Heteroformic parallel composite cross-section fiber and manufacturing method of heteroformic cross-section fiber and cloth using the same

Abstract

A profiled side-by-side composite cross-section fiber is composed of two polymers having different glass transition temperatures, and the cross-section shape of the polymer components is profiled, and the ratio of the polymer distance X connecting the centers of the smallest containing circles of the profiled cross-section of each polymer component to the distance Y of the joint surface of the cross-section, i.e., X / Y, is 1.1 or more. The polymer components are preferably a polyamide polymer and a copolymer polyester polymer, and the cross-section shape preferably has two or more protruding shapes. Also included are a method for manufacturing profiled cross-section fibers using the profiled side-by-side composite cross-section fiber, and a method for manufacturing a cloth having both a delicate cashmere effect and wear resistance.

Description

Technical Field

[0001] This invention relates to a non-circular cross-section fiber with excellent process passability, and a method for using it to manufacture non-circular cross-section fibers and fabrics with good texture and unique appearance. Background Technology

[0002] Extensive technological development has been carried out on parallel composite cross-section fibers (hereinafter, sometimes referred to as "composite fibers"), which are also widely used in industry.

[0003] Among them, composite fibers composed of polyester polymers and polyamide polymers have been developed in various forms due to the easy availability of the polymers. For example, copolyesters containing sulfoisophthalic acid, which are polyester polymers, are known to be a good combination with excellent cross-sectional forming properties because their sulfonate groups and amide groups of polyamide polymers exhibit good electrostatic adhesion. Furthermore, various cross-sectional shapes, such as island-type cross-sections, parallel-type composite cross-sections, and π-type split-fiber composite cross-sections, have been proposed.

[0004] For example, Patent Document 1 discloses a moisture-sensitive shrinkage composite fiber, which is a fiber formed by bonding a copolymer of polyethylene terephthalate with sulfonate groups to a polyamide containing polyalkylene glycol in a side-by-side configuration. This fiber exhibits potential shrinkage characteristics where the shrinkage rate can reversibly change with humidity. However, these composite fibers utilize a technique that directly bonds the two components, and the bonded surface is long, without any consideration for subsequent splitting.

[0005] On the other hand, as a technique for splitting composite fibers after spinning, for example, Patent Document 2 discloses a method for manufacturing blended yarns that are directly bonded and used while simultaneously splitting the two components through a mild alkaline aqueous solution treatment. However, Patent Document 2 relates to an invention of composite fibers of copolyester and polyamide 46 or polyamide with the copolyester as the main component. It utilizes the poor affinity between nylon 46 and copolyester as a splitting method and is based on alkaline aqueous solution treatment. However, due to the large difference in melting points between nylon 46 and copolyester, there is a problem of deteriorated yarn-making properties, and compared to conventional methods that separately fiberize the two components and produce blended yarns, the texture is not considered superior.

[0006] Furthermore, Patent Document 3 proposes a copolyester-polyamide parallel composite fiber that offers cost control, excellent yarn-making properties, and good splitting properties in subsequent processes. However, the disclosed fiber shape is a cocoon shape formed by joining two circular cross-sections, and the split fibers are also roughly circular cross-sections. Compared to fibers obtained by separately fibrillating the two components using conventional methods, it offers no advantage in terms of texture.

[0007] Furthermore, in fabrics using such fibers, particularly in sportswear, consumer demands are becoming increasingly diversified, requiring not only functionality but also novel looks and textures. However, when using known composite fibers, there is a problem that the fibers, composed of multiple components, are not fully and evenly mixed, resulting in uneven color effects and poor chambray quality.

[0008] Existing technical documents

[0009] Patent documents

[0010] Patent Document 1: Japanese Patent Application Publication No. 2003-239140

[0011] Patent Document 2: Japanese Patent Application Publication No. 63-92721

[0012] Patent Document 3: Japanese Patent Application Publication No. 2018-59253 Summary of the Invention

[0013] The purpose of this invention is to provide an irregularly shaped parallel composite cross-section fiber and a method for manufacturing irregularly shaped cross-section fibers and fabrics using the same, wherein the irregularly shaped parallel composite cross-section fiber is easy to split in subsequent processes after spinning and can become an irregularly shaped cross-section fiber with excellent texture.

[0014] To address the aforementioned issues, the following invention is provided.

[0015] 1. A non-circularly shaped composite cross-section fiber, characterized in that it is composed of two polymers with different glass transition temperatures, the cross-sectional shape of the polymer components is non-circular, wherein the ratio of the polymer spacing X connecting the centers of the smallest enclosing circles of the non-circular cross-sections of each polymer component to the joint surface distance Y of the cross-sections, i.e., X / Y, is 1.1 or more.

[0016] 2. The irregularly shaped parallel composite cross-section fiber according to 1 above, wherein the cross-sectional shape of the polymer component has two or more protrusions relative to the bonding surface of each polymer.

[0017] 3. The irregularly shaped parallel composite cross-section fiber according to 1 or 2 above, wherein the irregularly shaped parallel composite cross-section fiber is a crimped fiber.

[0018] 4. The irregularly shaped parallel composite cross-section fiber according to any one of 1 to 3 above, wherein the two polymers are composed of a polyamide polymer and a copolyester polymer.

[0019] 5. The irregularly shaped parallel composite cross-section fiber according to 4 above, wherein the polyamide polymer is nylon 6 polymer.

[0020] 6. The irregularly shaped parallel composite cross-section fiber according to 4 or 5 above, wherein the copolyester polymer is sodium sulfoisophthalate copolyester.

[0021] 7. The irregularly shaped parallel composite cross-section fiber according to any one of 1 to 6 above, wherein the irregularly shaped parallel composite cross-section fiber is a three-dimensional crimped fiber composed of two polymers, namely nylon 6 polymer and copolyester polymer, with nylon 6 polymer disposed on the inner side.

[0022] 8. The irregularly shaped parallel composite cross-section fiber according to 7 above, wherein the fiber includes a fiber in which the following phenomenon can be repeatedly observed: in a hot water bath at a temperature above 80°C, due to the self-elongation of the nylon 6 polymer inside the three-dimensional crimped coil, the three-dimensional crimped structure changes into a straight fiber shape; upon removal from the hot water bath, due to the decrease in yarn temperature and the drying of absorbed water, it returns to the three-dimensional crimped state; the elongation change rate (Equation 1) of this irregularly shaped parallel composite cross-section fiber after boiling water treatment for 30 minutes is 130-200%.

[0023] Elongation change rate:

[0024] (Length after hot water treatment - Length during drying) / Length during drying × 100 (%) Formula 1

[0025] The length measurements were all taken as the light load length of the yarn fineness (dtex) × 2 mg / dtex.

[0026] 9. According to the irregularly shaped parallel composite cross-section fiber described in 7 or 8 above, when the nylon 6 polymer inside the three-dimensional coil elongates and changes from a three-dimensional coil structure to a straight fiber shape in a hot water bath at a temperature of 80°C or above, the joint surface peels off.

[0027] 10. According to the irregularly shaped parallel composite cross-section fiber described in 7 or 8 above, wherein, in a hot water bath at a temperature of 80°C or above, the nylon 6 polymer inside the three-dimensional coil is reversed and arranged on the outside of the three-dimensional coil due to self-elongation, and the joint surface is peeled off.

[0028] 11. A method for manufacturing irregular cross-section fibers, characterized in that the joint surfaces of the irregular parallel composite cross-section fibers described in 1 above are peeled off.

[0029] 12. The method for manufacturing irregular cross-section fibers according to 11 above, wherein the peeling method is hot water shrinkage treatment.

[0030] 13. A method for manufacturing a fabric, characterized in that a sheet is made using the irregularly shaped parallel composite cross-section fibers described in 1 above, which are composed of two polymers with different glass transition temperatures and whose polymer components have irregular cross-sectional shapes, and the irregularly shaped parallel composite cross-section fibers are peeled off.

[0031] 14. The fabric manufacturing method according to 13 above, wherein the two polymers with different glass transition temperatures are polyester and polyamide.

[0032] 15. The method for manufacturing fabric according to 13 or 14 above, wherein the irregular cross-sectional shape of each polymer is the same cross-sectional shape.

[0033] 16. The method for manufacturing fabric according to any one of 13 to 15 above, wherein the fineness of each component after peeling is 2.0 dtex or less.

[0034] 17. The fabric according to any one of claims 13 to 16 above, wherein the weight per unit area of ​​the fabric is between 30 and 300 g / m². 2 Within the range.

[0035] 18. A method for manufacturing fabric according to any one of 13 to 17 above, wherein the fabric is a knitted fabric having a density of 50 to 120 rows / 2.54 cm and 40 to 100 columns / 2.54 cm.

[0036] 19. The method for manufacturing the fabric according to any one of 13 to 17 above, wherein the fabric is a woven fabric with a warp density of 50 to 300 threads / 2.54 cm and a weft density of 50 to 300 threads / 2.54 cm.

[0037] 20. A method for manufacturing a fabric according to any one of 13 to 19 above, wherein the fabric has an abrasion durability of 30,000 cycles or more as determined by the Martindale method according to JIS-L1096.

[0038] According to the present invention, a method for manufacturing irregularly shaped cross-section fibers that are easy to divide in subsequent processes after spinning and can become irregularly shaped cross-section fibers with excellent texture, as well as an irregularly shaped cross-section fiber and fabric using the same, can be provided. Attached Figure Description

[0039] Figure 1 The present invention comprises irregularly shaped, side-by-side composite cross-section fibers in which each polymer has an X-shaped protrusion.

[0040] Figure 2 The present invention comprises irregularly shaped, side-by-side composite cross-section fibers in which each polymer has three protrusions.

[0041] Figure 3 The present invention is a non-circular, parallel composite cross-section fiber in which each polymer is C-shaped and has two protrusions.

[0042] Figure 4The present invention is a non-circular, parallel composite cross-section fiber in which each polymer is rectangular and joined at the short sides.

[0043] Figure 5 The comparative example uses parallel cross-section fibers with circular cross-sections formed by bonding semicircles together.

[0044] Figure 6 The comparative example uses rhomboid-shaped parallel cross-section fibers formed by bonding triangles together.

