound, for
example, sulfonic acid metal salts and sulfonic acid quaternary
phosphonium salts represented by the following formulae (II)
and (III) , respectively, can be mentioned as preferable ones.
RS03 M (II)
(wherein R represents an alkyl group having 3 - 30 carbon atoms,
or an aryl group having 7 - 40 carbon atoms, and M represents
an alkali metal or an alkali earth metal) .
RSO, P R2 R3 R4 (III)
(wherein R represents an alkyl group having 3 - 30 carbon atoms,
or an aryl group having 7 - 40 carbon atoms, R1, R2, R3 and R4
each represents an alkyl group or aryl group, and among these
a lower alkyl group, phenyl group or benzyl group is
preferable) .
When R is an alkyl group in the formula (II), the alkyl
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group may be linear or have a branched side chain. M is an
alkali metal such as Na, K and Li, or an alkali earth metal
such as Mg and Ca. Among these, Li, Na and K are preferable.
Such sulfonic acid metal salts may be used in only one kind
singly or in two or more kinds in combination.
Preferable specific examples can include sodium
stearylsulfonate, sodium octylsulfonate, sodium
dodecylsulfonate, a mixture of sodium alkylsulfonates having
average carbon atoms of 14, a mixture of sodium
dodecylbenzenesulfonates, sodium dodecylbenzenesulfonate
(hard type, soft type), lithium dodecylbenzenesulfonate (hard
type, soft type), magnesium dodecylbenzenesulfonate (hard
type, soft type), and the like.
The sulfonic acid quaternary phosphonium salt in the
formula (III) maybe used in one kind singly or in two or more
kinds in combination. Preferable specific example can include
tetrabutylphosphonium alkylsulfonate having average carbon
atoms of 14, tetraphenylphosphonium alkylsulfonate having
average carbon atoms of 14, butyltriphenylphosphonium
alkylsulfonate having average carbon atoms of 14,
tetrabutylphosphonium dodecylbenzenesulfonate (hard type,
soft type), tetraphenylphosphonium dodecylbenzenesulfonate
(hard type, soft type), benzyltriphenylphosphonium
dodecylbenzenesulfonate (hard type, soft type) and the like.
Such organic ionic compounds may be used in one kind or
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in two or more kinds in combination. The blending amount
thereof needs to be in the range of from 0.05 to 10 parts by
weight relative to 100 parts by weight of the aromatic polyester.
When a blending amount of the organic ionic compound is less
than 0.05 part by weight, the effect of improving antistatic
property is small, and when it is more than 10 parts by weight,
mechanical properties of the composition tends to be degraded,
and, in addition, since the ionic compound also tends to bleed
out to lower the biting property of the chip to a ruder upon
melting and molding, and also to degrade molding stability.
In the polyester B, a publicly known delustering agent,
for example, titanium dioxide or the like may be blended in
such a range that does not prevent the purpose of the invention.
But, 10% by weight or more of a delustering agent results in
degradation of spinning property of an undrawn yarn, which is
to be a parent yarn of the invention, therefore the range is
preferably from 0.01 to 10% by weight.
The ultrafine false-twist textured yarn of the invention
needs to have a single filament fineness of 1.6 dtex or less,
and a crimp percentage of from 3 to 30%. By determining them
in these ranges, a woven or knit fabric excellent in soft
feeling is obtained. The crimp percentage of less than 3% does
not give sufficiently swollen feeling when the ultrafine yarn
is made into a woven or knit fabric, and, on the other hand,
the percentage of more than 30% tends to lower antistatic
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performance, unpreferably.
Further, the ratio SA:SB of the core part area SA and
the sheath part area SB needs to be in the range of from 5:95
to 80:20. The area ratio of less than 5:95 results in an
insufficient expression of antistatic performance by the
polyester A, and the ratio of more than 80:20 leads to elution
of an antistatic polyester of the core part when an alkali
weight reduction of 10% or more is conducted, to lower
antistatic performance or lower the strength of a false-twist
textured yarn to 3.0 cN/dtex or less, to result in an
insufficient strength when it is formed into textile, and make
it unsuitable for such applications as sportswear that require
strength, thereby limiting applications, unpreferably.
