Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DESCRIPTION
TITLE OF THE INVENTION: HIGH-STRENGTH FINE-DENIER POLYESTER
MULTIFILAMENT
TECHNICAL FIELD
[0001]
The present invention relates to a high-strength
fine-denier multifilament that is excellent in weaving
properties and wear resistance and that can be used in
particular in a high-density thin woven fabric suitable for
use with athletic and outdoor clothing.
BACKGROUND ART
[0002]
Until now, many high-density woven fabrics made of
synthetic fiber multifilaments such as those of polyesters
and nylons have been proposed mainly for uses such as
athletic clothing and airbags. Along with the
sophistication of uses, there has been a demand for lighter
woven fabrics, that is, thinner woven fabrics, and
accordingly higher-strength woven fabrics. In particular,
in athletic and outdoor clothing, there is an increasing
demand for improved durability against active movements,
and woven fabrics have been desired to have improved wear
resistance.
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[0003]
In Patent Document 1, a single-component polyester
multifilament woven fabric is proposed. The single-
component polyester multifilament woven fabric has high
strength because it contains polyethylene terephthalate
having an intrinsic viscosity of 0.70 to 1.20, and has
improved weaving properties because it contains 0.3 to 0.8
wt% of titanium oxide containing 60% or more of particles
having a primary particle diameter of 0.1 to 0.6 pm based
on the total number of titanium oxide particles.
[0004]
In addition, for thinning a woven fabric, it is
required to reduce the total fineness of the yarn, and the
number of constituent filaments of the yarn is inevitably
reduced. Therefore, the filaments are interlaced with
difficulty, and the polyester multifilament has poor
convergence. The poor convergence deteriorates the process
passability in the production process, and makes handling
during warping and weaving difficult. In addition, because
of insufficient convergence, filament breakage (separation
into single yarns) may occur, the working of the warp
during the weaving may be deteriorated, and the warp
breakage may easily occur. The warp breakage not only
merely stops the loom but also requires a large amount of
labor to reconnect and restore the warp, and may
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inconveniently reduce the productivity greatly. Also in
respect of the woven fabric quality, filament breakage may
cause streak-like defects. In Patent Document 2, in order
to provide a polyamide multifilament excellent in
convergence, it is proposed to reduce the single-yarn
fineness to 0.8 dtex or less to facilitate interlacing in
spite of a small total fineness of 6 to 18 dtex, thereby
making the degree of interlacement 25 or more.
[0005]
In Patent Document 3, a polyester monofilament for
screen gauze is proposed. The polyester monofilament is a
core-in-sheath composite yarn, a polyester used in the core
component has a limiting viscosity of 0.70 or more so that
the monofilament may have high strength, and a polyester
used in the sheath component has a limiting viscosity lower
by 0.15 to 0.30 than that of the polyester used in the core
component to suppress the scum (improve the wear
resistance).
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
[0006]
Patent Document 1: Japanese Patent Laid-open
Publication No. 2009-074213 (paragraph numbers [0008] to
[0009])
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Patent Document 2: Japanese Patent Laid-open
Publication No. 2009-013511 (paragraph numbers [0008] to
[0009])
Patent Document 3: Japanese Patent Laid-open
Publication No. 2003-213528 (paragraph numbers [0013] to
[0014])
SUMMARY OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0007]
The single-component polyester disclosed in Patent
Document 1, however, has a problem in wear resistance, and
hardly meets the demand for durability in sophisticated
uses.
[0008]
In Patent Document 2, the weaving properties are
indeed greatly improved by increasing the degree of
interlacement to improve the convergence. The small
single-yarn fineness, however, may cause problems such as
breakage of warp and weft during the weaving as well as
generation of fluff.
[0009]
As for Patent Document 3, it is difficult to make the
monofilament into a high-density woven fabric, and the
monofilament is unsuitable for use in clothing because a
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cloth made of the monofilament has high rigidity due to the
high single-yarn fineness. Moreover, in the case where the
core-in-sheath composite yarn technique is applied to a
fine-denier multifilament, a core-in-sheath composite yarn
having a small single-yarn fineness may inconveniently
cause sheath breakage or may be excessively thinned in the
sheath part so that sufficient wear resistance may not be
ensured. On the contrary, in a core-in-sheath composite
yarn having a large single-yarn fineness, due to the small
number of filaments, the filaments are interlaced with
difficulty, the core-in-sheath composite yarn has poor
convergence, and the weaving properties and woven fabric
quality are deteriorated.
[0010]
In other words, it is difficult with conventional
techniques to obtain a polyester multifilament for thin
woven fabrics that combine the durability, weaving
properties, and woven fabric quality required in
sophisticated uses. Therefore, development of a high-
strength fine-denier polyester multifilament having
excellent wear resistance and convergence has been
expected.
[0011]
An object of the present invention is to solve the
above-mentioned problems of the conventional techniques,
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and to provide a high-strength fine-denier polyester
multifilament having excellent wear resistance and
convergence for the purpose of providing a high-density
thin woven fabric that combines excellent durability,
weaving properties, and woven fabric quality and that is
suitable for use with athletic and outdoor clothing.
SOLUTIONS TO THE PROBLEMS
[0012]
The object of the present invention can be achieved
using the following polyester multifilament.