[0045] Figure 7 This is a SEM image showing the curled state of the yarn composed of irregularly shaped parallel composite cross-section fibers from Example 1 after hot water treatment.

[0046] Figure 8 This is a SEM image showing the curled state of the yarn composed of parallel cross-section fibers with circular cross-sections from Comparative Example 1 after hot water treatment.

[0047] Figure 9 These are the knitting pattern diagrams used in Examples 6, 11, and Comparative Example 4.

[0048] Figure 10 These are the knitting pattern diagrams used in Examples 7 and 10.

[0049] Figure 11 These are the weaving patterns used in Examples 8, 9, 12, 13, 14, and Comparative Example 5. Detailed Implementation

[0050] The present invention will now be described in detail.

[0051] The irregularly shaped parallel composite cross-section fiber of the present invention (hereinafter, sometimes referred to as the "composite cross-section fiber" or "composite fiber" of the present invention) is an irregularly shaped parallel composite cross-section fiber composed of two polymers with different glass transition temperatures and whose polymer components have irregular cross-sectional shapes. Furthermore, the ratio of the polymer spacing X, where the centers of the smallest enclosing circles of the irregular cross-sections of each polymer component in the fiber cross-section are connected, to the distance Y of the joint surface of the cross-section, i.e., X / Y, must be 1.1 or higher. It should be noted that the smallest enclosing circle refers to the circle containing the smallest area of ​​the irregular cross-section. In special cases such as regular polygons, this smallest enclosing circle coincides with the circumscribed circle, but is a circle whose diameter is equal to or smaller than that of the circumscribed circle. It should be noted that although there are cross-sections for which the circumscribed circle cannot be defined, the smallest enclosing circle can still be drawn.

[0052] Furthermore, the irregularly shaped fiber of the present invention is preferably a fiber with a protruding irregular cross-section, and more preferably an irregularly shaped parallel composite cross-section fiber formed by bonding the protruding irregular cross-sections of polymers with different glass transition temperatures side by side. More preferably, it is an irregularly shaped parallel composite cross-section fiber having two or more, particularly two to four, protruding shapes in its irregular cross-section. In addition, it is also preferred to have an irregularly shaped parallel composite cross-section fiber with high shrinkage properties.

[0053] It should be noted that the term "irregular shape" in this invention refers to a non-circular shape or a shape that is not similar to a circle. For example, it refers to a shape in which the cross-section of the fiber formed from the polymer is not circular or semi-circular, or is simply a division of a circle.

[0054] In this invention, by making each polymer component a non-circular shape, preferably a non-circular shape with protrusions, the polymer spacing X connecting the centers of the smallest included circles of the irregular cross-sections of the polymer components in the fiber cross-section can be larger than that of a fiber with a circular cross-section of the same fineness. This increases the torque applied to each component during processing, resulting in a composite cross-section fiber that is easier to coil and break.

[0055] As a more specific example of a non-circular irregular cross-sectional shape, such as... Figure 1 The fiber shown is a V-shaped fiber with two polymers joined side-by-side, and the overall cross-section of the composite fiber is an X-shaped cross-section. Alternatively, it can be as follows: Figure 2 As shown, the cross-section of a polymer fiber component has three protruding shapes, or as... Figure 3 The image shows a cross-section with two protruding portions bent into shape. Furthermore, for ease of processing, the two polymer components are preferably symmetrical about the interface, particularly point-symmetrical.

[0056] In composite cross-section fibers where different types of polymers are joined in a side-by-side manner, the force acting on each polymer component is proportional to the polymer spacing between the two polymer components. In this invention, by employing a non-circular irregular cross-section with protruding shapes, the polymer spacing between the two components can be increased. For example, even with a finer fineness, the amount of torque applied to each component will increase, thereby enabling the production of irregularly shaped side-by-side composite cross-section fibers exhibiting large coils.

[0057] like Figures 1-6As shown, the polymer spacing X defined in this invention is the distance between the centers of the smallest containment circles of the protruding cross-sections of each component. Furthermore, the interface distance Y is the length of the interface distance of the cross-section that forms the boundary between the two polymers; in the case of a curve, the length along the curve of the interface is defined as the interface distance Y. Incidentally, as the interface distance Y increases, the overlap of the smallest containment circles of each component tends to increase; therefore, the greater the degree of overlap of the smallest containment circles, the smaller the polymer spacing X of this invention. For example, Figure 5 In the process, since the two polymer components are joined at the position of the diameter of the circle, the distance Y between the joining surfaces is the largest among the smallest enclosing circles of the same diameter (which are consistent with the circumscribed circle), and the smallest enclosing circles of the two polymer components are the same, the polymer spacing X is 0 (zero).

[0058] Furthermore, the polymer spacing X, which is the minimum enclosing circle connecting the centers of the irregular cross-sections, has a significant impact on the coil diameter when the composite fiber forms a coiled shape. In the case of composite fibers with a finer overall fineness, the value of the polymer spacing X inevitably becomes smaller. However, as in this invention, when using fiber cross-sectional shapes with irregular cross-sections such as protruding shapes, even with the same fineness, the polymer spacing X between the two components can be increased. In particular, in the case of fine-fine fibers, composite fibers that easily exhibit large coiled shapes can be produced.

[0059] Here, the value of the polymer spacing X is preferably 10 μm or less, and particularly preferably in the range of 1 to 8 μm.

[0060] Furthermore, the bonding distance Y defined in this invention is the length of the bonding surface between two polymers with different glass transition temperatures; if it is a curve, it is the length of the curve along the bonding surface. In this invention, a small bonding distance is preferred from the perspective of increasing the curl size or facilitating fiber splitting. However, if it is too small, the two polymers cannot bond after being ejected from the spinneret, resulting in a cross-section that is difficult to form a composite fiber and a tendency to curl. Conversely, if the bonding distance is too large, the curl size of the composite fiber becomes smaller, or the separation of the two components becomes insufficient during textile processing.

[0061] The value of the joint surface distance Y is preferably in the range of 3 to 13 μm, and particularly preferably in the range of 5 to 12 μm.

[0062] Furthermore, in this invention, the ratio of polymer spacing X to bonding distance Y, i.e., X / Y, needs to be 1.1 or higher. This value indicates that the polymer spacing X of the two components of the cross-section is larger than the bonding distance Y. This results in the irregularly shaped parallel composite cross-section fiber of this invention becoming a fiber with a large coil diameter and exhibiting strong coiling performance. Moreover, when the coil is large, fabrics made using this irregularly shaped parallel composite cross-section fiber of the present invention produce a fluffy and soft fabric. Furthermore, this fiber exhibits significant morphological changes when the coil shape changes (described later), enabling the production of fabrics with varying textures.

[0063] Furthermore, the irregularly shaped, parallel-section composite cross-section fibers of the present invention exhibit strong curling performance, capable of resisting the constraint forces of the woven fabric and exhibiting fiber curling. As a result, fabrics such as woven fabrics made using this method also become high-quality fabrics with a fine texture and appearance. This is because the shapes of the fibers are highly variable, and as described below, each component of the composite cross-section fibers of the present invention easily splits into irregularly shaped cross-section fibers, and the mixing of these split irregularly shaped cross-section fibers within and outside the fiber bundle easily becomes random.

[0064] When X / Y is less than 1.1, only fabrics lacking both a fluffy and natural feel can be obtained. This is because the coils of composite cross-section fibers tend to shrink, yarns or fabrics using these fibers lack bulkiness, and the two components have poor fiber splitting properties.

[0065] However, in the irregularly shaped parallel composite cross-section fibers of the present invention, the value of X / Y is 1.1 or higher. Therefore, the curling loops become larger, and when using this composite fiber, a high-quality fabric with a fine texture and appearance can be obtained. Furthermore, when using a component such as nylon 6, which self-elongates in warm water, as one of the polymers constituting the composite fiber, its characteristics are particularly pronounced. That is, due to the large change in curling shape or high elongation, the bonding surface peels off easily, leading to fiber breakage. Moreover, the fine-grained and irregularly shaped split fibers are randomly present inside and outside the fiber bundle, thereby achieving a fabric appearance with a fluffy and natural feel. The value of X / Y, the ratio of polymer spacing X to bonding distance Y, is further preferably 1.2 to 5, and particularly preferably 1.3 to 2.5. However, if this value is too large, the irregularity is too large, and to reduce the swelling effect or surface tension after being ejected from the spinneret, it is necessary to lower the polymer temperature, which may lead to a decrease in fiber strength. The elongation length tends to decrease.

[0066] As a more specific example of the irregularly shaped cross-section of the composite fiber in the present invention, the irregularly shaped cross-section of each component is preferably, for example, as shown in the figure below. Figures 1 to 4 The shape shown. Furthermore, as... Figures 1-3As shown, each polymer component preferably has an irregular cross-sectional shape with two or more protrusions. Alternatively, the protrusions of the polymer component may be curved.

[0067] More specifically, for example Figure 1 The fiber is a fiber with an X-shaped cross section when viewed from the joint surface of two polymers. Each of the two polymers has two protrusions on the left and right sides, forming a V-shape. The overall cross section of the fiber is formed by the two polymers joining in a parallel manner. Figure 2 When viewed from the mating surface, each surface has three protruding shapes. Figure 3 Viewed from the mating surface, it has two curved protrusions. It should be noted that... Figure 4 Although it has only one protruding shape, the polymer spacing X is relatively long relative to the bonding surface Y, making it a fiber that is prone to splitting in subsequent processes. Conversely, as... Figure 5 In the case of such a composite fiber in which each component is semi-circular, the outer tangent circles of the left and right components are consistent, the polymer spacing X connecting the centers of the outer tangent circles of the irregular cross-sections of each polymer component disappears, and the bonding surface becomes larger. Therefore, it becomes a fiber with less shrinkage and is difficult to split in subsequent processes.

[0068] In the irregularly shaped composite cross-section fiber of the present invention, by making the cross-section of the fiber irregularly shaped and optimizing the value of the ratio X / Y of the polymer spacing X and the bonding distance length Y, it becomes a fiber that is easy to curl and easy to break through small strain or stress concentration, and the fabric formed by using the irregularly shaped fiber after breaking becomes a fabric with excellent texture.