The polyester ultrafine false-twist textured yarn of the
invention described above can give stable antistatic
performance by subjecting an undrawn yarn, which has been drawn
at a ratio of discharge velocity and drawing velocity at
spinning (drawing velocity/discharge velocity, hereinafter it
is referred to as draft) in the range of from 150 to less than
800 upon melt spinning an undrawn yarn to be a parent yarn
thereof, to a false-twist texturing. The draft of less than
150 results in an insufficient expression of antistatic
performance by the polyester A, and the draft of more than 800
lowers spinnability, unpreferably, although the antistatic
performance is expressed.
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In order to set the draft within the above range, the
diameter of spinneret discharge opening and spinning velocity
are approximately set. And, it can preferably be obtained
easily and efficiently by performing melt spinning at a
spinning velocity of from 2000 to 4500 m/min, particularly in
the range of from 2500 to 3500 m/min, while setting the
discharge opening diameter (I) to from 0.1 to 0.3 mm.
The double refractive index of an undrawn multifilament
on this occasion is preferably in the range of from 0.02 to
0.05. In the case where the double refractive index is less
than 0.02, tension at false-twist texturing is low and tends
to generate surging, which results in filament sway to cause
a heat set spot and dyeing unevenness defect, and increase in
texturing magnification and weak yarn, unpreferably. On the
other hand, in the case where the double refractive index is
greater than 0.05, fluff of raw thread tends to occur to cause
process disorder, unpreferably.
There is no necessity to limit a method for false-twist
texturing the undrawn yarn, but, for example, such a method
as described below is employed.
Firstly, an air interlacing treatment may be performed
in a process other than a drawing and false-twist texturing,
but it is preferably performed just before the drawing and
false-twist texturing by providing an interlace nozzle to a
false-twist texturing apparatus, as shown in Fig. 1. This
CA 02668002 2009-04-29
prevents fluff generation to result in a preferable effect on
handling properties, and, in addition, by giving an air
interlacing to a yarn after a heat-set false-twisting,
perfectly uniformizes blending and interlacing and results in
antistatic property and the expression of high-grade feeling
based on the effect of uniformity in the length direction of
the yarn.
Next, the undrawn yarn that has been given an interlacing
treatment is loaded on a drawing and false-twist texturing
machine provided with two-stage heaters, for example, as shown
in Fig. 1, to form into a polyester false-twist textured yarn
having crimps.
In Fig. 1, there is illustrated a process in which the
above-described polyester undrawn yarn (1) is subjected to an
air interlacing treatment with interlace nozzles (4, 4') that
are set up between two pairs of feed rollers (3, 3'). The
undrawn yarn having been subjected to interlacing treatment
here is twisted through friction with the rotating
false-twisting disc (7) while being drawn between the feed
rollers (3') and the first delivery rollers (8). During this
time, the yarn is heat-treated with the first stage heater (5),
cooled with the cooling plate (6), and passes though the
false-twisting disc (7) to be detwisted. Further, running
yarn is heat-treated again, according to need, with the second
stage heater (9) that is set up between the first delivery
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rollers (8) and the second delivery rollers (10), and,
furthermore, after giving an air interlacing (4') to the yarn
after a heat-set false-twisting, it is wound with the winding
roller (11) as a cheese-shaped package (12), to produce a
polyester false-twist textured yarn.
While taking a high speed drawing and false-twist
texturing into consideration, the first stage heater (5) and
the second stage heater (9) are preferably of a non-contacting
system. Particularly the second stage heater is not often used,
but it may be used for the purpose of providing feeling and
the like, according to need.
In the invention, it is preferable that the
false-twisting tool (7) is of a three-axis friction disc type
as shown in Fig. 2, wherein a disc at the lowest stage has the
material of ceramic and the contact length of the running yarn
and the disc is determined to be from 2.5 to 0.5 mm, and that,
further, the disc has a diameter of from 90 to 98% of the diameter
of a disc just upstream thereof.