[0013]
The polyester multifilament is a polyester
multifilament characterized in that it contains: a high-
viscosity polyester as a core component; and a low-
viscosity polyester as a sheath component, the core
component and the sheath component forming a core-in-sheath
composite, and that the polyester multifilament has a
difference in intrinsic viscosity between the core
component and the sheath component of 0.20 to 1.00, a total
fineness of 4 to 30 dtex, a single-yarn fineness of 1.0 to
5.0 dtex, a breaking strength of 5.0 to 9.0 cN/dtex, a
fracture elongation of 12 to 45%, a degree of interlacement
of 2.0 to 15.0/m, and a number of filaments of 3 to 15.
[0014]
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Further, the polyester multifilament is characterized
in that the high-viscosity polyester as the core component
has an intrinsic viscosity of 0.70 to 1.50, and the sheath
component has a high viscosity of 0.40 to 0.70.
EFFECTS OF THE INVENTION
[0015]
The high-strength polyester multifilament of the
present invention has excellent wear resistance and
convergence, and is capable of providing a high-density
thin woven fabric that combines excellent durability,
weaving properties, and woven fabric quality and that is
suitable for use with athletic and outdoor clothing.
EMBODIMENT OF THE INVENTION
[0016]
The polyester multifilament of the present invention
will be described.
[0017]
The polyester multifilament of the present invention
is made of a core-in-sheath composite fiber in which, in a
cross section of a single yarn, a core component and a
sheath component are arranged such that the core component
is covered with the sheath component and the core component
is not exposed to the surface of the polyester
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multifilament. In general, in order to increase the
strength of a polyester fiber, it is known that drawing at
a high draw ratio is required in the production process of
an original yarn for high orientation and high
crystallization. In weaving a high-density thin woven
fabric, since a yarn having a small total fineness is woven
at high density, the warp is subjected to intense abrasion
with a reed under a heavy load so that fluff due to single
yarn breakage may be generated. Further, thin woven
fabrics used in sophisticated uses are required to have
durability against friction, and it is an important issue
to improve the wear resistance of the original yarn.
[0018]
In the polyester multifilament of the present
invention, from the viewpoint of obtaining excellent wear
resistance, the polyester used in the sheath component is
required to have an intrinsic viscosity lower than that of
the core component polyester, and the difference in
intrinsic viscosity is preferably 0.20 to 1.00. A
difference in intrinsic viscosity of 0.20 or more can
suppress the degree of orientation and degree of
crystallinity of the sheath component polyester, that is,
the polyester at the fiber surface of the polyester
multifilament, and can provide satisfactory wear
resistance. In addition, since the sheath component bears
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the shear stress at the inner wall surface of the discharge
hole of the melt spinning spinneret, the core component
receives weak shear force, has a low degree of molecular
chain orientation, and is spun in a uniform state.
Therefore, the finally obtained polyester multifilament has
improved strength. Meanwhile, in order for the polyester
multifilament to have high strength, the sheath component
is also required to be moderately oriented. Therefore, if
the difference in intrinsic viscosity is larger than 1.00,
a satisfactory original yarn strength is not obtained. A
more preferable difference in intrinsic viscosity of the
polyester is 0.30 to 0.70.
[0019]
The high-viscosity polyester as the core component
used in the polyester multifilament of the present
invention preferably has an intrinsic viscosity in the
range of 0.70 to 1.50. An intrinsic viscosity of 0.70 or
more enables production of a polyester multifilament
combining sufficient strength and elongation. A more
preferable intrinsic viscosity is 0.80 or more. The upper
limit of the intrinsic viscosity is preferably 1.50 or less
from the viewpoint of ease of molding such as melt
extrusion. In consideration of the production cost, the
reduction in molecular weight due to molecular chain
scission caused by heat or shear force in the production
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process, and the melt flow stability, the upper limit of
the intrinsic viscosity is more preferably 1.20 or less.
[0020]
Meanwhile, an intrinsic viscosity of the low-
viscosity polyester as the sheath component of 0.40 or more
provides stable yarn-making properties. A more preferable
intrinsic viscosity is 0.50 or more. Further, in order to
obtain satisfactory wear resistance, the intrinsic
viscosity is preferably 0.70 or less.
[0021]
The polyester used in the polyester multifilament of
the present invention may be a polyester containing
polyethylene terephthalate (hereinafter referred to as PET)
as a main component.
[0022]
PET used in the present invention may be a polyester
containing terephthalic acid as a main acid component and
ethylene glycol as a main glycol component, and containing
90 mol% or more of ethylene terephthalate repeating units.
PET may, however, contain other copolymer components
capable of forming an ester bond in a proportion of less
than 10 mon-. Examples of such copolymer components
include, as an acid component, bifunctional aromatic
carboxylic acids such as isophthalic acid, phthalic acid,
dibromoterephthalic acid, naphthalene dicarboxylic acid,
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and o-ethoxybenzoic acid, bifunctional aliphatic carboxylic
acids such as sebacic acid, oxalic acid, adipic acid, and
dimer acid, and dicarboxylic acids such as
cyclohexanedicarboxylic acid, and as a glycol component,
ethylene glycol, diethylene glycol, propanediol,
butanediol, neopentyl glycol, bisphenol A, cyclohexane
dimethanol, and polyoxyalkylene glycols such as
polyethylene glycol and polypropylene glycol, but the
copolymer components are not limited thereto.
[0023]
In addition, PET may contain, as additives, titanium
dioxide as a matting agent, silica or alumina fine
particles as a lubricant, a hindered phenol derivative as
an antioxidant, and further, a flame retardant, an
antistatic agent, an ultraviolet absorber, a coloring
pigment, and the like as required.
