Polyester resin composition for melt spinning, method for producing polyester fibers, and polyester fibers

Abstract

This invention makes it possible to suppress the decrease in dyeability and colorfastness when dyeing conditions are relaxed for polyester fibers, and to reduce uneven dyeing. [Solution] (B) The polyester copolymer has constituent units derived from (B1) polyalkylene glycol. The average molecular weight of (B1) polyalkylene glycol is in the range of 400 or more and 4000 or less. The content of constituent units derived from (B1) polyalkylene glycol in (B) the polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, and the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less. (B) The polyester copolymer is mixed with (A) polyester in an amount of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of (A) polyester and (B) polyester copolymer and used for melt spinning applications.

Description

Technical Field

[0001] The present disclosure relates to a polyester copolymer, a polyester resin composition for melt spinning, a method for producing polyester fibers, and polyester fibers.

Background Art

[0002] In a polyester resin composition for melt spinning for melt-spinning polyester fibers, a polyester copolymer may be contained for the purpose of modification. As such a polyester polymer, for example, those containing polytetramethylene glycol as a copolymer component are known as described in Patent Documents 1 to 3.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] When dyeing polyester fibers, relaxing the dyeing conditions such as the dyeing temperature is advantageous, for example, from the viewpoint of reducing the energy consumption in the dyeing process. When the dyeing conditions are relaxed, in order to suppress a decrease in the dyeability and fastness of the polyester fibers, when attempting to mix a polyester copolymer into the polyester, the following phenomenon occurred. By mixing a polyester copolymer containing a polyalkylene glycol as a copolymer component into the polyester, it is possible to suppress a decrease in the dyeability and fastness of the polyester fibers, but dyeing unevenness occurred.

Means for Solving the Problems

[0005] The polyester copolymer that solves the above problems is a (B) polyester copolymer used for the purpose of obtaining a polyester resin composition for melt spinning by mixing with (A) polyester, wherein it has constituent units derived from (B1) polyalkylene glycol, the average molecular weight of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less, the content of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, and the content of low molecular weight components having a molecular weight of 600 or less in the (B) polyester copolymer is 15% by mass or less, and is used by mixing with the (A) polyester in an amount of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

[0006] A polyester resin composition for melt spinning that solves the above problems is a polyester resin composition for melt spinning that contains (A) polyester and (B) polyester copolymer, wherein the (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, the average molecular weight of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less, the content of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, the content of low molecular weight components having a molecular weight of 600 or less in the (B) polyester copolymer is 15% by mass or less, and the content of the (B) polyester copolymer in the melt spinning polyester resin composition is in the range of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

[0007] A method for producing polyester fibers that solves the above problems is a method for producing polyester fibers comprising the step of melt-spinning a polyester resin composition for melt-spinning, wherein the polyester resin composition for melt-spinning contains (A) polyester and (B) a polyester copolymer, the (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, and the average molecular weight of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less. The content of constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, the content of low molecular weight components having a molecular weight of 600 or less in the (B) polyester copolymer is 15% by mass or less, and the content of the (B) polyester copolymer in the melt-spinning polyester resin composition is in the range of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

[0008] A polyester fiber that solves the above problems is a polyester fiber containing (A) polyester and (B) a polyester copolymer, wherein the (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, the average molecular weight of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less, the content of the constituent units derived from (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, the content of low molecular weight components having a molecular weight of 600 or less in the (B) polyester copolymer is 15% by mass or less, and the content of the (B) polyester copolymer in the polyester fiber is in the range of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer. [Effects of the Invention]

[0009] This disclosure provides the effect of suppressing the decrease in dyeability and fastness when dyeing conditions are relaxed for polyester fibers, as well as reducing uneven dyeing. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described below. The polyester resin composition for melt spinning contains (A) polyester and (B) a polyester copolymer.

[0011] <(A) Polyester> (A) Polyester is the main component of polyester resin compositions for melt spinning. (A) Examples of polyester include aromatic polyesters and aliphatic polyesters. Examples of aromatic polyesters include polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate. Examples of aliphatic polyesters include polylactic acid and polyglycolic acid.

