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Amorphous heat-fusible fiber, fiber structure, and heat-resistant molded article

a technology of amorphous heat-fusible fibers and molded articles, which is applied in the direction of monocomponent polyester artificial filaments, synthetic polymer artificial filaments, textiles and paper, etc., can solve the problems of large dry heat shrinkage percentage, extreme deterioration of processability in post-processing, and insufficient oriented pes-type polymers in the core part, etc., to achieve heat-resisting properties, fire retardancy, and dimensional stability

Inactive Publication Date: 2013-05-16
KURARAY CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides an amorphous heat-fusible fiber that has excellent heat-resisting property, fire retardancy, and dimensional stability. The fiber is made by mixing an amorphous PES type polymer and an amorphous PEI type polymer at a specific ratio, resulting in a uniform compatibilized state. The amorphous heat-fusible fiber can be used in various applications such as fiber structure, paper, nonwoven fabric, textile, and knitting. The fiber has a single glass transition temperature, making it compatible with other polymers and easy to manufacture. The amorphous heat-fusible fiber can be obtained by an ordinary fiber manufacturing process without special process. The invention also provides a heat-resistant molded article made from the amorphous heat-fusible fiber.

Problems solved by technology

However, when the drawing temperature is set above the glass transition temperature of the amorphous PES type polymer in a sheath part, agglutination will arise between fibers resulting in extreme deterioration of processability in the post processes such as card process.
Therefore, the crystalline PES type polymer in a core part cannot be sufficiently oriented and crystallized at the drawing process and / or heat treatment process.
Such a fiber inherently has strain caused by drawing, resulting in larger dry heat shrinkage percentage.
As a result, such fiber products have troubles such as poor thermal dimensional stability.
Moreover, since the sheath core composite fiber described in Patent Document 2 comprises the special component as a copolymerizable component, such a fiber has problems of increased manufacture cost etc.
Furthermore, such a fiber having a form of sheath core composite type can increase neither drawing temperature nor heat treatment temperature, resulting in failing to solve the problem of thermal dimensional stability.
In such a case, considering that the obtained article cannot have the stabilized quality and has seriously declined mechanical properties such as elasticity around the glass transition temperature of polymer, the sheath core composite type heat-fusible fiber cannot be substantially used in these applications because the heat resistance of the molded article is consequently governed by the nature of the amorphous PES type polymer.
Such a fiber is unsuitable for use to a thermoplastic composite as described above, and is not used in the practical application.
In addition, non-compatible two polymer species existing at random in the fiber render the fiber having trouble for securing the quality.

Method used

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  • Amorphous heat-fusible fiber, fiber structure, and heat-resistant molded article
  • Amorphous heat-fusible fiber, fiber structure, and heat-resistant molded article
  • Amorphous heat-fusible fiber, fiber structure, and heat-resistant molded article

Examples

Experimental program
Comparison scheme
Effect test

reference example 1

[0075](1) By using a polymerization reaction equipment, polycondensation reaction was carried out at 280° C. in an ordinary method to produce an amorphous PES type polymer comprising terephthalic acid (hereinafter may be abbreviated as TA) and isophthalic acid (hereinafter may be abbreviated as IPA) in the copolymerization ratio (mole %) of 57 / 43, ethylene glycol (hereinafter may be abbreviated as EG) at 98 mol %, and diethylene glycol (hereinafter may be abbreviated as DEG) at 2 mol %; and having an intrinsic viscosity (η) of 0.69. The produced polymer was extruded from the bottom of the polymerization reaction equipment into water in the shape of strand to be cut into a pellet. The endothermic peak was not observed by DSC measurement in the obtained PES type polymer so as to determined as amorphous.

[0076](2) The amorphous PES type polymer obtained above was supplied to a vent type coaxial twin-screw extruder with screws rotatable in the same direction heated at 270° C. After two m...

example 1

[0078](1) The amorphous PES type polymer chips obtained in the above Reference Example 1 and an amorphous PEI-type polymer chips (“ULTEM 1040” produced by SABIC Innovative Plastics Holding, glass-transition temperature: 215° C.) were blended in the mixture ratio (weight ratio) of 50 / 50, and the mixture was supplied to the vent type coaxial twin-screw extruder heated at 300° C. After two minutes detention period, the heated polymer was guided to a spinning head heated at 325° C., and discharged from a spinning nozzle having round holes at a discharge rate of 28 g / min. The discharged polymer was wound at a spinning rate of 1,000 m / min. to obtain multi filaments (280 dtex / 50 f) consisting of the amorphous PES type polymer. The performance evaluation result of the obtained fiber is shown in Table 1.

[0079](2) The appearance of the obtained fiber was good and no fluff was observed. The fiber was amorphous and had a single glass transition temperature of 124° C., a dry heat shrinkage perce...

examples 2 to 5

[0080](1) Except for changing the mixture ratio of amorphous PES type polymer and the amorphous PEI-type polymer in Example 1 into the ratios recited in Table 1, fibers were obtained in the same spinning method as Example 1. The performance evaluation result of the obtained fiber is shown in Table 1.

[0081](2) The appearances of the obtained fibers were good and no fluff was observed. The fibers were amorphous in any of the mixture ratio of Examples 2 to 5 and had a single glass transition temperature and a dry heat shrinkage percentage at a temperature of (glass transition temperature −10) ° C. of 3% or less. Further, the higher mixture ratios of the amorphous PEI-type polymer were, the higher glass transition temperature and LOI value were. The obtained fibers shows excellent fire retardancy and heat-resisting property.

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Abstract

Provided are a heat-fusible fiber having excellent heat resistance, flame retardancy and dimensional stability; a fiber structure comprising the heat-fusible fiber; and a molded article produced by applying a heat fusion treatment to the fiber structure and having excellent heat resistance. The heat-fusible fiber comprises an amorphous PES type polymer (A) not substantially having a melting point and an amorphous PEI type polymer (B) in the mixture ratio (weight) of (A) / (B)=5 / 95 to 95 / 5, the fiber having a single glass transition temperature in the range between 80° C. and 200° C., and being amorphous. The fiber structure comprises 10% by weight or higher of the amorphous heat-fusible fiber. The molded article comprises at least a fiber structure comprising 10% by weight or higher of the amorphous heat-fusible fiber, to be fusion-bonded at a temperature higher than the glass transition temperature of the amorphous heat-fusible fiber.

Description

CROSS REFERENCE TO THE RELATED APPLICATIONS[0001]This application is based on and claims Convention priority to Japanese application No. 2010-170350, filed Jul. 29, 2010, the entire disclosure of which is herein incorporated by reference as a part of this application.FIELD OF THE INVENTION[0002]The present invention relates to an amorphous heat-fusible fiber having an outstanding heat resistance, fire retardancy, and dimensional stability; a fiber structure containing the fiber; and a heat-resistant molded article formed by fusion-bonding the fiber structure. In particular, the present invention relates to an amorphous heat-fusible fiber being extremely effective to a use frequently exposed to high temperature environment in general industrial material fields, electric and electronic fields, agricultural material fields, optical material fields, aircraft, automobile, and vessel material fields, apparel fields, etc; a fiber structure containing the fiber; and a heat-resistant molded ...

Claims

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Application Information

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IPC IPC(8): C08L79/08C08L67/02
CPCB29C43/003D01F6/92D04H1/55C08L67/02C08L79/08D01F6/94D01F6/74D01F6/84D04H1/541D10B2331/04D10B2331/14D10B2401/04
Inventor ENDO, RYOKEIWASHITAKE, YOSUKEARAMAKI, JUN
Owner KURARAY CO LTD