[0024]
PET in the core component is mainly responsible for
the strength of the polyester multifilament. Therefore,
the amount of an inorganic particle additive usually added
to a polyester fiber, which is typified by titanium oxide,
is preferably 0.5 wt% or less. Meanwhile, PET in the
sheath component is mainly responsible for the wear
resistance of the polyester multifilament. Therefore, it
is preferable to add inorganic particles typified by
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titanium oxide in an amount of about 0.1 wt% to 0.5 wt% to
the sheath component.
[0025]
Next, the cross-sectional shape of the polyester
multifilament of the present invention will be described.
[0026]
As described above, the polyester multifilament of
the present invention is a core-in-sheath composite
polyester multifilament in which, in a cross section of a
single yarn, the core component and the sheath component
are arranged such that the core component is covered with
the sheath component and the core component is not exposed
to the surface of the polyester multifilament. Here, in
the "core-in-sheath" composite polyester multifilament, it
is only required that the core component be completely
covered with the sheath component, and it is not
necessarily required that the core component and the sheath
component be concentrically arranged. The polyester
multifilament may have any of number of cross-sectional
shapes, such as round, flat, triangular, square, and
pentagonal cross-sectional shapes. In view of ease of
achieving stable yarn-making properties and high-order
processability as well as densification of a woven fabric,
a round cross-sectional shape is preferable.
[0027]
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In the present invention, since both the core
component and the sheath component contain a polyester, a
phenomenon of delamination at a composite interface, which
frequently occurs in polyester/nylon composite yarns, is
unlikely to occur. However, in view of achieving both an
effect of improving the wear resistance exerted by the
sheath component and increase of the strength by the core
component, the composite ratio of core component : sheath
component is preferably in the range of 60 : 40 to 95 : 5,
and is more preferably in the range of 70 : 30 to 90 : 10.
[0028]
Here, the "composite ratio" defined in the present
invention refers to, in a cross-sectional photograph of a
single yarn of the polyester multifilament, a cross-
sectional area ratio between two types of polyesters
constituting the single yarn.
[0029]
The polyester multifilament of the present invention
is required to have a total fineness of 4 to 30 dtex. A
total fineness of 4 dtex or more enables stable yarn making
and weaving, whereas a total fineness of 30 dtex or less
may provide a desired high-density thin woven fabric. A
preferable range of the total fineness is 8 to 25 dtex.
[0030]
The polyester multifilament of the present invention
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is required to have a single-yarn fineness of 1.0 to 5.0
dtex. If the single-yarn fineness is less than 1.0 dtex,
it is difficult to form a desired core-in-sheath cross
section, and sheath breakage tends to occur or the sheath
component tends to have a small thickness so that the
polyester multifilament may have insufficient wear
resistance. Moreover, the process passability such as
yarn-making properties and weaving properties also tends to
deteriorate. A single-yarn fineness of 5.0 dtex or less
may facilitate interlacing and improve convergence, and may
provide an effect of improving process passability and
weaving properties. Moreover, the obtained woven fabric
has a satisfactory texture without being too hard while
maintaining denseness. A preferable range of the single-
yarn fineness is 1.5 to 3.0 dtex. In order to achieve a
single-yarn fineness in the above-mentioned range, in the
method for producing a polyester multifilament, the
discharge amount and the spinneret are required to be
appropriately changed.
[0031]
Further, the polyester multifilament of the present
invention is required to have a number of filaments of 3 to
15. A number of filaments of 3 or more may facilitate
interlacing. Moreover, since an increased number of
filaments can distribute the contact with a reed or a guide
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during the weaving among single yarns, the load of friction
applied to a single yarn can be reduced, and the wear
resistance of the original yarn and the durability of the
woven fabric are greatly improved. The upper limit of the
number of filaments depends on the total fineness and
single-yarn fineness, but is 15 or less.
[0032]
The polyester multifilament of the present invention
is required to have improved convergence in order to
achieve excellent weaving properties and woven fabric
quality. If the convergence is insufficient, filament
breakage (separation into single yarns) may occur, the
working of the warp during the weaving may be deteriorated,
and the warp breakage may easily occur. Also in respect of
the woven fabric quality, filament breakage may cause
streak-like woven fabric defects.
[0033]
The polyester multifilament of the present invention
is required to have a degree of interlacement of 2.0 to
15.0/m, the degree of interlacement representing the number
of interlacements per meter. If the degree of
interlacement is less than 2.0/m, weaving properties tend
to deteriorate, that is, warp breakage may occur. The
obtained woven fabric tends to have streak-like woven
fabric defects due to filament breakage, and tends to be
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poor in the woven fabric quality. A degree of
interlacement of 2.0/m or more may provide excellent
weaving properties and woven fabric quality. Meanwhile, if
the degree of interlacement is too high, the polyester
multifilament has too many constraint points, and the
above-mentioned effect of distributing the contact with a
reed or a guide during the weaving among single yarns to
reduce the load of friction applied to a single yarn may be
reduced, and therefore the wear resistance of the original
yarn and the durability of the woven fabric tend to
deteriorate. Therefore, the degree of interlacement is
required to be 15.0/m or less. Further, when the degree of
interlacement is further increased, the load in the
interlacing step increases, yarn breakage frequently
occurs, and the productivity may be reduced. A more
preferable range of the degree of interlacement is 4.0 to
10.0/m.