[0012] (A) One or more types of polyester may be used. (A) From the viewpoint of further improving dyeability, the polyester preferably contains at least one selected from polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate. (A) The intrinsic viscosity of the polyester is preferably in the range of 0.3 or more and 1.7 or less, and more preferably in the range of 0.4 or more and 1.0 or less.

[0013] <(B) Polyester copolymer> (B) Polyester copolymers have structural units derived from (B1) polyalkylene glycol. The structural units derived from (B1) polyalkylene glycol in (B) polyester copolymers are groups obtained by removing the terminal OH from polyalkylene glycol. In other words, (B) polyester copolymers contain (B1) polyalkylene glycol as a copolymer component. A copolymer component refers to a monomer unit that forms a (B) polyester copolymer.

[0014] (B) The average molecular weight of the constituent units derived from (B1) polyalkylene glycol in the polyester copolymer is in the range of 400 or more and 4000 or less, preferably in the range of 400 or more and 3000 or less. When this average molecular weight is 400 or more, it is possible to suppress the occurrence of yarn breakage in the melt spinning process of the polyester resin composition for melt spinning. When this average molecular weight is 4000 or less, it is possible to improve the dyeability of the polyester fibers obtained from the polyester resin composition for melt spinning.

[0015] In this specification, the average molecular weight of the constituent units derived from (B1) polyalkylene glycol is the number-average molecular weight. The number-average molecular weight of (B1) polyalkylene glycol can be measured by GPC (gel permeation chromatography).

[0016] (B) The content of constituent units derived from (B1) polyalkylene glycol in the polyester copolymer is in the range of 15% by mass or more and 60% by mass or less, preferably in the range of 15% by mass or more and 50% by mass or less. When this content is 15% by mass or more, it is possible to improve dyeability. When this content is 60% by mass or less, it is possible to suppress the occurrence of yarn breakage in the melt spinning process of the polyester resin composition for melt spinning.

[0017] (B) The content of constituent units derived from (B1) polyalkylene glycol in the polyester copolymer is (B) 1It can be determined based on the peak intensity obtained by 1H-NMR spectrum analysis.

[0018] (B1) The polyalkylene glycol may be a homopolymer of an alkylene glycol or a copolymer of an alkylene glycol. Examples of the homopolymer of an alkylene glycol include polyethylene glycol, polypropylene glycol, polytetramethylene glycol, etc. Examples of the copolymer of an alkylene glycol include polyethylene glycol-polypropylene glycol copolymer (polyoxyethylene polyoxypropylene glycol), polyethylene glycol-polytetramethylene glycol copolymer, etc.

[0019] (B1) The polyalkylene glycol preferably contains at least one selected from polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and polyethylene glycol-polypropylene glycol copolymer.

[0020] (B) The polyester copolymer contains, for example, a structural unit derived from at least one of (B21) an aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid, and a structural unit derived from (B22) a diol. The structural unit derived from (B21) an aromatic dicarboxylic acid in the (B) polyester copolymer is a group obtained by removing the COOH group from the aromatic dicarboxylic acid. The structural unit derived from the ester-forming derivative of (B21) an aromatic dicarboxylic acid in the (B) polyester copolymer is a group obtained by removing the COOR group from the ester-forming derivative of (B21) an aromatic dicarboxylic acid. R in the COOR group is, for example, an alkyl group having 1 to 6 carbon atoms or a hydroxyalkyl group having 1 to 6 carbon atoms. The structural unit derived from (B22) a diol in the (B) polyester copolymer is a group obtained by removing OH from (B22) a diol.

[0021] In other words, the (B) polyester copolymer contains, for example, as the (B2) second copolymer component copolymerized with (B1) a polyalkylene glycol, at least one of (B21) an aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid, and (B22) a diol.

[0022] (B21) Examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, phthalic acid, 5-sodium sulfoisophthalic acid, 5-lithium sulfoisophthalic acid, 5-(tetraalkyl)phosphonium sulfoisophthalic acid, 4,4'-diphenyldicarboxylic acid, 2,6-naphthalenedicarboxylic acid, and the like. One or more kinds of aromatic dicarboxylic acids can be used.