[0069] Here, the two polymers with different glass transition temperatures constituting the irregularly shaped side-by-side composite cross-section fibers of the present invention will be described in further detail. Preferably, the two polymers used in the present invention are polymers that, when spun, stretched, and subsequently heat-treated, produce fibers with significantly different shrinkage rates. It should be noted that the two polymers can be any polymers constituting one side of the irregularly shaped side-by-side composite cross-section fiber; the polymers can also be copolymers, etc. Furthermore, as long as the glass transition temperatures are different, the two polymers can also be two polymers with different degrees of polymerization or different ratios of various components, additives, etc.

[0070] However, these two polymers are preferably well bonded during spinning and can be stably melt-spun as composite fibers; for example, a combination of polyamide and polyester is preferred. More specifically, a copolyester containing nylon 6 as the polyamide and sulfonate groups as the polyester is particularly preferred. Furthermore, polyethylene terephthalate or polyethylene terephthalate is preferred as the polyester.

[0071] Polyamides are preferably the polymer with the lower glass transition temperature (GVT) side constituting this composite fiber, and its GVT is preferably in the range of 45–55°C. Furthermore, the polymer with the higher GVT side preferably has a GVT in the range of 70–90°C. The temperature difference between the two polymers is preferably 50°C or less, and more preferably in the range of 10–40°C. If the temperature difference is greater than this range, the refining and following properties of the two components deteriorate during the spinning process, leading to poor spinning or significant orientation suppression of the component with the lower GVT, thus increasing practical disadvantages such as reduced fiber elongation. Conversely, if the temperature difference between the GVTs is too small, there is a tendency for small differences in physical properties, reduced shrinkage of the composite fiber, and difficulty in peeling off irregularly shaped fibers derived from each polymer from the composite fiber.

[0072] Furthermore, the limiting viscosity η of the polymer on the low glass transition temperature side, when measured with a m-cresol solution at 30°C, is preferably in the range of 1.0 to 1.6. Similarly, the limiting viscosity η of the polymer on the high glass transition temperature side, when measured with a m-cresol solution at 30°C, is preferably in the range of 0.4 to 0.7.

[0073] As described above, copolyesters are preferably used as polymers for the high glass transition temperature side of such composite fibers. Polyesters that are the main component are preferably polyethylene terephthalate or polyethylene terephthalate.

[0074] In particular, modified polyesters containing sulfonate groups are preferred as copolyesters. Furthermore, as a method for modifying polyesters containing sulfonate groups, it is preferable to copolymerize compounds having sulfonic acid salts or alkaline earth metal salts, phosphonium salts, and having one or more functional groups capable of forming esters.

[0075] More specifically, examples of copolymer components for polymers used on the high glass transition temperature side include 5-sulfoisophthalic acid and its ester derivatives, 5-sulfonylisophthalic acid and its ester derivatives, and sodium p-hydroxyethoxybenzenesulfonate. Among these, 5-sulfoisophthalic acid is preferred.

[0076] The preferred copolymer content for this copolymer component is 0.5 to 7 mol%, more preferably 1.5 to 4 mol%. If the amount is too low, the adhesion to polymers with low glass transition temperatures, such as nylon-6, will be insufficient, and peeling may occur during the spinning process, which is undesirable. On the other hand, if the amount is too high, the melt viscosity of the copolymer will increase, and there is a tendency for process stability problems, such as reduced fiber drawability.

[0077] Furthermore, in the polyester preferably used in this invention, other copolymer components may also be included, such as diethylene glycol, hexanediol and other dioxy compounds, adipic acid, isophthalic acid, phthalic acid and other aliphatic dicarboxylic acids.

[0078] It should be noted that the glass transition temperature of this polymer on the high glass transition temperature side can be adjusted by the molar percentage of copolymer components such as sodium sulfoisophthalate.

[0079] In addition, as additives used in polymers such as polyesters or polyamides used in this invention, titanium dioxide, colorants, light stabilizers, etc., may also be added without affecting spinning and stretching, or textile processing.

[0080] Furthermore, from the viewpoint of shrinkage performance, the ratio of the two polymer components in the irregularly shaped parallel composite cross-section fiber of the present invention is particularly preferably close to 50:50, and preferably varies in the range of 40:60 to 60:40.

[0081] Next, the irregularly shaped parallel composite cross-section fiber of the present invention is preferably a three-dimensionally wound irregularly shaped parallel composite cross-section fiber with polymers of different glass transition temperatures as described above, resulting in a polymer with a low glass transition temperature being configured on the inside of the wound.

[0082] To form the coiled shape of the composite cross-section fiber of the present invention, it is preferable that the difference in glass transition temperatures between the two polymers constituting the parallel components is large, resulting in a larger coiled shape. The reason for this is that during the spinning process, after the polymer is ejected from the injection orifice and passes through the heat-insulating zone, it requires cooling air to cool the spun yarn while simultaneously undergoing orientation crystallization. At this time, the tensile viscosity of the polymer with the higher glass transition temperature increases first, thus promoting orientation crystallization compared to the other polymer. Meanwhile, the polymer with the lower glass transition temperature, while its tensile viscosity has not increased sufficiently, promotes deformation to follow the spinning linear speed of the polymer with the higher glass transition temperature, resulting in a state where orientation crystallization is suppressed. Thus, by widening the difference in crystallization orientation between the two components, the difference in shrinkage force between the two components increases, thereby further exhibiting coiling properties. At this time, the polymer with the lower glass transition temperature becomes the polymer component with less orientation, and due to its low crystallinity and high shrinkage rate, it is positioned inside the coiled shape.

[0083] The temperature difference between the glass transition temperatures of the two polymer components used in this invention, as described above, is preferably below 50°C. More preferably, it is in the range of 10–40°C. With a larger temperature difference, the refining and following properties of the two components deteriorate during the spinning process, potentially leading to poor spinning or greater orientation suppression of the component with the lower glass transition temperature, thus tending to reduce elongation.

[0084] Thus, the irregularly shaped, parallel-section composite fiber of the present invention is preferably curled as described above. Here, as the curled fiber, three-dimensional curling or false twisting curling is preferred, and three-dimensional curled fiber is particularly preferred.

[0085] Furthermore, when fabrics are made using the irregularly shaped parallel composite cross-section fibers of the present invention and subjected to heat treatments such as scouring and dyeing, the composite cross-section fibers in the final fabric preferably include the following two forms.

[0086] (1) Composite fibers that repeatedly exhibit the following phenomenon: after changing from a crimped structure to a flat, straight fiber form, they are removed from a warm water bath and, due to the decrease in yarn temperature and the natural drying of absorbed moisture, return to their original crimped state.

[0087] (2) Two irregular cross-section fibers peeled off from the joint surface.

[0088] Furthermore, the irregular cross-section fibers composed of each individual component in (2) are mainly produced in the following processes (2-1) and (2-2). In particular, when using polymers such as nylon 6 that are prone to self-elongation due to water, it is especially preferable to produce irregular cross-section fibers with peeled joint surfaces in (2) through process (2-2).

[0089] (2-1) When the composite cross-section fiber changes from a coiled structure to a flat, straight fiber shape, the joint surface peels off, resulting in two different cross-section fibers.

[0090] (2-2) The nylon 6 polymer and other fiber components inside the coil are arranged on the outside of the coil through self-elongation and reversal, becoming two irregular cross-section fibers peeled off from the joint surface.

[0091] Furthermore, in order to form the state described above, the irregularly shaped parallel composite cross-section fiber of the present invention is particularly preferably a three-dimensional crimped fiber, which in particular uses nylon 6 polymer as a polymer with a low glass transition temperature and copolyester polymer as a polymer with a high glass transition temperature, and the nylon 6 polymer is disposed on the inner side.

[0092] Furthermore, when using nylon 6 polymer and copolyester polymer in this way, the irregularly shaped parallel composite cross-section fiber of the present invention comprising (1) or (2) above is further preferably the fiber described below.

[0093] That is, the irregularly shaped parallel composite cross-section fiber of the present invention as described in (1) above is preferably an irregularly shaped parallel composite cross-section fiber containing fibers that repeatedly exhibit the following phenomenon: in a hot water bath at a temperature of 80°C or higher, the nylon 6 polymer inside the three-dimensional crimped coil elongates, thereby changing from a three-dimensional crimped structure to a straight fiber shape; after being removed from the hot water bath, the yarn temperature is lowered and the absorbed water is dried, and the fiber returns to a three-dimensional crimped state; and the elongation change rate (Formula 1) of the irregularly shaped parallel composite cross-section fiber after boiling water treatment for 30 minutes is 130 to 200%.

[0094] Elongation change rate:

[0095] (Length after hot water treatment - Length during drying) / Length during drying × 100 (%) Formula 1

[0096] (Among them, the length measurement is the light load length of skein fineness (dtex) × 2mg / dtex)

[0097] Here, the irregularly shaped parallel composite cross-section fibers of the present invention are not necessarily all the coiled fibers mentioned in (1) above. Fibers with reversible variations between linear fibers are preferred, as are fibers containing irregularly shaped cross-section fibers with the joint surface peeled off as described in (2) above.

[0098] Furthermore, when containing irregularly shaped parallel composite cross-section fibers that can change reversibly, Nylon 6, due to its low orientation, although initially positioned inside the loops of the irregularly shaped parallel composite cross-section fibers, undergoes a change in the curling state of the composite cross-section fibers during subsequent processes due to its self-elongation property caused by warm water. Thus, in the textile processing using the irregularly shaped parallel composite cross-section fibers of the present invention, by subjecting the fibers to hot water or drying treatment, the apparent fiber length changes due to changes in the loop structure. Even when the fibers are mutually constrained in the woven structure, the fiber stretching or curling loop structure changes, resulting in the exchange and arrangement of individual yarns within the fiber bundle, thus presenting a blending effect. Consequently, filaments or fabrics using the composite fibers of the present invention can exhibit changes in fiber morphology as natural as those of natural fibers.

[0099] Furthermore, at this point, nylon 6 stretches and expands in the hot water, its length under light load, i.e., the elongation change rate, is preferably 130-200%. Afterwards, through drying, it returns to its original curled state, its apparent length shortens, and it returns to its original shape. Since the recovery speed differs between the individual yarns, various yarn configurations can be used to achieve a blending effect. If the elongation rate is low, it tends to be difficult to obtain a split fiber or blending effect. Furthermore, if the elongation rate is too high, the fiber structure of nylon 6 is not fully developed, thus the repeatability of elongation / shrinkage cannot be obtained, resulting in limited effects. A further preferred elongation change rate is in the range of 140-180%.