[0034]
The polyester multifilament of the present invention
having a breaking strength of 5.0 cN/dtex or more may have
sufficient mechanical properties even when being made into
a thin woven fabric. The breaking strength is more
preferably 6.0 cN/dtex or more. In addition, the
orientation and degree of crystallinity are required to be
suppressed from the viewpoint of wear resistance.
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Therefore, the breaking strength is 9.0 cN/dtex or less,
more preferably 8.0 cN/dtex or less.
[0035]
Further, the polyester multifilament of the present
invention having a fracture elongation of 12% or more can
suppress yarn breakage and generation of fluff during the
weaving, and is excellent in handleability. The polyester
multifilament of the present invention having a fracture
elongation of 45% or less may have a desired breaking
strength. A more preferable range of the fracture
elongation is 17 to 35%.
[0036]
Further, as for the strength at 5% elongation (5% Mo)
and the strength at 10% elongation (10% Mo) of the
polyester multifilament of the present invention, from the
viewpoint of dimensional stability of the woven fabric, the
5% Mo is preferably 3.5 cN/dtex or more, more preferably
3.8 cN/dtex or more. The 10% Mo is preferably 4.0 cN/dtex
or more, more preferably 4.5 cN/dtex or more. In addition,
for suppressing the orientation and degree of crystallinity
from the viewpoint of wear resistance, the 5% Mo is
preferably 6.0 cN/dtex or less, more preferably 5.0 cN/dtex
or less. The 10% Mo is preferably 8.0 cN/dtex or less,
more preferably 7.0 cN/dtex or less.
[0037]
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Next, a preferable method for producing the polyester
multifilament of the present invention will be described.
[0038]
A feature of the method for producing a polyester
multifilament of the present invention is that the position
at which the filaments are interlaced is after the drawing.
When the filaments are subjected to interlacing at the
stage of an undrawn yarn, it is difficult to interlace the
filaments in the ranges of the total fineness, single-yarn
fineness, and number of filaments of the multifilament of
the present invention. Therefore, interlacing the
filaments at the stage after the drawing, at which the
single-yarn fineness is reduced, can achieve a desired
degree of interlacement.
[0039]
In addition, in the method for interlacing the
filaments in the polyester multifilament of the present
invention, a known interlacing nozzle can be used. The
compressed air pressure in the interlacement is preferably
0.10 to 0.40 MPa. If the compressed air pressure is less
than 0.10 MPa, it is difficult to sufficiently interlace
the filaments, whereas if the compressed air pressure
exceeds 0.40 MPa, yarn breakage frequently occurs, and the
productivity may be reduced. The compressed air pressure
is more preferably 0.15 to 0.30 MPa.
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[0040]
The method for spinning the polyester multifilament
of the present invention is not particularly limited, and
the polyester multifilament can be spun according to a
known technique. For example, high-viscosity PET as a core
component and low-viscosity PET as a sheath component are
each melt-extruded and sent to a predetermined composite
pack using a composite spinning machine, both the polymers
are filtered in the pack and then bonded together in a
core-in-sheath form and subjected to composite spinning
with a spinneret, and a yarn discharged from the spinneret
is taken up to produce an undrawn yarn. The undrawn yarn
may be subjected to a two-step method in which the undrawn
yarn is wound up once and then drawn in a drawing machine,
or a one-step method in which the undrawn yarn is
continuously drawn without being wound up once. The two-
step method is more preferable because, in the interlacing
described later, the filaments are hardly interlaced if the
yarn speed is high.
[0041]
The method for drawing the polyester multifilament of
the present invention is not particularly limited, and the
polyester multifilament can be drawn according to a known
technique. For example, the drawing method can be suitably
selected from a method of performing one-stage hot drawing
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between a first hot roll and a second hot roll, a method of
performing one-stage hot drawing with a first hot roll, an
unheated roll, and a hot plate between the rolls, a method
of performing the first stage hot drawing between a first
hot roll and a second hot roll and performing the second
stage hot drawing between the second hot roll and a third
hot roll, and the like. In particular, in order to achieve
high strength, it is required to draw an undrawn yarn at a
high draw ratio. When an undrawn yarn is drawn in one-
stage drawing, however, high drawing tension is applied, so
that problems such as increased yarn unevenness and
frequent yarn breakage may occur. Therefore, it is
preferable to draw an undrawn yarn in two or more stages.
[0042]
Further, as for the drawing temperature of the
polyester multifilament of the present invention, in the
case of one-stage drawing, it is preferable that the first
hot roll usually have a temperature of (glass transition
temperature of the high-viscosity PET as the core
component) + 10 to 30 C, and the second hot roll or the hot
plate have a temperature in the range of 130 to 230 C. A
temperature of the second hot roll or the hot plate of
130 C or more controls the orientation, promotes the
crystallization of the fiber, and increases the strength.
Meanwhile, a temperature of the second hot roll or the hot
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plate of 230 C or less prevents fusion at the hot roll or
the hot plate, and provides satisfactory yarn-making
properties. In the case of multi-stage drawing, it is
preferable that the first hot roll have a temperature of
(glass transition temperature of the high-viscosity PET as
the core component) + 10 to 30 C, the second and subsequent
hot rolls have gradually increased temperatures, and the
last hot roll have a temperature in the range of 100 to
230 C.
[0043]
Further, the polyester multifilament of the present
invention is preferably drawn at a draw ratio of 3.0 to 7.0
in total. The draw ratio is more preferably 3.5 to 6.0,
still more preferably 3.8 to 5Ø
EXAMPLES
[0044]
Hereinafter, the polyester multifilament of the
present invention will be specifically described with
reference to examples. The measured values in the examples
were measured by the following methods.