That is, the false-twisting tool (7) as exemplified in
Fig. 2 is of a three-axis friction disc type having three
rotation axes (15) to each of which two false-twisting discs
(13) are fixed, wherein each of rotation axes (15) is rotated
at a predetermined velocity with the timing belt (16) that is
driven with the driving belt (17), to enable respective
false-twisting discs (13) to rotate. In the method of the
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CA 02668002 2009-04-29
'
,
invention, as at least the bottom disc located in the detwisting
section among false-twisting discs (13) (in the example shown
in Fig. 2, the bottom disc fixed to the left side rotation axis) ,
a disc that is made of ceramic and has a diameter of from 90
to 98% of the diameter of a disc on just upstream side thereof
(in the example shown in Fig. 2, the bottom disc fixed to the
central rotation axis) is used. And, the contact length of
the ceramic disc and a running yarn is determined to be from
2.5 to 0.5 ram.
On this occasion, the material of the bottom disc is
preferably ceramic from the viewpoint of abrasion resistance.
According to studies of the present inventors, it was revealed
that, in the composite false-twist texturing according to the
invention, by determining the contact length of the running
yarn and the disc to be from 2.5 to 0.5 mm, it became possible
to make a contact area as small as possible when the yarn having
a crimped state after the termination of twisting entered the
last detwisting section to reduce resistance and, as the result,
fluff significantly to improve strength as the result, and that
determining the diameter of the disc to be in the range of from
90 to 98% of the diameter of a disc just above thereof reduced
resistance value when the yarn moved to a subsequent step
(specifically, heat set) and was effective for smooth movement,
and the like. It was confirmed that, among these, determining
the contact length of the running yarn and the above-described
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=
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disc to be from 2.5 to 0.5 mm reduced significantly texturing
fluff and, as the result, was particularly effective for
improving strength.
Temperature in false-twist texturing in the invention
is preferably set to be from the glass transition temperature
(hereinafter, referred to as TG) TG + 100 C to TG + 200 C,
specifically from 170 to 300 . A temperature less than 170 C
results in low crimpability and solid feeling, and a
temperature more than 300 C results in progress of an extreme
flatness of a textured yarn to tends to generate texturing fluff,
unpreferably. When an apparatus provided with a heater of
non-contact system is used as a false-twist texturing machine,
heat treatment is preferably performed while setting the
temperature of the first stage non-contacting heater at from
170 to 300 C. Meanwhile, an appropriate heater temperature is
based on a commercially available false-twist texturing
machine (216 spindles, Model HTS-15V, manufactured by Teijin
Seiki), wherein such a specification as anon-contacting length
of from 1.0 to 1.5 m and a yarn velocity of 800 m/min or more
is assumed. Therefore, it is a matter of course that a preset
temperature should be adjusted suitably in such cases where
a special heater is used or a texturing is performed at a
hypervelocity.
Here, the first heater in a twisting area is one for
improving drawing property and false-twist texturing property
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(twistability) of an undrawn yarn. When the temperature
thereof is a temperature less than 170 C in the case of a
non-contacting heater, twistability lowers and the intended
crimp of the invention can not be given, to result in paper-like
feeling when the yarn is formed into a woven or knit fabric.
Further, yarn breakage and fluff at drawing and false-twist
texturing occur frequently, and a crimp spot and dyeing spot
at dyeing tends to occur, unpreferably. On the other hand,
when the temperature of the first heater exceeds 300 C, single
filament breakage tends to occur at drawing and false-twist
texturing, in particular, single filament breakage tends to
occur for an undrawn yarn (B') on a high elongation percentage
side, to give a polyester composite false-twist textured yarn
having a lot of fluff, unpreferably. Depending on the type
of drawing and false-twist texturing machines, a first stage
heater may be divided into a first half section and a latter
half section. In the method of the invention, the first half
and latter half sections of the first stage heater may be set
at the same temperature.