[0023] (B21) Examples of the ester-forming derivative of an aromatic dicarboxylic acid include an alkyl ester having 1 to 6 carbon atoms or a hydroxyalkyl ester having 1 to 6 carbon atoms of the above (B21) aromatic dicarboxylic acid, and examples thereof include dimethyl terephthalate, diethyl terephthalate, dipropyl terephthalate, dibutyl terephthalate, dihexyl terephthalate, bis(hydroxyethyl) terephthalate, bis(hydroxypropyl) terephthalate, bis(hydroxybutyl) terephthalate, bis(hydroxyhexyl) terephthalate, and the like. One or more kinds of ester-forming derivatives of an aromatic dicarboxylic acid can be used.

[0024] (B21) The aromatic dicarboxylic acid in at least one of (B21) an aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid preferably contains at least one selected from terephthalic acid, isophthalic acid, and 2,6-naphthalenedicarboxylic acid from the viewpoint of enhancing the spinnability and the dyeability of the obtained polyester fiber.

[0025] (B) The total content of constituent units derived from (B21) aromatic dicarboxylic acid and constituent units derived from ester-forming derivatives of aromatic dicarboxylic acid in the polyester copolymer is preferably in the range of 15% by mass or more and 50% by mass or less, and more preferably in the range of 20% by mass or more and 40% by mass or less. When this content is 15% by mass or more, it is possible to improve spinability. When this content is 50% by mass or less, it is possible to improve spinability.

[0026] Examples of (B22) diols include aliphatic diols, alicyclic diols, and aromatic diols. Examples of aliphatic diols include ethylene glycol, 1,2-propanediol (propylene glycol), 1,3-propanediol (trimethylene glycol), 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, neopentyl glycol, and diethylene glycol. Examples of alicyclic diols include cyclopentanediol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, and 1,4-cyclohexanedimethanol. Examples of aromatic diols include naphthalenediol, bisphenol A, and resorcinol. As the (B22) diol, polyalkylene glycols other than the (B1) polyalkylene glycol mentioned above (such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, etc.) may also be used. One or more types of (B22) diols may be used.

[0027] (B22) Diol preferably contains at least one selected from ethylene glycol, propanediol, and butanediol, from the viewpoint of improving spinnability and the dyeability of the resulting polyester fibers.

[0028] (B) The content of constituent units derived from (B22) diol in the polyester copolymer is preferably in the range of 0.5% by mass or more and 20% by mass or less, and more preferably in the range of 5% by mass or more and 15% by mass or less. When this content is 0.5% by mass or more, it is possible to improve spinability. When this content is 20% by mass or less, it is possible to improve spinability.

[0029] (B) Polyester copolymers can be obtained, for example, by the reaction of (B1) polyalkylene glycol with (B21) at least one of aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid and (B22) diol. (B) Polyester copolymers can be synthesized in a single step or in a multi-step reaction. For example, a polyester can be obtained by first reacting (B21) at least one of aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid with (B22) diol, and then reacting that polyester with (B1) polyalkylene glycol.

[0030] (B) The polyester copolymer may contain polyfunctional compounds of trivalent or higher as copolymer components, provided that the polymer chains constituting the (B) polyester copolymer are substantially linear. Examples of polyfunctional compounds of trivalent or higher include trimellitic acid, trimesic acid, pyromellitic acid, tricarbaryl acid, and gallic acid. The (B) polyester copolymer may also contain monofunctional compounds as copolymer components. Examples of monofunctional compounds include benzoic acid, toluic acid, 1-naphthoic acid, 2-naphthoic acid, and o-benzoylbenzoic acid. The (B) polyester copolymer may also contain hydroxycarboxylic acids as copolymer components. Examples of hydroxycarboxylic acids include lactic acid, glycolic acid, and hydroxybenzoic acid.