[0045]
(1) Intrinsic viscosity (IV)
The relative viscosity lir defined by 11/110 was
determined according to the following mathematical formula
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at a temperature of 25 C using an Ostwald viscometer by
dissolving 0.8 g of a sample polymer in 10 mL of o-
chlorophenol (hereinafter abbreviated as "OCP") having a
purity of 98% or more at a temperature of 25 C to prepare a
polymer solution. The intrinsic viscosity (IV) was
calculated from lir according to the following mathematical
formula.
lir = 11/110 = (t x d)/(to x do)
Intrinsic viscosity (IV) = 0.0242nr + 0.2634
In the formula, ri is the viscosity of the polymer
solution, no is the viscosity of OCP, t is the dropping
time of the solution (sec), d is the density of the
solution (g/cm3), to is the dropping time of OCP (sec), and
do is the density of OCP (g/cm3).
[0046]
(2) Total fineness (dtex)
A yarn was wound up into a 500-m skein, and a value
obtained by multiplying the mass (g) of the skein by 20 was
defined as the fineness.
[0047]
(3) Breaking strength (cN/dtex), fracture elongation
(%), and strength (modulus) at 5% elongation (cN/dtex) and
strength (modulus) at 10% elongation (cN/dtex)
The breaking strength, fracture elongation, and
strength at 5% elongation and strength at 10% elongation
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were measured according to JIS L1013 (1999) using TENSILON
UCT-100 manufactured by ORIENTEC CORPORATION.
[0048]
(4) Degree of interlacement (number/m)
A yarn was floated on water, and the number of
convergence points per meter was counted as the degree of
interlacement. The number was counted 10 times, and the
average of the counted numbers was calculated.
[0049]
(5) Wear resistance of original yarn
A yarn was subjected to a yarn tension of 0.9 g/dtex,
a flat part of a reed (material: SK material, 7 mm in width
x 50 mm in length x 50 pm in thickness) was pressed against
the yarn at a contact angle of 20 , and the yarn was
subjected to a reciprocating motion at a stroke length of
30 mm and a speed of 670 times/min for 10 minutes. The
treated yarn was magnified and observed with a microscope.
The wear resistance of the original yarn was evaluated as
"A" when no fluff or fibrillation (surface fraying) was
observed, and was evaluated as "C" when fluff or
fibrillation was observed.
[0050]
(6) Evaluation of weaving properties and weaving
quality
A fabric was woven so that the fabric may have a
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basis weight in the range of 30 to 35 g/m2 by adjusting the
basis weight using a water jet loom according to the total
fineness of the filaments used. The weaving properties
were evaluated as "S" when the number of loom stoppages per
100 m due to yarn breakage or the like was less than 3
times, "A" when the number of loom stoppages was 3 times or
more and less than 10 times, and "C" when the number of
loom stoppages was 10 times or more. The weaving quality
was evaluated by counting the total number of defects such
as fluff and filament breakage. The weaving quality was
evaluated as "S" when the total number of defects was less
than 3 per 100 m, "A" when the total number of defects was
3 or more and less than 10, and "C" when the total number
of defects was 10 or more.
[0051]
(7) Wear resistance of fabric
The wear resistance of the fabric was measured
according to JIS L1096 (2010), method E (Martindale
method). The test was performed under the conditions of a
polyester standard friction cloth and a pressing load of 9
kPa. The judgment was made according to the number of
friction cycles before the generation of fluff. The wear
resistance of the fabric was evaluated as "A" when the
number of friction cycles was 5,000 times or more, "B" when
the number of friction cycles was 3,000 times or more and
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less than 5,000 times, and "C" when the number of friction
cycles was less than 3,000 times.
[0052]
As for the production methods in examples and
comparative examples, polyester filaments were obtained
under the production conditions shown in Tables 1 to 3
according to a known technique.
[0053]
[Example 1]
PET having an intrinsic viscosity of 0.80 as a core
component and PET having an intrinsic viscosity of 0.50 as
a sheath component were melted at a temperature of 295 C
using an extruder type extrusion machine. Then, the
polymers were metered with a pump at a polymer temperature
of 290 C so that the composite ratio might be core
component : sheath component - 80 : 20, and allowed to flow
into a known composite spinneret having five holes arranged
in a core-in-sheath structure. A yarn discharged from the
spinneret was wound up once at a spinning speed of 1,200
m/min, and then drawn with a known drawing device between a
first hot roll heated to 90 C and a second hot roll heated
to 130 C at a draw ratio of 4.2 and heat-set. The obtained
drawn yarn was interlaced with an interlacing nozzle
disposed between a final roll and a winder at an
interlacing pressure of 0.23 MPa, and then wound up at 800
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m/min. No particular problem was found in yarn-making
properties, and a polyester multifilament having a total
fineness of 12.0 dtex, a single-yarn fineness of 2.4 dtex,
a breaking strength of 6.5 cN/dtex, a fracture elongation
of 17.7%, and a degree of interlacement of 5.8/m was
obtained. The polyester multifilament had satisfactory
wear resistance of the original yarn. Other physical
properties of the original yarn were as shown in Table 1.
[0054]
Using the polyester multifilament, a fabric was woven
with a water jet loom so that the fabric might have a basis
weight of 30 g/m2. No yarn breakage occurred during 100 m
of weaving, and the polyester multifilament had very
satisfactory weaving properties. The obtained fabric was
free from defects such as fluff, and had a very
satisfactory weaving quality. In addition, the wear
resistance of the fabric was satisfactory, and no fluff was
generated even after a number of friction cycles of 6,000
times.