The heat treatment time of a yarn in the first stage heater
may be approximately set depending on the type of a heater,
length and temperature thereof, and the like. However, a too
short heat treatment time tends to results in an insufficient
crimp percentage, and to generate a drawn false-twist yarn
breakage, fluff of a false-twist textured yarn, and a dyeing
= CA 02668002 2009-04-29
spot for woven or knit fabric due to tension variation. On
the other hand, a too long heat treatment time tends to result
in a too large crimp percentage. Consequently, in the case
where the heat treatment is performed with a non-contact type
heater, usually, the range of from 0.04 to 0.12 second, in
particular the range of from 0. 06 to 0.10 second is appropriate.
Regarding the draw ratio at texturing, the area of from
1.4 to 2.4 is the optimal zone. In a ratio outside this area,
on a lower ratio side, surging and heat set spot due to yarn
sway occur, and, on a higher ratio side, flatness of a textured
yarn proceeds to generate texturing fluff, unpreferably.
Regarding a false-twist count, when the fineness of a
composite false-twist textured yarn is denoted by Y (dtex),
the count is set in the range of [(15000 to 35000) /y1/2] time/m,
more preferably [(20000 to 30000)/y1/2] time/m. When a
false-twist count is less than 15000/y1/2 time/m, it becomes
difficult to provide fine and solid crimp, and an obtained
textile becomes paper-like to result in a hard feeling. When
a false-twist count exceeds 35000/y1/2 time/m, yarn breakage
and fluff occur often.
The ultrafine polyester false-twist textured yarn of the
present invention thus obtained can also keep performances such
as soft feeling, warmth-retaining property, water-absorbing
property, hygroscopic property, which belong to conventional
ultrafine polyester false-twist textured yarns, and can give
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polyester textiles also excellent in antistatic performance.
Example
Hereinafter, the present invention is described more
specifically on the basis of Examples and Comparative Examples.
Respective measured values shown in Examples are values that
were measured by the following methods. Simply denoted "part"
in Examples and Comparative Examples means "part by weight,"
if not otherwise specified.
(1) Intrinsic viscosity
A sample was dissolved in o-chlorophenol, and
measurement was performed with an Uberode viscosity tube at
35 C.
(2) Transit angle
A yarn running on a false-twisting disc was photographed,
then a transit angle 0 of the yarn on respective false-twisting
discs was actually measured on the photograph, and the average
value of these measured values was defined as the transit angle.
(3) Crimp percentage
A sample of a polyester false-twist textured yarn was
wound on a cassette frame with an applied tension of 0.044
cN/dtex to form a cassette of about 3300 dtex. To one end of
the cassette, two weights of 0.0177 cN/dtex and 0.177 cN/dtex
were loaded, and length SO (cm) after the lapse of 1 minute
was measured. Subsequently, in a state where the weight of
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CA 02668002 2009-04-29
0.177 cN/dtex had been removed, the sample was treated in
boiling water at 100 C for 20 minutes. After the boiling water
treatment, the weight of 0.0177 cN/dtex was removed. The
sample was air dried for 24 hours in a free state, to which
weights of 0.0177 cN/dtex and 0.177 cN/dtex were loaded again,
and length Si (cm) after the lapse of 1 minute was measured.
Subsequently, the weight of 0.177 cN/dtex was removed, and
length S2 after the lapse of 1 minute was measured. A crimp
percentage was calculated according to the following
calculating formula, and the average value of 10 measured
values was used.
Crimp percentage (%)=[ (S1-S2) /SO] x 100
(4) Feeling
The false-twist textured yarn of the invention was used
for forming a textile, which was classified into following
levels 1 to 3 according to organoleptic tests by authorities.