[0100] Furthermore, the irregularly shaped parallel composite cross-section fiber of the present invention as described in (2) above is preferably a fiber that has undergone the processes described in (2-1) above to become the fiber described below.

[0101] That is, the irregularly shaped parallel composite cross-section fiber of the present invention is preferably the irregularly shaped parallel composite cross-section fiber that peels off from the joint surface when the three-dimensional coiled structure changes from a three-dimensional coiled structure to a straight fiber form in a hot water bath at a temperature of 80°C or higher due to the self-elongation of the nylon 6 polymer inside the three-dimensional coiled coil.

[0102] As a result, the split fibers exhibit a variety of characteristics such as softness, luster, and ultra-fine touch due to their fine fineness and irregular cross-section.

[0103] Furthermore, the irregularly shaped parallel composite cross-section fiber of the present invention, as another example of (2) above, is preferably the fiber that has been processed through the above-described (2-2) process to become the fiber described below.

[0104] That is, the irregularly shaped parallel composite cross-section fiber of the present invention is preferably an irregularly shaped parallel composite cross-section fiber in which the nylon 6 polymer inside the three-dimensional coil is reversed and arranged outside the three-dimensional coil due to self-elongation in a hot water bath at a temperature of 80°C or above, so that the joint surface is peeled off.

[0105] Utilizing this phenomenon, when the corresponding polymer components are dyed with different dyes, they are randomly mixed due to the movement of the split single yarns inside the fiber bundle. This results in a subtle color mixing effect rather than an artificial one, which can produce high-quality fabrics with hues that change depending on the viewing angle or have deep shadows.

[0106] As a property of the irregularly shaped, parallel-section composite fiber of the present invention, its thermal stress is preferably in the range of 0.15 cN / dtex to 0.5 cN / dtex. More preferably, it is 0.2 cN / dtex to 0.4 cN / dtex. Thermal stress indicates the shrinkage performance during subsequent textile processing. If the thermal stress is too low, a large curl structure cannot be exhibited, the fabric has less fluffiness, and it is difficult to obtain the good mixing effect of the fine fibers randomly arranged inside and outside the fiber bundle after splitting. In addition, if the thermal stress is too high, the fibers themselves become stiff due to shrinkage or the fabric density increases, making it difficult to obtain the fluffy and soft texture that is the goal of the present invention.

[0107] Furthermore, the shrinkage rate of irregularly shaped parallel composite cross-section fibers is preferably 4% or more, more preferably 4.5% to 20%, and particularly preferably in the range of 10% to 18%. If the shrinkage rate is too low, the difference in physical properties between the bonded cross-sectional components is small, the coil performance generated by the shrinkage is small, and there is a tendency to make it difficult to obtain high-quality textures such as fluffiness and softness.

[0108] Furthermore, the fineness of the single fiber of the irregularly shaped parallel composite cross-section fiber of the present invention is preferably in the range of 0.2 dtex to 5 dtex. More preferably, it is in the range of 0.5 to 4 dtex. If the fineness of the single fiber yarn is too small, it is difficult to separate and form two irregularly shaped cross-section fibers, or the fiber strength... If the elongation becomes too small, it becomes difficult to handle, which also makes engineering difficult. In addition, if the single fiber fineness is too large, it is difficult to achieve a soft and delicate texture.

[0109] Furthermore, the fineness of the components that become irregular cross-section fibers after the irregularly shaped parallel fibers are peeled or split is preferably 2 dtex or less for both components, more preferably 1.6 dtex or less and 0.1 dtex or more, and particularly preferably microfibers with a fineness of less than 1.2 dtex and 0.5 dtex or more. By making the irregular cross-section fiber component in the composite cross-section fiber have such a low fineness, in the fabric using the irregularly shaped parallel composite cross-section fiber of the present invention, the microfiber cross-section yarns are randomly mixed, thereby obtaining softness and excellent appearance variation.

[0110] As for the strength and elongation of the irregularly shaped parallel composite cross-section fibers of the present invention, a strength of 1.8 cN / dtex or higher and an elongation of 20% or higher are preferred. Particularly preferred are a strength in the range of 2 to 4 cN / dtex and an elongation in the range of 25 to 40%. Strength When the elongation is too low, problems with fabric quality may occur in subsequent weaving or processing steps due to single yarn breakage or friction.

[0111] Such irregularly shaped parallel composite cross-section fibers of the present invention can be obtained, for example, by the following method for manufacturing irregularly shaped parallel composite cross-section fibers.

[0112] Specifically, the method for manufacturing irregularly shaped parallel composite cross-section fibers is characterized by spraying two polymers with different glass transition temperatures from irregularly shaped cross-section holes, joining the two components inside and / or outside the spray holes to form a parallel cross-sectional shape, and then performing spinning, stretching, and heat setting. Furthermore, the irregularly shaped parallel composite cross-section fibers obtained by this manufacturing method are irregularly shaped parallel composite cross-section fibers composed of two polymers with different glass transition temperatures and whose polymer components have irregular cross-sectional shapes. Specifically, the ratio of the polymer spacing X connecting the centers of the circumscribed circles of the irregular cross-sections of each polymer component to the distance Y of the joint surface of the cross-section, i.e., X / Y, is 1.1 or more.

[0113] A further preferred method is to bond protruding irregular cross-sections of polymers with different glass transition temperatures into parallel cross-section fibers.

[0114] The manufacturing method is disclosed in more detail, for example, by melting two polymers separately in their respective extruders and introducing them into a spinning assembly equipped with spinnerets using a metering pump such as a gear pump. In the spinnerets, the two components are distributed by multiple orifices and ejected from different shaped jet orifices, thereby bonding the two components together to form a composite cross-section with shaped cross sections. The cross-section is then wound up at various speeds to produce unstretched yarn.

[0115] Furthermore, the unstretched yarn can be stretched using a separate stretching machine after being wound up. Alternatively, a direct stretching spinning process can be used, where the unstretched yarn is preheated on the traction rollers, stretched and heat-set between the heat-setting rollers, and then wound up. Furthermore, it is also preferable to produce partially oriented yarn (POY) with a residual elongation in the range of 100-150% at high spinning speeds, to produce false-twist processed yarn (DTY processed yarn) in the false-twist process, or to blend it with other yarns to produce composite fibers. The preferred spinning speed for these processes is in the range of 1000 m / min to 3500 m / min.

[0116] Furthermore, as a stretching process, it is preferable to use a high-temperature roller with a glass transition temperature of +10 to 30°C for polymers with high glass transition temperatures. Heat setting is performed by winding the polymer onto a high-temperature roller with a crystallization temperature of +20 to 50°C, or by passing it through a non-contact heater for preheating and heat setting. To adjust the shrinkage rate during subsequent textile processing, it is also a preferred process to perform relaxation heat treatment by setting a cooling roller after the heat setting roller, thereby reducing the shrinkage rate.

[0117] The irregularly shaped, parallel-section composite fiber of the present invention thus obtained is further processed by peeling off the joint surface of the irregularly shaped, parallel-section composite fiber, thereby constituting another method for manufacturing irregularly shaped cross-section fibers of the present invention. As such another method for manufacturing irregularly shaped cross-section fibers of the present invention, the peeling method is further preferably hot water treatment. As a hot water shrinkage treatment, hot water at a temperature of 80°C or higher is preferred. More preferably, boiling water treatment at 90–100°C is used. As a treatment time, 1–10 minutes is preferred, and particularly preferably 2–5 minutes.

[0118] It should be noted that, preferably before the hot water shrinkage treatment, the joint surface has not yet disintegrated, while after the hot water shrinkage treatment, the joint surface separates into two fibers composed of each polymer single component.

[0119] After hot water treatment, drying is preferable to restore the fibers to their original length. This improves the processability of the fibers later. Furthermore, to further ensure complete separation of the bonded surfaces, it is preferable to repeat the hot water treatment and drying process multiple times. It is also preferable to repeat the process 2 to 5 times.

[0120] It should be noted that in the manufacturing method of the irregularly shaped cross-section fiber that peels off the joint surface of the irregularly shaped parallel composite cross-section fiber, the weaving can be carried out in subsequent processing steps. The degree of fiber breakage (such as peeling of the joint surface) is adjusted in each process, including weaving, refining, pre-forming, dyeing and final shaping.

[0121] Next, by using the irregularly shaped, parallel-section composite cross-section fibers of the present invention, a method for manufacturing a fabric with a good texture and a natural blended appearance, as another aspect of the present invention, can be obtained. That is, a method for manufacturing a fabric having the following characteristics: a sheet is made using the irregularly shaped, parallel-section composite cross-section fibers of the present invention described above, and the irregularly shaped, parallel-section composite cross-section fibers are then peeled off.

[0122] The irregularly shaped, side-by-side composite cross-section fibers used in the fabric are irregularly shaped, side-by-side composite cross-section fibers of the present invention, and it is particularly preferred that the two polymers with different glass transition temperatures are polyester and polyamide (sometimes also referred to as "nylon"). Furthermore, each irregularly shaped cross-section fiber component composed of the two polymers preferably has the same cross-sectional shape.

[0123] By employing this manufacturing method, for example, the following fabric can be obtained: the fabric comprises polyester profiled cross-section fibers and polyamide profiled cross-section fibers, characterized in that the polyester profiled cross-section fibers and the aforementioned polyamide profiled cross-section fibers have the same surface shape.

[0124] In the fabric of this invention, polymer fibers with different cross-sections are randomly mixed within the fiber bundle, thereby possessing a deep hue, a delicate coin blotting effect, a fluffy yarn texture, and further abrasion resistance.

[0125] Here, the ratio of the fineness of the single fiber (A:B) of the two different polymer profiled cross-section fibers (A) and (B) is preferably in the range of 40:60 to 60:40.

[0126] Furthermore, in the cross-sectional shape of the aforementioned irregularly shaped fibers, having two or more (more preferably two to four) protrusions is preferred, as it provides a fluffy and woolen texture. Specific shapes include, for example, V-shaped, three-protrusion type, C-shaped, etc.