[0055]
[Examples 2 and 3]
A polyester multifilament was obtained in the same
manner as in Example 1 except that the draw ratio was
changed to 3.9 and 3.6, respectively. The original yarn of
the obtained polyester multifilament had physical
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properties as shown in Table 1. In each of Examples 2 and
3, no yarn breakage occurred during 100 m of weaving, and
the polyester multifilament had very satisfactory weaving
properties. The obtained fabric was free from defects such
as fluff, and had a very satisfactory weaving quality. In
addition, the wear resistance of the fabric was
satisfactory, and no fluff was generated even after a
number of friction cycles of 6,000 times.
[0056]
[Examples 4 and 5] and [Comparative Examples 1 and 2]
A polyester multifilament was obtained in the same
manner as in Example 1 except that the interlacing pressure
was changed in the range of 0.08 to 0.42 MPa. The original
yarn of the obtained polyester multifilament had physical
properties as shown in Table 1. In Example 4, the degree
of interlacement was 9.9/m, and satisfactory results were
obtained as in Example 1 as for the wear resistance of the
original yarn, weaving properties, weaving quality, and
wear resistance of the fabric. In Example 5, the degree of
interlacement was 4.2/m, and the polyester multifilament
had slightly lower convergence than that of Example 1.
Therefore, 3 times of yarn breakage occurred during 100 m
of weaving, but the polyester multifilament had
satisfactory weaving properties. Although no fluff was
observed in the obtained fabric, defects of filament
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breakage were observed, and the fabric was slightly
inferior to that of Example 1. In Comparative Example 1,
the interlacing pressure was high, the yarn swayed largely
at an interlacing position, and yarn breakage occurred.
The degree of interlacement was as high as 15.3/m. The
wear resistance of the original yarn was lower than that in
Example 1, and the polyester multifilament easily generated
fluff. During the weaving, 6 times of yarn breakage
occurred. The weaving quality was lower than that in
Example 1 and fluff was observed. As for the wear
resistance of the fabric, fluff was generated even after a
number of friction cycles of 3,500 times. In Comparative
Example 2, the interlacing pressure was low. The degree of
interlacement was 1.7/m, and the filaments were
insufficiently interlaced. During the weaving, warp
breakage frequently occurred, and loom stoppages occurred
every few meters. As for the weaving quality, filament
breakage frequently occurred, and many streak-like defects
were observed.
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[0057]
[Table 1]
Example 1 Example 2 Example 3 Example 4
Example 5 Comparative Comparative
Example 1 Example 2
High-viscosity
component (core Intrinsic viscosity 0.80 0.80 0.80 0.80
0.80 0.80 0.80
component)
Low-viscosity
component (sheath Intrinsic viscosity 0.50 0.50 0.50 0.50
0.50 0.50 0.50
component)
Difference in Core component -
= 0.30 0.30 0.30 0.30 0.30 0.30
0.30
intrinsic viscosity sheath component
Core component :
Composite ratio 80 : 20 80 : 20 80 : 20 80 : 20 80 : 20
80 : 20 80 : 20
sheath component
Two-step Two-step Two-step Two-step Two-step
Two-step Two-step
Production method
method method method method method method
method
Spinning speed [m/min] 1200 1200 1200 1200 1200 1200
1200
Draw ratio [times] 4.2 3.9 3.6 4.2 4.2 4.2 4.2
Interlacing position After
drawingAfter drawingAfter drawingAfter drawingAfter drawingAfter drawingAfter
drawing
Single-yarn fineness at interlacing
2.4 2.4 2.4 2.4 2.4 2.4 2.4
position Mem)
Compressed air pressure in interlacement
[mPa] 0.23 0.23 0.23 0.30 0.15 0.42
0.08
Total fineness [dtex] 12.0 12.0 12.0 12.0 12.0 12.0
12.0
Single-yarn fineness [dtex] 2.4 2.4 2.4 2.4 2.4 2.4 2.4
Number of filaments 5 5 5 5 5 5
Breaking strength [cN/dtex] 6.5 6.0 5.5 6.4 6.4 6.4 6.5
Fracture elongation [9] 17.7 24.6 31.7 17.2 17.2 17.2
17.3
Strength at 5% elongation [cN/dtex] 5.0 4.3 3.6 5.0 5.0 5.0
5.0
Strength at 10% elongation [cN/dtexl 5.9 5.4 4.2 5.9 5.9 5.9
5.9
Degree of interlacement [number/ml 5.8 5.9 5.8 9.9 4.2 15.3
1.7
Wear resistance of original yarn A A a A A C A
Weaving properties 0 0 0 0 A A
Weaving quality 0 0 0 0 A A
Wear resistance of fabric A A A A A B A
[0058]
[Comparative Example 3]
A polyester multifilament was obtained in the same
manner as in Example 1 except that the interlacing position
was changed to before winding of the spun yarn. The
physical properties of the original yarn of the obtained
polyester multifilament were as shown in Table 2. The
degree of interlacement was 0.8/m, and the filaments were
insufficiently interlaced. During the weaving, warp
breakage frequently occurred, and loom stoppages occurred
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every few meters. As for the weaving quality, filament
breakage frequently occurred, and many streak-like defects
were observed.