(Soft feeling)
Level 1: exerting soft and flexible feeling
Level 2: exerting a slightly poor soft feeling, but
repulsion power can be felt
Level 3: giving desiccated feeling or hard feeling
(5) Count of fluff
Generated fluffs was counted for a polyester false-twist
textured yarn sample by performing continuous measurement with
a fluff counter type DT-104 manufactured by Toray at a velocity
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CA 02668002 2009-04-29
of 500 m/min for 20 minutes, and was denoted by fluff counts
per sample length of 10000 meters.
(6) Test method of charging property
(Measurement method of friction-charged electrostatic
potential)
A test piece was scrubbed with a friction cloth while
rotating the piece, and generated friction-charged
electrostatic potential was measured. It follows the L1094
charging property test method B method (friction-charged
electrostatic potential measurement method). An antistatic
effect was exerted when a friction-charged electrostatic
potential was about 2000 V or less (preferably 1500 V or less).
Example 1
Into an ester exchange reaction can, 100 parts of
dimethyl terephthalate, 60 parts of ethylene glycol, 0.06 part
(0.066% by mol relative to dimethyl terephthalate) of calcium
acetate monohydrate, and 0.013 part (0.01% by mol relative to
dimethyl terephthalate) of cobalt acetate tetrahydrate as an
orthochromatic agent were put. The temperature of these
reaction materials was raised from 140 C to 220 C over 4 hours
under a nitrogen atmosphere to subject the materials to an ester
exchange reaction, while distilling methanol that generated
in the reaction can out of the reaction system.
After the termination of the ester exchange reaction,
to the reaction mixture, 0.058 part (0.080% by mol relative
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CA 02668002 2013-12-19
to dimethyl terephthalate) of trimethyl phosphate as a
stabilizer and 0.024 part of dimethylpolysiloxane as a
defoaming agent were added.
Next, after 10 minutes, to the
reaction mixture, 0.041 part (0.027% by mol relative to
dimethyl terephthalate) of antimony trioxide was added, the
temperature of which was raised, at the same time, to 240 C
while distilling excess ethylene glycol, and subsequently the
reaction mixture was moved to a polymerization reaction can.
Next, the pressure was reduced from 760 mmHg to 1 mmHg and,
simultaneously, the temperature was raised from 240 C to 280 C
over 1 hour and 40 minutes, to subject the mixture to a
polycondensation reaction, followed by adding 4 parts of water-
insoluble polyoxyethylene-based polyether represented by the
following formula and 2 parts of sodium dodecylbenzenesulfonate
under vacuum, which was subjected to an additional
polycondensation reaction for 240 minutes, followed by adding
0.4 part of IRGANOXTM 1010 manufactured by Ciba-Geigy as an
oxidation inhibitor under vacuum, which was subjected to a
further additional polycondensation reaction for 30 minutes.
In the polymerization reaction process, an antistatic agent was
added, and an obtained polymer was formed into a chip with an
ordinary method.
CA 02668002 2009-04-29
HO--(-CHCH2 0)- -E-CH22 0.)-
C
+ I
C H C H 0 -)-- H
2 ,
C H
2 .1 I
(wherein j is an integer of from 18 to 28 and is 21 as an average
value; P is 100 as an average value; and m is 5 as an average
value. Here, the average value means an average value of the
number of oxyethylene units in
copolymerized
polyoxyethylene-based polyether composed of two kinds or more
of oxyethylene units) .
The intrinsic viscosity of the obtained polymer was 0.657,
and the softening point was 258 C.
The obtained chip, and a usual polyethylene
terephthalate chip that contained 0.4% by weight of titanium
oxide fine particles and had an intrinsic viscosity of 0.65
were dried according to an ordinary method. Then each of chips
was molten with a spinning apparatus by an ordinary method,
which was passed through a spinning block and guided into a
spin pack for a composite filament. Filaments from a spinneret
having 72 pierced core-sheath type composite circular
discharge openings that was mounted on the spin pack were cooled
and solidified with cooling wind from a spinning cylinder of
an ordinary cross flow type, and converged into one yarn while
being given a spinning oil agent. The yarn was pulled out at
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CA 02668002 2009-04-29
a velocity of 3000 m/min (draft magnification: 200), to give
a polyester core-sheath type composite undrawn yarn of 140
dtex/72filament, which had a core/sheath area ratio of 70:30.