[0031] (B) In the polyester copolymer, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less, preferably 10% by mass or less, more preferably 7% by mass or less, and even more preferably 3% by mass or less. When the content of these low molecular weight components is 15% by mass or less, it is possible to reduce uneven dyeing.

[0032] In this specification, the molecular weight of low molecular weight components refers to the number-average molecular weight. The number-average molecular weight of low molecular weight components can be measured by GPC (gel permeation chromatography). Low molecular weight components can be extracted from (B) polyester copolymers using tetrahydrofuran.

[0033] Examples of low molecular weight components having a molecular weight of 600 or less include unreacted raw materials, aromatic monoester compounds, aromatic diester compounds, and aromatic polyester oligomers. Examples of unreacted raw materials include at least one of the above-mentioned (B21) aromatic dicarboxylic acid and ester-forming derivatives of aromatic dicarboxylic acid, and (B22) diols. Examples of aromatic monoester compounds and aromatic diester compounds include reaction products of at least one of (B21) aromatic dicarboxylic acid and ester-forming derivatives of aromatic dicarboxylic acid with (B22) diols. Examples of aromatic polyester oligomers include linear oligomers and cyclic oligomers. Examples of linear oligomers include dimers and trimers consisting of polyester monomer structures. Examples of cyclic oligomers include trimers consisting of polyester monomer structures. Among the cyclic oligomers, for example, the molecular weight of a trimer consisting of polyethylene terephthalate monomer structure is 576.5.

[0034] (B) The intrinsic viscosity of the polyester copolymer is preferably in the range of 0.1 to 1.7, and more preferably in the range of 0.3 to 1.0, from the viewpoint of improving spinnability and the dyeability of the resulting polyester fibers.

[0035] (B) Polyester copolymers can be synthesized using well-known esterification and polymerization (polycondensation) reactions. Alternatively, (B) polyester copolymers can also be synthesized using transesterification and polymerization reactions of ester-forming derivatives.

[0036] (B) The raw material composition for obtaining a polyester copolymer contains the above (B1) polyalkylene glycol. (B) The raw material composition for obtaining a polyester copolymer further contains (B21) at least one of an aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid, and (B22) a diol.

[0037] The content of (B1) polyalkylene glycol in the raw material composition is preferably in the range of 10% by mass or more and 60% by mass or less. The content of at least one of (B21) aromatic dicarboxylic acid and aromatic dicarboxylic acid ester-forming derivatives in the raw material composition is preferably in the range of 20% by mass or more and 50% by mass or less. The content of (B22) diol in the raw material composition is preferably in the range of 3.0% by mass or more and 55% by mass or less.

[0038] The reaction conditions for the esterification reaction or the transesterification reaction affect the content of the low molecular weight component in the polyester copolymer (B). By setting the reaction conditions for the esterification reaction or the transesterification reaction as follows, the content of the low molecular weight component in the polyester copolymer (B) can be reduced.

[0039] • Increase the reaction time. • Slow down the heating rate. - In the raw material composition, increase the content of (B1) polyalkylene glycol relative to the content of at least one of (B21) aromatic dicarboxylic acid and aromatic dicarboxylic acid ester-forming derivatives.

[0040] - In the raw material composition, increase the content of (B22) diol relative to the content of at least one of (B21) aromatic dicarboxylic acid and aromatic dicarboxylic acid ester-forming derivatives.

[0041] For example, the reaction start temperature is preferably in the range of 130°C to 160°C. The reaction end temperature is preferably in the range of 220°C to 300°C, and more preferably in the range of 230°C to 280°C.

[0042] The reaction time is preferably in the range of 180 minutes or more and 500 minutes or less, and more preferably in the range of 200 minutes or more and 500 minutes or less. The heating rate from the reaction start temperature to the reaction end temperature is, for example, within the range of 0.1°C / min or more and 5°C / min or less. The heating rate may be constant or varied.