[0059]
[Examples 6 to 8] and [Comparative Examples 4 and 5]
A polyester multifilament was obtained in the same
manner as in Example 2 except that the discharge amount and
the number of holes of the spinneret were adjusted to
change the total fineness, single-yarn fineness, and number
of filaments. The physical properties of the original yarn
of the obtained polyester multifilament were as shown in
Table 2. In Examples 6 to 8, the physical properties of
the original yarn, weaving properties, weaving quality, and
wear resistance of the fabric were comparable to those in
Example 2. In Comparative Example 4, since the single-yarn
fineness was as large as 5.6 dtex, the degree of
interlacement was 1.2/m, and the filaments were
insufficiently interlaced. During the weaving, warp
breakage frequently occurred, and loom stoppages occurred
every few meters. As for the weaving quality, filament
breakage frequently occurred, and many streak-like defects
were observed. Moreover, the obtained fabric had a rough
texture. In Comparative Example 5, single yarn breakage
frequently occurred during spinning, and single yarn
wrapping frequently occurred during drawing. The obtained
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polyester multifilament had a single-yarn fineness as small
as 0.8 dtex, and thus the degree of interlacement was as
high as 18.8/m. The polyester multifilament after the wear
test of the original yarn had a large amount of fluff, and
had poor wear resistance. In addition, when the obtained
polyester multifilament was subjected to weaving, warp
breakage frequently occurred and no fabric was woven.
[0060]
[Comparative Example 6]
A polyester monofilament was obtained in the same
manner as in Example 1 except that the number of holes of
the spinneret was changed to one to change the discharge
amount, and that no interlacing nozzle was used. The
physical properties of the original yarn of the obtained
polyester monofilament were as shown in Table 2. The
obtained polyester monofilament frequently caused both warp
breakage and weft breakage in a water jet loom, and no
fabric was woven.
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[0061]
[Table 2]
Comparative Example 6 Example 7 Example 8
Comparative Comparative Comparative
Example 3 Example 4 Example 5
Example 6
High-viscosity
component (core Intrinsic viscosity 0.80 0.80 0.80 0.80
0.80 0.80 0.80
component)
Low-viscosity
component (sheath Intrinsic viscosity 0.50 0.50 0.50 0.50
0.50 0.50 0.50
component)
Difference in Core component -
0.30 0.30 0.30 0.30 0.30 0.30 0.30
intrinsic viscosity sheath component
Core component :
Composite ratio 80:20 80 : 20 80 : 20 80 : 20 80 : 20
80 : 20 80 : 20
sheath component
Two-step Two-step Two-step Two-step Two-step
Two-step Two-step
Production method
method method method method method method
method
Spinning speed [m/min] 1200 1200 1200 1200 1200 1200
1200
Draw ratio [times] 4.2 3.9 3.9 3.9 3.9 3.9 4.2
Interlacing position Spun yarn After drawingAfter drawingAfter drawingAfter
drawingAfter drawing
Single-yarn fineness at interlacing
10.1 2.2 1.9 1.6 5.6 0.8
position (dtexl
Compressed air pressure in interlacement
[era] 0.23 0.23 0.23 0.23 0.23 0.23
Total fineness [dtex] 12.0 21.7 28.1 8.2 28.2 12.0 9.8
Single-yarn fineness [dtex] 2.4 2.2 1.9 1.6 5.6 0.8 9.8
Number of filaments 5 10 15 5 5 15 1
Breaking strength [cN/dtex] 6.2 6.1 6.0 6.4 5.8 6.1 6.3
Fracture elongation [6] 16.7 23.2 23.5 21.3 26.4 19.8
21.2
Strength at 5% elongation [cN/dtex] 4.9 4.2 4.2 4.4 4.0 4.6
3.9
Strength at 10% elongation [cN/dtex] 5.8 5.4 5.3 5.5 5.0 5.8
5.5
Degree of interlacement [number/ml 0.8 6.3 6.4 6.9 1.2 18.8
Wear resistance of original yarn A A a A A C A
Weaving properties C 0 0 0 C C C
Weaving quality C 0 0 0 C
Wear resistance of fabric A A A A B
[0062]
[Example 9]
Spinning was performed in the same manner as in
Example 1 except that PET having an intrinsic viscosity of
1.00 was used as a core component and that the spinning
speed was adjusted to 600 m/min. The yarn was wound up
once, and then drawn in the same manner as in Example 1
except that the yarn was subjected to two-stage drawing
with a known drawing device between first and second hot
rolls heated to 90 C and between the second hot roll and a
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third hot roll heated to 200 C at a draw ratio of 4.5 and
heat-set, whereby a polyester multifilament was obtained.
The physical properties of the original yarn of the
obtained polyester multifilament were as shown in Table 3.
During the weaving, no yarn breakage occurred over 100 m,
and the polyester multifilament had very satisfactory
weaving properties. The obtained fabric was free from
defects such as fluff, and had a very satisfactory weaving
quality. In addition, the wear resistance of the fabric
was satisfactory, and no fluff was generated even after a
number of friction cycles of 6,000 times.
[0063]
[Example 10]
A polyester multifilament was obtained in the same
manner as in Example 9 except that PET having an intrinsic
viscosity of 1.25 was used as a core component and that the
spinning speed and the draw ratio were adjusted to 500
m/min and 5.8, respectively. The physical properties of
the original yarn of the obtained polyester multifilament
were as shown in Table 3. As for the wear resistance of
the original yarn, no fluff or fibrillation was observed,
but 8 times of warp breakage occurred during 100 m of
weaving. The quality of the obtained fabric was lower than
in Example 1 and fluff was observed. The wear resistance
of the fabric was lower than in Example 1, and fluff was
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generated after a number of friction cycles of 4,500 times.