[0127] Furthermore, the fineness of the individual fibers (A) and (B) of the two aforementioned irregular cross-section fibers is preferably 2.0 dtex or less. More preferably, it is 1.6 dtex or less, and particularly preferably in the range of 0.1 to 1.5 dtex or 0.5 to 1.2 dtex. Random blending of irregular cross-section fibers with fine fineness at the individual fiber level can achieve higher softness and an excellent chambray-like appearance.

[0128] Furthermore, these irregularly shaped cross-section fibers are preferably crimped fibers. More preferably, two irregularly shaped cross-section fibers (A) and (B) are formed by splitting parallel composite fibers.

[0129] The irregularly shaped composite cross-section fibers used in the fabric are the irregularly shaped composite cross-section fibers of the present invention described above. The two irregularly shaped cross-section fibers (A) and (B) that ultimately constitute the fabric are preferably irregularly shaped cross-section fibers obtained by the manufacturing method of the irregularly shaped cross-section fibers using irregularly shaped composite cross-section fibers of the other present invention described above.

[0130] The cross-sectional shape of the irregularly shaped parallel composite cross-section fibers is preferably as described above. Figures 1-4 The cross-sectional shape is shown. It should be noted that the distance X between the centers of the two components is proportional to the diameter of the coil in the resulting curled shape. The inventors have discovered that by using an irregularly shaped cross-section with a protruding shape, the distance between the centers of the two components can be increased, resulting in a large curled coil even at finer denier. Furthermore, the irregularly shaped parallel composite cross-section fibers are curled fibers, thus creating a fabric with excellent texture.

[0131] In particular, by making the ratio of the distance X between the centers of the two components to the joint distance Y of the two cross sections 1.1 or higher, the fiber shape changes significantly when the fabric's fluffiness or loop shape changes, resulting in a rich and varied fabric texture. Furthermore, high curling performance means the ability to resist the constraints of the weave and exhibit fiber curling, which also makes the shape of the fibers varied, and the mixing of the split fibers inside and outside the fiber bundle becomes random, thus forming a high-quality, delicate texture and appearance. A ratio of 1.2 to 2.5 is preferred. If it is too high, due to the increased irregularity, reducing the swelling effect or surface tension after the spinneret is required to lower the polymer temperature, leading to a decrease in fiber strength. The reduced elongation poses challenges in practical applications.

[0132] In this invention, the preferred fiber used is an irregularly shaped, parallel composite cross-section fiber in which different polymers with different glass transition temperatures and a low glass transition temperature are arranged on the inner side of the coil.

[0133] Furthermore, in the above-mentioned composite fibers, the different polymers combined are preferably nylon 6 and sulfoisophthalate cationic salt copolyester (more preferably sodium sulfoisophthalate copolyester), and particularly preferred are irregularly shaped side-by-side composite fibers in which nylon 6 is located on the inside after shrinkage.

[0134] Since the glass transition temperature of nylon 6 is lower than that of the aforementioned copolyester, it is disposed on the inner side of the coil. The glass transition temperature of nylon 6 is around 50°C, preferably in the range of 45 to 55°C. For the aforementioned copolyester, when the polyester as the main component is polyethylene terephthalate or polyethylene terephthalate, the glass transition temperature, although also depending on the copolymer molar percentage of sodium sulfoisophthalate, is approximately 70°C to 90°C, resulting in irregularly shaped parallel composite cross-section fibers with nylon 6 disposed on the inner side of the coil.

[0135] The nylon 6 located on the inner side, due to its low orientation state, has a large self-elongation rate caused by warm water. Therefore, it may shrink or attempt to stretch beyond the length of the polyester component, thus easily causing interfacial delamination.

[0136] Here, sulfonyl isophthalic acid cationic salt copolyester refers to a modified polyester obtained by copolymerizing compounds containing sulfonic acid alkali metal salts or alkaline earth metal salts, phosphonium salts, etc., and having one or more functional groups with ester formation ability. The limiting viscosity η of this modified polyester (measured with o-chlorophenol solution at 25°C) is preferably 0.4 to 0.7.

[0137] The preferred copolymer components are sodium 5-sulfoisophthalate and its ester derivatives, phosphonium 5-sulfoisophthalate and its ester derivatives, and sodium p-hydroxyethoxybenzenesulfonate. Sodium 5-sulfoisophthalate is preferred, and the copolymerization amount, based on the acid content of the copolyester, is preferably 0.5–7 mol%, more preferably 1.5–4 mol%.

[0138] The sulfonate groups in the polyester copolymerized with sulfoisophthalic acid exhibit excellent electrostatic adhesion to the amide groups in the polyamide polymer, resulting in fibers with excellent cross-sectional shape formation. If the copolymer content is too low, the adhesion to nylon 6 tends to be insufficient, potentially leading to peeling during the spinning process, or a lower glass transition temperature. On the other hand, if the copolymer content is too high, the polymer's melt viscosity tends to increase, potentially causing reduced process stability, such as decreased fiber drawability.

[0139] Furthermore, as other copolymerizing components, it can also copolymerize diethylene glycol, hexanediol and other dioxy compounds, adipic acid, isophthalic acid, phthalic acid and other aliphatic dicarboxylic acids.

[0140] For Nylon 6, the limiting viscosity η (measured with m-cresol solution at 30°C) is preferably 1.0 to 1.6.

[0141] Furthermore, in this combination of nylon-6 and sodium sulfoisophthalate copolyester, especially in subsequent dyeing, the use of suitable acid dyes and cationic dyes is effective in achieving a delicate fabric appearance by utilizing different dyeing properties.

[0142] The aforementioned composite fiber preferably includes fibers that repeatedly exhibit the following phenomenon during textile processing: when the fiber is placed in a hot water bath at a temperature of 80°C or higher, the nylon 6 or similar fibers inside the loops self-elongate, changing from a coiled structure to a flat, straight fiber morphology. Upon removal from the warm water bath, the yarn temperature decreases and the absorbed water is dried, restoring the original coiled state. This phenomenon utilizes the property of low-orientation nylon 6 or similar fibers arranged inside the loops and self-elongating through warm water to change the fiber's coiled state. Therefore, during textile processing, the apparent fiber length changes due to changes in the loop structure caused by the fiber being in hot water or through drying. Thus, even when fibers are mutually constrained in the woven fabric structure, the fiber's stretching or coiling loop structure changes, resulting in the exchange and arrangement of individual fibers within the fiber bundle, creating a mixing effect. This allows for the display of a natural fiber morphology change similar to that of natural fibers.

[0143] The fabric of the present invention is obtained from irregularly shaped parallel composite cross-section fibers, which are composed of two polymers with different glass transition temperatures. In addition to being composed of only these two polymers, the fabric may also contain other fibers (e.g., fibers with a normal circular cross-section, or irregularly shaped cross-section fibers with different cross-sectional shapes).

[0144] The fabric structure of the present invention is not particularly limited and can be any type of knitted or woven fabric. For example, knitted fabrics with knitted structures such as plain knit, knit, double rib, rib, raised knit, yarn-padded, warp plain, and half-weave are preferred examples, as are woven fabrics with knitted structures such as plain weave, twill weave, and satin weave, but are not limited to these. The number of layers can be a single layer or multiple layers (two or more).

[0145] In this case, if the fabric is knitted, the preferred knitting density is 50-120 loops per 2.54 cm (both horizontal and vertical rows) and 40-100 loops per 2.54 cm (both vertical rows). Furthermore, if the fabric is woven, the preferred woven fabric density is 50-300 warp threads per 2.54 cm and 50-300 weft threads per 2.54 cm. In the fabric of this invention, the weight per unit area is preferably 30-300 g / m². 2 Within the range.

[0146] The fabric of the present invention can be obtained, for example, by manufacturing and weaving the above-mentioned composite fibers (other fibers may also be used if necessary) using conventional methods, and then by heat treatment such as dyeing or water-repellent processing, splitting the composite fibers into two different cross-section fibers.

[0147] During the dyeing process, the temperature is preferably 100–140°C (more preferably 110–135°C), and the holding time at the highest temperature is preferably in the range of 5–40 minutes. For the fabric after the dyeing process, a final heat setting is preferably performed. The final heat setting temperature is preferably 120–200°C (more preferably 140–180°C), and the holding time is preferably in the range of 1–3 minutes.

[0148] Furthermore, it can also be further processed using conventional methods such as napping, and imbued with functions such as UV shielding, antibacterial agents, deodorants, insect repellents, light-emitting agents, re-reflective agents, negative ion generators, water-absorbing agents, and water-repellent agents. Through heating and drying processes, the degree of fiber breakage in the fabric of this invention is further increased, resulting in a fabric with excellent texture.

[0149] The fabric obtained in this way, due to the above-mentioned composition, has a deep tone, a delicate coin blotting effect, a fluffy yarn texture, and excellent abrasion resistance.

[0150] Here, regarding the abrasion resistance of the fabric, the abrasion durability measured according to the Martindale method of JIS-L1096 is preferably 30,000 cycles or more. More preferably, it is in the range of 35,000 to 100,000 cycles.

[0151] Furthermore, according to the present invention, any fiber product made using the aforementioned fabric, selected from clothing, linings, interlinings, socks, bellybands, hats, gloves, pajamas, bedding side panels, duvet covers, and automotive seat upholstery materials, can be provided. Because the aforementioned fiber products use the aforementioned fabric, they exhibit a deep color tone, a delicate coin blouse effect, a fluffy woolen texture, and excellent abrasion resistance.

[0152] The irregularly shaped, parallel-section composite fiber of this invention does not involve cross-section peeling during the yarn-making stage. By using irregularly shaped cross-sections for bonding, the center-to-center distance between the two cross-sections increases, resulting in a larger curl loop. Furthermore, when fabric is made using this composite cross-section fiber, subsequent processing involves fiber splitting, whereby extremely fine irregularly shaped cross-section yarns with different polymers are randomly mixed within the fiber bundle, thereby producing a fabric with a fluffy, good texture and a naturally blended appearance.

[0153] Example

[0154] The present invention will now be described in detail. It should be noted that the present invention is not limited to the embodiments described below. The following describes embodiments. The measurement methods used in the comparative examples.