[0043] <Polyester resin composition and polyester fiber for melt spinning> The content of (B) polyester copolymer in the melt-spinning polyester resin composition is in the range of 0.5 parts by mass or more and 15 parts by mass or less, preferably in the range of 1 part by mass or more and 10 parts by mass or less, based on 100 parts by mass of the total of (A) polyester and (B) polyester copolymer. When this content is 0.5 parts by mass or more, it is possible to improve dyeability. When this content is 15 parts by mass or less, it is possible to suppress the occurrence of yarn breakage in the melt-spinning process of the melt-spinning polyester resin composition.

[0044] The content of (A) polyester in the melt-spinning polyester resin composition is preferably in the range of 50% by mass or more and 99.5% by mass or less, more preferably in the range of 60% by mass or more and 99.0% by mass or less, even more preferably in the range of 70% by mass or more and 98.0% by mass or less, and most preferably in the range of 80% by mass or more and 97.0% by mass or less, from the viewpoint of improving spinnability.

[0045] The content of (B) polyester copolymer and (A) polyester in the polyester fibers is the same as that in the polyester resin composition for melt spinning described above.

[0046] Polyester resin compositions for melt spinning may also contain, for example, heat-resistant agents, antioxidants, ultraviolet absorbers, infrared absorbers, fluorescent whitening agents, conductive agents, antistatic agents, compatibilizers, plasticizers, mold release agents, antibacterial agents, nucleating agents, matting agents, defoaming agents, preservatives, gelling agents, latex, fillers, fragrances, and the like.

[0047] A polyester resin composition for melt spinning can be prepared by mixing (A) polyester and (B) a polyester copolymer such that the amount of (B) polyester copolymer is within the above-mentioned range. Alternatively, a polyester resin composition for melt spinning can also be prepared by pre-preparing a mixture of (A) polyester and (B) polyester copolymer and then diluting that mixture with (A) polyester. Furthermore, a polyester resin composition for melt spinning can also be prepared by pre-preparing a mixture of (A) polyester and (B) polyester copolymer and then further mixing in the (B) polyester copolymer.

[0048] The mixing of (A) polyester and (B) polyester copolymer can be carried out by well known methods. Examples of mixers used for this mixing include tumblers, V-type blenders, super mixers, Banbury mixers, kneading rolls, and single-screw or twin-screw extruders.

[0049] The fineness of a single polyester fiber is preferably in the range of 0.01 dtex or more and 300 dtex or less, and more preferably in the range of 0.05 dtex or more and 250 dtex or less, from the viewpoint of improving spinnability and the dyeability of the resulting polyester fiber.

[0050] Polyester fibers are used for dyeing purposes. Polyester fibers can be dyed using, for example, disperse dyes. Examples of disperse dyes include benzeneazo, heterocyclic azo, disazo, anthraquinone, quinoline, nitro, coumarin, methine, and aminoketone dyes.

[0051] Examples of staining methods include printing, continuous staining, and immersion staining. Examples of immersion staining methods include jet staining, cheese staining, beam staining, Obermeyer staining, and high-pressure jet staining.

[0052] From the viewpoint of reducing energy consumption in the dyeing process, the dyeing temperature is preferably, for example, 125°C or lower, more preferably in the range of 95°C to 125°C, even more preferably in the range of 97°C to 120°C, and most preferably in the range of 100°C to 120°C. The dyeing pressure is the saturated vapor pressure of water contained in the dyeing solution.

[0053] Polyester fibers can be used in various forms, such as yarn, knitted fabrics, woven fabrics, and nonwoven fabrics. Examples of applications for polyester fibers include apparel, interior design, and industrial materials.

[0054] <Method for manufacturing polyester fibers> A method for producing polyester fibers comprises a step of melt-spinning the above-mentioned polyester resin composition for melt-spinning. A well-known method can be used for the melt-spinning step. Preferably, the method for producing polyester fibers comprises a step of drying the polyester resin composition for melt-spinning as a step prior to the melt-spinning step. In this case, it is possible to suppress the decrease in molecular weight due to hydrolysis of the polyester resin and to suppress foaming caused by moisture during the melt-spinning step. The step of drying the polyester resin composition for melt-spinning may be a step of drying a mixture of (A) polyester and (B) polyester copolymer, or it may be a step of drying (A) polyester and (B) polyester copolymer separately.