The polyester undrawn yarn was set on a 216-spindle
HTS-15V manufactured by TEIJIN SEIKI, which was given air
interlacing with a flow volume of 60 nL/min so as to give a
interlace degree of 50 points/m while allowing the yarn to pass
through an interlace nozzle having a pressured air-blowing
opening with a diameter of 1.8 ram in the first stage and latter
stage, as shown in Fig. 1 (4, 4'). Then, while setting
conditions so that a draw ratio was 1.60 and first heater
(non-contact type) temperature was 250 C, and using an urethane
disc having a diameter of 60 mm and thickness of 9 mm as a
false-twisting disc, drawing and false-twist were performed
at a transit angle of 43 degrees so that false-twist count x
(false-twist yarn fineness (dtex)) 1/2 was near 26000, which was
wound in a cheese-like figure at a velocity of 800 m/min, to
give a polyester false-twist textured yarn of 84
dtex/72filament (average single filament fineness of 1.17
dtex) having a core/sheath ratio of 70:30.
These polyester false-twist textured yarns were used for
producing a tubular knitted fabric, and antistatic property
was measured. The friction-charged electrostatic potential
of the obtained polyester false-twist textured yarn was 1200
V. In addition, these polyester false-twist textured yarns
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CA 02668002 2009-04-29
were formed into a woven fabric according to an ordinary method,
for which the grade was organolepticly evaluated, to show that
the fabric had a very deep and high-grade feeling, and exerted
soft feeling. The results are shown in Table 1.
Comparative Example 1
Polyethylene glycol was reacted with acrylonitrile in
the presence of an alkali catalyst, which was further subjected
to a hydrogen addition reaction, to synthesize polyethylene
glycol diamine (number average molecular weight of 4000) that
included an amino group at 97% or more of both terminals. The
diamine was subjected to salt reaction with adipic acid
according to an ordinary method to give a 45% aqueous solution
of polyethylene glycol diammonium adipate.
Into a concentration can having a volume of 2 m3, 200
kg of the 45% aqueous solution of polyethylene glycol
diammonium adipate, 120 kg of a 85% caprolactam aqueous
solution, and 16 kg of 40% hexamethylenediammonium
isophthalate aqueous solution were put. They were heated for
about 2 hours until the interior temperature was 110 C at normal
pressure to be concentrated to a concentration of 80%.
Subsequently, the concentrated liquid was moved to a
polymerization can having a volume of 800 litters. Then,
heating was started while flowing nitrogen into the
polymerization can at 2.5 1/min.
At the time when the interior temperature became 120 C,
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CA 02668002 2009-04-29
5.2 kg (2.5% by weight) of sodium dodecylbenzenesulfonate and
5.2 kg (2.5% by weight) of
1,5,5-trimethy1-2,4,6¨tri (3,5-di-tert-buty1-4-hydroxybenze
ne) benzene (TTB) were added, followed by starting the stirring
and heating of the system for 18 hours until the interior
temperature became 245 C to complete polymerization. After
the end of the polymerization, it was pelletized according to
an ordinary method to give a pellet consisting of a block
polyetheramide composition.
The pellet consisting of a block polyetheramide
composition was blended to usual polyethylene terephthalate
chip having an intrinsic viscosity of 0.65 that did not contain
titanium oxide so as to give 1.4% by weight. Then, a polyester
false-twist textured yarn of 84 dtex/72filament (average
single filament fineness of 1.17 dtex) having a core/sheath
ratio of 70:30 was obtained in the same way as in Example 1,
except that the above-described blended material was used for
a core component. A textile consisting of the fiber showed
soft and excellent feeling similar to that in Example 1, however,
it had such a very poor friction-charged electrostatic
potential as 3400 V. Results are shown collectively in Table
1.