[0155] (1) Tensile strength elongation

[0156] According to JIS L1013, the test was conducted under the conditions of a sample yarn length of 20 cm and a constant stretching speed of 20 cm / min. Then, the maximum value of the load in the load-elongation curve was divided by the fineness to obtain the breaking tensile strength (or tensile strength) (cN / dtex), and the elongation at this point was taken as the breaking elongation (%).

[0157] (2) Curl-up ratio

[0158] A 30cm long strand of yarn was prepared, and a heavy load of 220mg / dtex and a light load of 20mg / dtex were applied, with lengths L0 and L1 measured respectively. Then, under the light load, the yarn was treated with boiling water for 30 minutes to induce shrinkage, and the moisture was removed with filter paper and dried for 3 hours. Next, the length L3 was measured again under the heavy load, and then the heavy load was removed, with the length L2 measured under the light load.

[0159] Using L0, L2, and L3, the shrinkage rate is determined using the following formula.

[0160] Shrinkage rate (TC) (%) = (L2 - L3) / L0 × 100 (%)

[0161] (3) Rate of change of elongation

[0162] A 30cm long strand of yarn was prepared, treated in boiling water for 30 minutes, then removed from the water, and the moisture was absorbed with filter paper. The length L4 was measured under a light load. Then, the load was removed, and the yarn was dried for 3 hours. The length L5 was measured under a light load afterward.

[0163] The elongation is determined using the values ​​of lengths L4 and L5 through the following formula.

[0164] Elongation at boiling water = (L4 - L5) / L4 × 100 (%)

[0165] (4) Glass transition temperature (Tg)

[0166] Approximately 10 mg of particles were sealed in an aluminum dish for measurement and measured using a differential scanning calorimeter manufactured by TA Instruments under a nitrogen atmosphere and a heating rate of 10 °C / min.

[0167] (5) Polymer spacing X and joint surface distance Y

[0168] like Figures 1-6 As illustrated in the diagram, the length of the fiber cross-section of the two side-by-side components is taken as the joint surface distance Y, and the length of the center of the smallest enclosing circle connecting the two components with irregular cross-sections is taken as the polymer spacing X. The ratio X / Y is then calculated.

[0169] (6) Degree of fiber breakage

[0170] A 36G tubular knitted fabric was made using raw yarn composed of irregularly shaped, parallel-section composite fibers. The fabric was scoured at 80°C, then dyed with acid dyes at 100°C, followed by cationic dyeing. The tubular knitted fabric was cut perpendicular to the fiber length, and the cross-section was observed using an electron microscope. Cases where the separation from the irregularly shaped, parallel-section composite fibers to the irregularly shaped cross-section fibers was less than 50% were classified as Grade 1; cases with a separation of 50%–80% were classified as Grade 3; and cases with a separation of more than 80% were classified as Grade 5.

[0171] (7) Random mixing

[0172] Observe the surface of the tubular knitted fabric used in (6) above, and dye the two polymer components separately with acid dyes and cationic dyes of different colors. Fibers in which two colors of single yarn can be uniformly identified in the observed area on the surface of the tubular knitted fabric are judged as grade 5, fibers in which two-color parts / one-color parts are mottled are judged as grade 3, and fibers in which only one color part is judged as grade 1.

[0173] (8) Weight per unit area of ​​cloth

[0174] The determination was carried out in accordance with JIS L1018-1998 6.4.

[0175] (9) Coverage coefficient of cloth

[0176] The meridional coverage factor (CF) and zonal coverage factor (CF) are calculated using the following formulas and then added together.

[0177] CF = (DWp / 1.1) 1／2 ×MWp

[0178] Latitude CF = (DWf / 1.1) 1／2 ×MWf

[0179] [DWp is the total warp fineness (dtex), MWp is the warp yarn density (threads / 2.54cm), DWf is the total weft fineness (dtex), and MWf is the weft yarn density (threads / 2.54cm).]

[0180] (10) Abrasion resistance of fabric

[0181] Perform the wear test as specified in JIS 1096 Martindale Method.

[0182] (11) The delicate, coin-like appearance of the fabric

[0183] Testers visually observed the product and judged it as "good" if it presented a delicate, single-fiber-level chambray-like appearance, and "bad" otherwise.

[0184] (Example 1)

[0185] The copolymer of nylon 6 (low glass transition temperature) and 2.6 mol% sodium 5-isophthalate was used to produce polyethylene terephthalate (η=0.55, high glass transition temperature). The resulting yarn was spun and wound at a spinning temperature of 265℃ and a spinning speed of 2500 m / min. The wound yarn contained components with two protrusions. Figure 1 X-shaped composite cross-section fibers were obtained. They were preheated and stretched at 90°C, and then heat-set in a 180°C slot heater. The fibers were then wound at a winding speed of 600 m / min to obtain irregularly shaped parallel composite cross-section fibers.

[0186] The cross section of the obtained fiber The evaluation results of fiber properties and splitting properties are shown in Tables 1 and 2.

[0187] (Examples 2-5)

[0188] Aside from changing the cross-sectional shape, the process was carried out in the same manner as in Example 1, resulting in irregularly shaped parallel composite cross-section fibers. Example 2 involved bonding together cross-sections with three protrusions. Figure 2 The cross-sectional shape, in embodiment 3, is C-shaped, with two protrusions. Figure 3 The cross-sectional shape. Example 4 is formed by bonding rectangular cross-sections together. Figure 4 The cross-sectional shape, in embodiment 5, has two protrusions. Figure 1 The X-shaped cross-section is finer than that of Example 1.

[0189] The cross section of the obtained fiber The evaluation results of fiber properties and splitting properties are shown in Tables 1 and 2.

[0190] (Comparative Examples 1-2)

[0191] Except for changing the cross-sectional shape, the same procedures as in Example 1 were followed to obtain parallel composite cross-section fibers. Comparative Example 1 was formed by bonding semicircles together. Figure 5 The circular cross-sections are parallel cross-sections; Comparative Example 2 is formed by fitting triangles together. Figure 6 The rhomboid parallel cross sections.

[0192] The cross section of the obtained fiber The evaluation results of fiber properties and splitting properties are shown in Tables 1 and 2.

[0193] (Comparative Example 3)

[0194] Instead of nylon 6 with a low glass transition temperature, two polymers with different molecular weights (excluding 2.6 mol% of sodium 5-isophthalate copolymerized polyethylene terephthalate (η=0.55)) were used, and the same procedure as in Example 1 was followed to obtain irregularly shaped side-by-side composite cross-section fibers.

[0195] The cross section of the obtained fiber The evaluation results of fiber properties and splitting properties are shown in Tables 1 and 2.

[0196]

[0197]

[0198] (Example 6)

[0199] The copolymer of nylon 6 (low glass transition temperature) and 2.6 mol% sodium 5-sulfoisophthalate was used to produce polyethylene terephthalate (η=0.55, high glass transition temperature). The yarn was spun at a spinning temperature of 265°C and taken at a spinning speed of 2500 m / min. Figure 1 The composite fiber shown is of the side-by-side type (weight ratio of the two components 50:50) and has an X-shaped cross-section. It is preheated and stretched at 90°C and heat-set in a 180°C slot heater, and wound at a winding speed of 600 m / min to obtain a yarn composed of irregularly shaped side-by-side composite cross-section fibers with a total fineness of 55 dtex / 48 fibers (shrinkage rate of 5.7%).

[0200] Next, using a 36-gauge circular knitting machine, the aforementioned composite fibers are knitted. Figure 9 The circular knit fabric with double rib knit shown.

[0201] Then, the knitted fabric was dyed using disperse dyes at 130°C for 15 minutes. During this process, a hydrophilic agent (polyethylene terephthalate-polyethylene glycol copolymer) was applied to the dye bath at a ratio of 2 ml / L to impart hydrophilicity to the fabric. Finally, the circular knitted fabric was subjected to dry heat setting at 160°C for 1 minute.

[0202] In the resulting knitted fabric, the aforementioned composite fibers were split, resulting in V-shaped cross-section fibers (with two protrusions) composed of nylon 6 and 2.6 mol% of 5-sulfoisophthalate copolymerized polyethylene terephthalate, which were randomly mixed to create a deep color tone, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the polyester (sulfoisophthalate copolymer) and polyamide (nylon 6) fibers contained in the knitted fabric both had a single fiber fineness of 0.6 dtex. The evaluation results are shown in Table 3.

[0203] (Example 7)

[0204] The copolymer of nylon 6 (low glass transition temperature) and 2.6 mol% sodium 5-sulfoisophthalate was used to produce polyethylene terephthalate (η=0.55, high glass transition temperature). The resulting yarn was spun at a spinning temperature of 265°C and wound at a spinning speed of 2500 m / min. Figure 1 The partially oriented yarn (POY) is a parallel type (50:50 weight ratio of the two components) with X-shaped composite fibers (total fineness 92 dtex / 48 ends). The obtained partially oriented yarn is subjected to false twisting and crimping under the conditions of yarn speed 500 m / min, heater temperature 155℃, and stretch ratio 1.6 times to obtain false twisted and crimped yarn (DTY processed yarn) (total fineness 55 dtex / 48 ends, crimping rate 4.7%).

[0205] Next, using a 28-gauge circular knitting machine, the false-twist crimped yarn and polyurethane yarn (ROICA (trade name), total fineness 22 dtex / 1 yarn) composed of the above-mentioned composite fibers are knitted using a feed knitting method. Figure 10 The circular knit fabric shown is made of plain knit fabric.

[0206] Then, under the same conditions as in Example 6, the knitted fabric was dyed using disperse dyes and hydrophilic agents, and dry heat final setting was performed at a temperature of 160°C for 1 minute.

[0207] In the resulting knitted fabric, the aforementioned composite fibers were split, resulting in V-shaped cross-section fibers (with two protrusions) composed of nylon 6 and 2.6 mol% of 5-sulfoisophthalate copolymerized polyethylene terephthalate, which were randomly mixed to create a deep color tone, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the polyester (sulfoisophthalate copolymer) and polyamide (nylon 6) fibers contained in the knitted fabric both had a single fiber fineness of 0.6 dtex. The evaluation results are shown in Table 3.