[0064]
[Comparative Example 7]
PET having an intrinsic viscosity of 0.80 was used as
a single component, and melted at a temperature of 295 C
using an extruder type extrusion machine. Then, the
polymer was allowed to flow into a known single-component
spinneret having five holes at a polymer temperature of
290 C. A yarn discharged from the spinneret was wound up
once at a spinning speed of 800 m/min, and then drawn with
a known drawing device between a first hot roll heated to
90 C and a second hot roll heated to 130 C at a draw ratio
of 4.3 and heat-set. The obtained drawn yarn was
interlaced with an interlacing nozzle disposed between a
final roll and a winder at an interlacing pressure of 0.23
MPa, and then wound up at 800 m/min. The physical
properties of the original yarn of the obtained polyester
multifilament were as shown in Table 3. The wear
resistance of the original yarn was lower than that in
Example 1, and the polyester multifilament easily generated
fluff. No yarn breakage occurred during 100 m of weaving,
and the polyester multifilament had very satisfactory
weaving properties. However, fluff was observed in the
obtained fabric, and the fabric was inferior to that of
Example 1. In addition, the wear resistance of the fabric
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was greatly lower than in Example 1, and generation of
fluff was observed after a number of friction cycles of 500
times.
[0065]
[Example 11]
PET having an intrinsic viscosity of 0.80 as a core
component and PET having an intrinsic viscosity of 0.50 as
a sheath component were used, and subjected to spinning and
drawing in a known direct spinning-drawing device. The
polymers were melted at a temperature of 295 C using an
extruder type extrusion machine. Then, the polymers were
metered with a pump at a polymer temperature of 290 C so
that the composite ratio might be core component : sheath
component = 80 : 20, and allowed to flow into a known
composite spinneret having five holes arranged in a core-
in-sheath structure. A yarn discharged from the spinneret
was taken up at a spinning speed of 1,300 m/min, and then
drawn at a draw ratio of 3.8 without being wound up once
and heat-set. The obtained drawn yarn was interlaced with
an interlacing nozzle disposed between a final roll and a
winder at an interlacing pressure of 0.23 MPa, and then
wound up at 5,000 m/min. The yarn-making properties were
inferior to those in the two-step method as in Example 1,
and yarn breakage was observed at the interlaced portion.
The physical properties of the original yarn of the
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obtained polyester multifilament were as shown in Table 3.
The single-yarn fineness at the interlacing position after
the drawing was 2.4 dtex, which was comparable to that of
Example 1. However, the speed of the yarn passing through
the interlacing nozzle was as high as 5,000 m/min, so that
the degree of interlacement was as small as 2.8/m. Since
the degree of interlacement was inferior to that of Example
1, the polyester multifilament had poor convergence, and 7
times of yarn breakage occurred during 100 m of weaving.
Although no fluff was observed in the obtained fabric,
defects of filament breakage were observed, and the fabric
was slightly inferior to that of Example 1.
[0066]
[Comparative Example 8]
A polyester multifilament was obtained in the same
manner as in Example 11 except that the interlacing
position was changed to before taking up of the spun yarn.
The physical properties of the original yarn of the
obtained polyester multifilament were as shown in Table 3.
The degree of interlacement was 0.7/m, and the filaments
were insufficiently interlaced. During the weaving, warp
breakage frequently occurred, and loom stoppages occurred
every few meters. As for the weaving quality, filament
breakage frequently occurred, and many streak-like defects
were observed.
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[0067]
[Table 3]
Comparative Comparative
Example 9 Example 10 Example 11
Example 7 Example 8
High-viscosity
component (core Intrinsic viscosity 1.00 1.25 0.80 0.80 .. 0.80
component)
Low-viscosity
component (sheath Intrinsic viscosity 0.50 0.50 0.50
0.50
component)
Difference in Core component -
0.50 0.75 0.30 0.30
intrinsic viscosity sheath component
Core component :
Composite ratio 80 : 20 80 : 20 100 : 0 80 : 20
80 : 20
sheath component
Production method Two-step Two-step Two-step One-step
One-step
method method method method method
Spinning speed [m/min] 600 500 800 1300 1300
Draw ratio [times] 4.5 5.8 4.3 3.8 3.8
Interlacing position After drawing After drawing After
drawing After drawing Spun yarn
Single-yarn fineness at interlacing
2.4 2.4 2.4 2.4 9.1
position [dtex]
Compressed air pressure in interlacement
0.23 0.23 0.23 0.23 0.23
[MPa]
Total fineness [dtex] 12.0 12.0 12.0 12.0 12.0
Single-yarn fineness [dtex] 2.4 2.4 2.4 2.4 2.4
Number of filaments 5 5 5 5 5
Breaking strength [cN/dtex] 7.4 8.5 5.6 6.1 6.0
Fracture elongation [%] 18.6 13.6 33.2 20.6 19.8
Strength at 5% elongation [cN/dtex] 4.8 5.7 3.2 3.9 3.9
Strength at 10% elongation [cN/dtex] 6.6 8.0 4.0 5.5 5.5
Degree of interlacement [number/m[ 5.3 5.1 5.5 2.8 0.7
Wear resistance of original yarn A A C A A
Weaving properties S A S A C
Weaving quality S A A A C
Wear resistance of fabric A B C A A
37
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