Examples 2 and 3
Each of core-sheath type composite polyester false-twist
textured yarns of 56 dtex/72filament (average single filament
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CA 02668002 2009-04-29
fineness of 0.78 dtex) and 111 dtex/72filament (average single
filament fineness of 1.54 dtex) having a core-sheath ratio of
70:30 was obtained in the same way as in Example 1 except for
changing the polymer discharging amount. Textiles made of
these yarns had both excellent friction-charged electrostatic
potential and feeling. Results are shown collectively in
Table 1.
Comparative Examples 2 and 3
Each of core-sheath type composite polyester false-twist
textured yarns of 56 dtex/72filament (average single filament
fineness of 0.78 dtex) and 111 dtex/72filament (average single
filament fineness of 1.54 dtex) having a core-sheath ratio of
70:30 was obtained in the same way as in Comparative Example
1 except for changing the polymer discharging amount.
Textiles made of these yarns had such excellent feeling as that
in Example 1, however, they had a high friction-charged
electrostatic potential and were unsuitable for practical use.
Results are shown collectively in Table 1.
Comparative Example 4
A core-sheath type composite polyester false-twist
textured yarn of 133 dtex/72filament (average single filament
fineness of 1.85 dtex) having a core-sheath ratio of 70:30 was
obtained in the same way as in Example 1 except for increasing
the polymer discharging amount. A textile made of the yarn
had such excellent friction-charged electrostatic potential
CA 02668002 2009-04-29
as that in Example 1, however, it had a hard feeling and was
unsuitable for practical use. Results are shown collectively
in Table 1.
Comparative Example 5
A core-sheath type composite polyester false-twist
textured yarn of 84 dtex/36filament (average single filament
fineness of 2.33 dtex) having a core-sheath ratio of 70:30 was
obtained in the same way as in Example 1 except for replacing
the spinneret with one having 36 holes. A textile made of the
yarn had such excellent friction-charged electrostatic
potential as that in Example 1, however, it had a hard feeling
and was unsuitable for practical use. Results are shown
collectively in Table 1.
Comparative Example 6
A core-sheath type composite polyester false-twist
textured yarn of 133 dtex/72filament (average single filament
fineness of 1.85 dtex) having a core-sheath ratio of 70:30 was
obtained in the same way as in Comparative Example 1 except
for increasing the polymer discharging amount. A textile made
of the yarn had a friction-charged electrostatic potential
which was improved as compared with that in Comparative Example
1 but still insufficient, and, in addition, it had a hard
feeling and was unsuitable for practical use. Results are
shown collectively in Table 1.
Comparative Example 7
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A core-sheath type composite polyester false-twist
textured yarn of 84 dtex/36filament (average single filament
fineness 2.33 dtex) having a core-sheath ratio of 70:30 was
obtained in the same way as in Comparative Example 1 except
for replacing the spinneret with one having 36 holes. A textile
made of the yarn had a friction-charged electrostatic potential
which was improved as compared with that in Comparative Example
1 but still insufficient, and, in addition, it had a hard
feeling and was unsuitable for practical use. Results are
shown collectively in Table 1.
Table 1
Draft Single Crimp Fluff
Friction-charged Feeling
magnification filament percentage (numbers/ electrostatic (level)
(times) fineness (%) 10000m) potential (V)
(citex)
Exam 200 1.17 15 20 1200 1
1
Exam 300 0.78 18 30 1200 1
2
Exam 180 1.54 20 15 1100 1
3
Comp 200 1.17 20 15 3400 1
Ex 1
Comp 300 0.78 15 30 4000 1
Ex 2
Comp 180 1.54 15 20 2700 1
Ex 3
Comp 120 1.85 20 13 1000 3
Ex 4
Comp 185 2.33 25 10 1000 3
Ex 5
Comp 120 1.85 18 10 2000 3
Ex 6
Comp 185 2.33 25 10 2000 3
Ex 7
* PEG (molecular weight of 20000)
** Sodium dodecylbenzenesulfonate
32