[0208] (Example 8)

[0209] The material obtained in Example 7, composed of nylon 6 and copolyethylene terephthalate... Figure 1 The X-shaped composite fiber POY shown was subjected to false twisting and shrinking processing under the conditions of yarn speed of 500m / min, heater temperature of 155℃, and stretch ratio of 1.6 times to obtain false twisted and shrinking yarn (total fineness of 55dtex / 48 ends, shrinkage rate of 5.7%).

[0210] Next, the false-twist, crimped yarn composed of the aforementioned composite fibers is configured as warp and weft yarns, and then, using a rapier loom, ... Figure 11 The fabric shown is a plain weave fabric.

[0211] Then, the woven fabric is subjected to a spreading and scouring treatment at 95°C using a scouring device. Next, after dyeing with disperse dyes at 130°C using a liquid dyeing machine, the following water-repellent treatment is performed. The water-repellent treatment uses the following processing agent, is performed with a liquid rate of 80%, is dried at 130°C for 3 minutes, and then heat-treated at 170°C for 45 seconds.

[0212] <Processing agent composition>

[0213] 5.0wt% non-fluorinated water repellent

[0214] (Made by Nichika Chemical Co., Ltd., Neoseed NR-7080, hydrocarbon compound)

[0215] 0.3wt% melamine resin

[0216] (Sumitex Resin M-3 manufactured by Sumitomo Chemical Co., Ltd.)

[0217] Catalyst 0.3wt%

[0218] (Sumitex Accelerator ACX manufactured by Sumitomo Chemical Co., Ltd.)

[0219] Water 94.4wt%

[0220] The woven fabric obtained in this way has a unit area weight of 76.7 g / m². 2 The warp density is 158 threads / 2.54cm, the weft density is 107 threads / 2.54cm, and the cover factor is 1874. The above composite fiber is produced by splitting fibers, with shaped cross-section fibers composed of nylon 6 and shaped cross-section fibers composed of 2.6 mol% of sodium 5-sulfoisophthalate copolymerized polyethylene terephthalate forming a V-shaped cross-section (with two protrusions) and randomly mixed, resulting in a combination of deep color tone, delicate coin bleed effect, fluffy yarn texture, and abrasion resistance. The evaluation results are shown in Table 4.

[0221] (Example 9)

[0222] The plain fabric obtained in Example 8 was used for post-processing. This plain fabric is composed of nylon 6 and a copolymer of polyethylene terephthalate. Figure 1 The X-shaped composite fiber false twisted yarn shown is configured as warp and weft yarns. Figure 11 The fabric shown is made of a specific material.

[0223] Then, the plain fabric was subjected to a spreading and scouring treatment at 95°C using a scouring device. Next, it was dyed with acid dyes and cationic dyes at 100°C using a liquid dyeing machine, and then subjected to the same water-repellent treatment as in Example 8.

[0224] The woven fabric obtained in this way has a unit area weight of 86.8 g / m². 2 The warp density is 158 threads / 2.54cm, the weft density is 140 threads / 2.54cm, and the cover factor is 2107. The above composite fiber is produced by splitting fibers, with shaped cross-section fibers composed of nylon 6 and shaped cross-section fibers composed of 2.6 mol% sodium 5-sulfoisophthalate copolymerized polyethylene terephthalate forming a V-shaped cross-section (with two protrusions) and randomly mixed, resulting in a product that combines deep color tones, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. The evaluation results are shown in Table 4.

[0225] (Example 10)

[0226] Except for changing the number of filaments from 48 to 24, under the same conditions as in Example 8, the filaments composed of nylon 6 and copolymer polyethylene terephthalate were tested. Figure 1The X-shaped composite fiber POY (total fineness 92 dtex / 24 ends) shown is subjected to false twisting and shrinking processing to obtain false twisted and shrinking yarn (total fineness 55 dtex / 24 ends, shrinkage rate 4.5%). The ratio of the polymer spacing X at the center of the smallest enclosing circle of the irregular cross-section connecting the polymer components to the joint surface distance Y of the cross-section, i.e., X / Y, is 1.7.

[0227] Next, using a 46-gauge circular knitting machine, the aforementioned composite fibers are knitted. Figure 10 The circular knit fabric shown is made of plain knit fabric.

[0228] Then, under the same conditions as in Example 6, the knitted fabric was dyed using disperse dyes and hydrophilic agents, and dry heat final setting was performed at a temperature of 160°C for 1 minute.

[0229] For the resulting knitted fabric, the aforementioned composite fibers were split, with shaped cross-section fibers composed of nylon 6 and shaped cross-section fibers composed of 2.6 mol% sodium 5-sulfoisophthalate copolymer polyethylene terephthalate forming V-shaped cross-sections (with two protrusions) and randomly mixed, resulting in a combination of deep color tone, delicate coin blew effect, fluffy yarn texture, and abrasion resistance. Furthermore, the single fiber fineness of both the polyester (sodium sulfoisophthalate copolymer polyester) and polyamide (nylon 6) fibers contained in the knitted fabric was 1.1 dtex. The evaluation results are shown in Table 3.

[0230] (Example 11)

[0231] Except for changing the number of filaments from 48 to 24, under the same conditions as in Example 6, a filament composition of nylon 6 and copolymer polyethylene terephthalate was obtained. Figure 1 The X-shaped composite fiber shown has a total fineness of 55 dtex / 24 fibers and a crimp rate of 5.7%. The ratio of the polymer spacing X (the distance between the centers of the smallest enclosing circles of the irregular cross-sections connecting the polymer components) to the distance Y (the distance between the joint surfaces of the cross-sections), i.e., X / Y, is 1.7.

[0232] Next, using a circular knitting machine with a 28-gauge gauge, the composite fibers are knitted. Figure 9 The circular knit fabric with double rib knit shown.

[0233] Then, under the same conditions as in Example 6, the knitted fabric was dyed using disperse dyes and hydrophilic agents, and dry heat final setting was performed at a temperature of 160°C for 1 minute.

[0234] In the resulting knitted fabric, the aforementioned composite fibers were split, resulting in V-shaped cross-section fibers (with two protrusions) composed of nylon 6 and 2.6 mol% of 5-sulfoisophthalate copolymerized polyethylene terephthalate, which were randomly mixed to create a deep color tone, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the single fiber fineness of both the polyester (sulfoisophthalate copolymer) and polyamide (nylon 6) fibers in the knitted fabric was 1.1 dtex. The evaluation results are shown in Table 3.

[0235] (Example 12)

[0236] The material obtained in Example 11, composed of nylon 6 and copolymer polyethylene terephthalate, was used. Figure 1 The X-shaped composite fiber shown (total fineness 55 dtex / 24 fibers, crimp rate 5.7%).

[0237] The composite fiber is configured as warp and weft yarns and used on a rapier loom to... Figure 11 The fabric shown is a plain weave fabric.

[0238] Then, the woven fabric was subjected to a spreading and scouring treatment at 95°C using a scouring device. After dyeing with disperse dyes at 130°C using a liquid dyeing machine, the same water-repellent treatment as in Example 8 was performed.

[0239] The woven fabric obtained in this way has a unit area weight of 75 g / m². 2 The warp density is 172 threads / 2.54cm, the weft density is 128 threads / 2.54cm, and the cover factor is 2153. The aforementioned composite fiber is split, with V-shaped cross-section fibers composed of nylon 6 and 2.6 mol% of 5-sulfoisophthalate copolymerized polyethylene terephthalate randomly mixed, resulting in a deep color tone, a delicate coin-blend effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the polyester (sulfoisophthalate copolymer) and polyamide (nylon 6) fibers in the woven fabric both have a single fiber fineness of 1.1 dtex. The evaluation results are shown in Table 4.

[0240] (Example 13)

[0241] Under the same conditions as in Example 10, the composition of nylon 6 and copolymer polyethylene terephthalate was tested. Figure 1The POY of the X-shaped composite fiber shown (total fineness 92 dtex / 24 ends) is subjected to false twisting and shrinking processing to obtain false twisted and shrinking yarn (total fineness 55 dtex / 48 ends, shrinkage rate 4.5%). The ratio of the polymer spacing X at the center of the smallest enclosing circle of the irregular cross-section connecting the polymer components to the joint surface distance Y of the cross-section, i.e., X / Y, is 1.7.

[0242] Next, the false-twist, crimped yarn composed of the aforementioned composite fibers is configured as warp and weft yarns, and then, using a rapier loom, ... Figure 11 The fabric shown is a plain weave fabric.

[0243] Then, under the same conditions as in Example 9, the plain fabric was expanded and refined, dyed with acid dyes and cationic dyes, and then subjected to a water-repellent treatment.

[0244] The woven fabric obtained in this way has a unit area weight of 88.3 g / m². 2 The warp density is 208 threads / 2.54cm, the weft density is 112 threads / 2.54cm, and the cover factor is 2251. The aforementioned composite fiber is split, with V-shaped cross-section fibers (with two protrusions) composed of nylon 6 and 2.6 mol% of 5-sulfoisophthalate copolymerized polyethylene terephthalate, randomly mixed to create a deep color tone, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the polyester (sulfoisophthalate copolymer) and polyamide (nylon 6) fibers in the woven fabric both have a fineness of 1.1 dtex. The evaluation results are shown in Table 4.

[0245] (Example 14)

[0246] The copolymer of nylon 6 (low glass transition temperature) and 2.6 mol% sodium 5-sulfoisophthalate was used to produce polyethylene terephthalate (η=0.55, high glass transition temperature). The yarn was spun at a spinning temperature of 265°C and wound at a spinning speed of 2500 m / min. The wound exhibited the following characteristics: Figure 4 The composite fiber shown has a side-by-side cross-sectional shape (50:50 weight ratio of the two components). It is preheated and stretched at 90°C, then heat-set in a 180°C slot heater, and wound at a speed of 600 m / min to obtain a yarn with a total fineness of 55 dtex / 24 yarns (shrinkage rate 13.3%). The ratio of the polymer spacing X (the distance between the centers of the smallest enclosing circles of the irregular cross-sections connecting the polymer components) to the distance Y (the distance between the joint surfaces of the cross-sections), i.e., X / Y, is 2.3.

[0247] Next, the composite fibers are configured as warp and weft yarns, and a rapier loom is used to... Figure 11 The fabric shown is a plain weave fabric.

[0248] Next, under the same conditions as in Example 12, the plain fabric was subjected to a spreading and scouring treatment, and then dyed with disperse dyes at a temperature of 130°C. Similarly to Example 12, the same water-repellent treatment as in Example 8 was performed.

[0249] The woven fabric obtained in this way has a unit area weight of 78 g / m². 2 The warp density is 180 threads / 2.54 cm, the weft density is 134 threads / 2.54 cm, and the cover factor is 2209. The aforementioned composite fiber is split, with irregularly shaped cross-section fibers composed of nylon 6 and irregularly shaped cross-section fibers composed of 2.6 mol% of sodium 5-sulfoisophthalate copolymer polyethylene terephthalate forming rectangular cross-sections and randomly mixed, resulting in a deep color tone, a delicate coin bleed effect, a fluffy woolen texture, and abrasion resistance. Furthermore, the single fiber fineness of both the polyester (sodium sulfoisophthalate copolymer polyester) and polyamide (nylon 6) fibers contained in the woven fabric is 1.1 dtex. The evaluation results are shown in Table 4.

[0250] (Comparative Example 4)

[0251] Using polyethylene terephthalate false twisted yarn (semi-dull) with a total fineness of 66 dtex / 48 threads, knitted on a 28-gauge circular knitting machine. Figure 9 The circular knit fabric with double rib knit shown.

[0252] Then, the knitted fabric was dyed using disperse dyes at 130°C for 15 minutes. During this process, a hydrophilic agent (polyethylene terephthalate-polyethylene glycol copolymer) was added to the dye bath at a ratio of 2 ml / L to impart hydrophilicity to the fabric. Next, the circular knitted fabric was subjected to final heat setting at 160°C for 1 minute. The resulting knitted fabric exhibited excellent absorbency and quick-drying properties, but the color was monochromatic, failing to achieve a chambray-like appearance. The evaluation results are shown in Table 3.

[0253] (Comparative Example 5)

[0254] As warp yarns, a 7:2 ratio of semi-dull polyester crimped yarn (38 dtex / 36 ends, twist S 300 t / m, yarn A) with a total fineness of 38 dtex / 36 ends and a bright polyester crimped yarn (33 dtex / 36 ends, twist Z 300 t / m, high-strength yarn B) with a yarn strength of 4.9 cN / dtex is used; as weft yarns, a bright polyester crimped yarn (4.9 cN / dtex, 33 dtex / 36 ends, twist Z 300 t / m, high-strength yarn B) with a yarn strength of 4.9 cN / dtex is used, on a rapier loom, with... Figure 11 The fabric shown is a plain weave fabric.

[0255] Then, under the same conditions as in Example 12, the plain fabric was subjected to a spreading and scouring treatment, and dyed with disperse dyes at a temperature of 130°C. Similarly to Example 12, the same water-repellent treatment as in Example 8 was performed.

[0256] The woven fabric obtained in this way has a unit area weight of 59.6 g / m². 2 The warp density is 165 threads / 2.54cm, the weft density is 130 threads / 2.54cm, and the coverage factor is 1667. Furthermore, the color is monochromatic, failing to achieve a chambray-like appearance. The evaluation results are shown in Table 4.

[0257]

[0258]

[0259] (Inspection)

[0260] The following further illustrates the application of the above embodiments 1 to 5. Detailed information on the results obtained from Comparative Examples 1 to 3.

[0261] In Examples 1-4, by combining two polymers with different glass transition temperatures and bonding them with irregularly shaped cross-sections, the ratio of the polymer spacing X to the bonding distance Y of each component, X / Y, is greater than 1.1, exhibiting a high shrinkage rate. Furthermore, one component is nylon 6, which exhibits a significant change in shrinkage morphology due to its elongation in boiling water. Thus, through reversal of the shrinkage coils inside and outside each component, peeling occurs at the bonding surface, resulting in fiber splitting and the mixing of the two separately dyed components. With the configuration change, two types of irregularly shaped cross-section fibers, separated from the irregularly shaped parallel composite cross-section fibers, can be identified on the fabric surface. It should be noted that the curling shape of Example 1 is as follows... Figure 7 As shown, the coil size is large.

[0262] Example 5 is a fiber that is further refined from Example 1, resulting in a soft texture due to the finer fibers. Furthermore, due to the blending effect of the finer fibers, it exhibits deep shadows and chanble effects.

[0263] Comparative Example 1 uses conventionally known fibers with side-by-side cross-sections formed by bonding semicircles. The distance X between the two polymer components is 0 (zero), and the distance between their centroids is shorter than the distance Y at the bonding surfaces, resulting in a small, curled shape and minimal change in length before and after boiling water treatment. Therefore, there are almost no split fibers, and no blending effect is achieved in the fabric. It should be noted that the curled shape of Comparative Example 1 is as follows: Figure 8 As shown, the coil size is small.

[0264] Comparative Example 2 is a parallel cross-section formed by fitting a triangular cross-section. Although it has one protrusion, the separation is insufficient because the distance Y between the joint surfaces is longer than the distance X between the two polymer components. The fabric contains portions where both components are visible, as well as portions where only one component is visible. The uneven shape formed on the fabric surface by the separated and unseparated portions also results in poorer quality.

[0265] In Comparative Example 3, the polymer compositions of the combination were the same. Due to the difference in molecular weight and cross-sectional shape, a large shrinkage property was obtained. However, since Nylon 6 was not used, the change in shrinkage morphology before and after boiling water treatment was small, and the fiber splitting and mixing properties were not obtained.

[0266] Industrial availability

[0267] According to the present invention, irregularly shaped parallel composite cross-section fibers with excellent process passability can be obtained. Furthermore, irregularly shaped cross-section fibers suitable for improving fabric quality can be obtained from these irregularly shaped parallel composite cross-section fibers, thereby creating fabrics with good texture and unique appearance.

[0268] Symbol Explanation

[0269] X is the minimum inter-center distance between the containment circles of each polymer component (polymer spacing).

[0270] Y represents the length (distance between the mating surfaces) of different polymer components.

Claims

1. A type of irregularly shaped parallel composite cross-section fiber, characterized in that, It is composed of two polymers with different glass transition temperatures. The cross-sectional shape of the polymer components is irregular. The ratio of the polymer spacing X connecting the centers of the smallest enclosing circles of the irregular cross-sections of each polymer component to the joint surface distance Y of the cross-sections is 1.1 or more.

2. The irregularly shaped parallel composite cross-section fiber according to claim 1, wherein, The cross-sectional shape of the polymer component has more than two protrusions relative to the bonding surface of each polymer.

3. The irregularly shaped parallel composite cross-section fiber according to claim 1 is a crimped fiber.

4. The irregularly shaped parallel composite cross-section fiber according to claim 1, wherein, The two polymers consist of a polyamide polymer and a copolyester polymer.

5. The irregularly shaped parallel composite cross-section fiber according to claim 4, wherein, The polyamide polymer is nylon 6 polymer.

6. The irregularly shaped parallel composite cross-section fiber according to claim 4, wherein, The copolyester polymer is sodium sulfoisophthalate copolyester.

7. The irregularly shaped parallel composite cross-section fiber according to claim 1 is a three-dimensional crimped fiber composed of two polymers: nylon 6 polymer and copolyester polymer, with nylon 6 polymer disposed on the inner side.

8. The irregularly shaped parallel composite cross-section fiber according to claim 7, wherein, The fiber contains fibers that repeatedly exhibit the following phenomenon: In a hot water bath at a temperature above 80°C, the nylon 6 polymer inside the three-dimensional crimped coil elongates, changing from a three-dimensional crimped structure to a straight fiber form. When removed from the hot water bath, the yarn temperature decreases and the absorbed water is dried, causing it to return to a three-dimensional crimped state. Furthermore, the elongation change rate of this irregularly shaped, parallel composite cross-section fiber after boiling water treatment for 30 minutes, i.e., Equation 1, is 130–200%. Elongation change rate: (Length after hot water treatment - Length during drying) / Length during drying × 100 (%) ... Equation 1 The length measurements were all light load lengths of yarn fineness × 2 mg / dtex, with fineness measured in dtex.

9. The irregularly shaped parallel composite cross-section fiber according to claim 7, wherein, In a hot water bath at a temperature above 80°C, the nylon 6 polymer inside the three-dimensional coil elongates and changes from a three-dimensional coil structure to a straight fiber form, causing the joint surface to peel off.

10. The irregularly shaped parallel composite cross-section fiber according to claim 7, wherein, In a hot water bath at a temperature above 80°C, the nylon 6 polymer inside the three-dimensional coil is reversed and positioned on the outside of the three-dimensional coil due to self-elongation, and the bonding surface peels off.

11. A method for manufacturing irregularly shaped cross-section fibers, characterized in that, Peel off the joint surface of the irregularly shaped parallel composite cross-section fibers as described in claim 1.

12. The method for manufacturing irregularly shaped cross-section fibers according to claim 11, wherein, The peeling method is hot water shrinkage treatment.

13. A method for manufacturing a fabric, characterized in that, A sheet is made using the irregularly shaped parallel composite cross-section fibers of claim 1, which are composed of two polymers with different glass transition temperatures and whose polymer components have irregular cross-sectional shapes, and the irregularly shaped parallel composite cross-section fibers are peeled off.

14. The method for manufacturing fabric according to claim 13, wherein, The two polymers with different glass transition temperatures are polyester and polyamide.

15. The method for manufacturing fabric according to claim 13, wherein, The cross-sectional shapes of the various polymers are the same.

16. The method for manufacturing fabric according to claim 13, wherein, The fineness of each individual fiber after peeling is less than 2.0 dtex.

17. The fabric according to claim 13, wherein, The weight per unit area of ​​the fabric is between 30 and 300 g / m². 2 Within the range.

18. The method for manufacturing fabric according to claim 13, wherein, The fabric is knitted and has a density of 50-120 loops per 2.54 cm in the horizontal row and 40-100 loops per 2.54 cm in the vertical row.

19. The method for manufacturing fabric according to claim 13, wherein, The fabric is woven, with a warp density of 50-300 threads / 2.54cm and a weft density of 50-300 threads / 2.54cm.

20. The method for manufacturing fabric according to claim 13, wherein, In fabrics, the abrasion durability, measured according to the Martindale method of JIS-L1096, is over 30,000 cycles.

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