[0055] (A) The water content of the polyester and (B) the water content of the polyester copolymer are preferably 0 ppm or more and 300 ppm or less, more preferably 0 ppm or more and 100 ppm or less, and even more preferably 0 ppm or more and 50 ppm or less.

[0056] The melt-spinning process may be carried out continuously with the process of preparing the polyester resin composition for melt-spinning, or solidified pellets of the polyester resin composition for melt-spinning may be prepared in advance and the process may be carried out using those pellets.

[0057] A melt extruder can be used to melt polyester resin compositions for melt spinning. Examples of melt extruders include pressure melter type melt extruders and single-screw or twin-screw extruder type melt extruders.

[0058] In the melt-spinning process, a polyester resin composition for melt-spinning is extruded in fibrous form from the spindle of a melt-spinning machine. In the melt-spinning process, polyester fibers can be obtained by solidifying the fibrous polyester resin composition for melt-spinning extruded from the spindle by cooling. The obtained polyester fibers are then wound up, for example, after being coated with a yarn oil.

[0059] The spinning temperature in the melt spinning process can be selected according to the melting point, heat resistance, etc., of (A) polyester and (B) polyester copolymer. The spinning temperature is preferably in the range of 190°C or higher and 320°C or lower, more preferably in the range of 240°C or higher and 310°C or lower, even more preferably in the range of 250°C or higher and 310°C or lower, and most preferably in the range of 260°C or higher and 300°C or lower. When the spinning temperature is 190°C or higher, the occurrence of yarn breakage can be suppressed. When the spinning temperature is 320°C or lower, the thermal decomposition of the polyester resin composition for melt spinning can be suppressed.

[0060] The spinning speed in the melt-spinning process can be selected according to the composition of the polyester resin composition for melt-spinning, the spinning temperature, etc. Furthermore, the spinning speed is selected as follows, for example, depending on whether it is a one-step method in which the melt-spinning and drawing processes are performed consecutively, or a two-step method in which the yarn is drawn or false-twisted in a separate process after the melt-spinning process. The one-step method is also called the FDY (Fully Draw Yarn) method. The two-step method is also called the POY (Partially Oriented Yarn) / DTY (Draw Textured Yarn) method.

[0061] In the above one-step method, the spinning speed is set, for example, by the first take-up roller and the second take-up roller. The speed of the first take-up roller is preferably in the range of 50 m / min or more and 5000 m / min or less, and more preferably in the range of 80 m / min or more and 4500 m / min or less. The speed of the second take-up roller is preferably in the range of 60 m / min or more and 6000 m / min or less, and more preferably in the range of 100 m / min or more and 5500 m / min or less.

[0062] In the two-step method described above, the spinning speed is preferably within the range of 500 m / min or more and 6000 m / min or less. This spinning speed is more preferably 1000 m / min or more, and even more preferably 1500 m / min or more. This spinning speed is more preferably 4500 m / min or less, and even more preferably 4000 m / min or less.

[0063] In the stretching step of the one-step or two-step method described above, either a single-stage stretching method or a multi-stage stretching method of two or more stages can be used. The yarn being stretched is heated by a direct or indirect heating method. Examples of heating methods include heating elements such as heating rollers, heating pins, and heating plates; a liquid bath using hot water or hot water; a gas bath using hot air or steam; and laser irradiation. One heating method or a combination of two or more methods can be used. As for the heating method, from the viewpoint of ease of temperature control, it is preferable that at least one of contact with a heating element and immersion in a liquid bath is used.

[0064] The stretching temperature in the stretching process can be selected according to the extrapolation melting start temperature of (A) polyester and (B) polyester copolymer, the strength and elongation of the fibers after stretching, etc. In the case of a one-step method, the stretching temperature in the stretching process is preferably in the range of 50°C to 150°C, more preferably in the range of 60°C to 145°C, and even more preferably in the range of 70°C to 140°C. If the stretching temperature in the one-step method is 50°C or higher, for example, the quality of the yarn can be improved. If the stretching temperature in the one-step method is 150°C or lower, for example, the stretching process can be carried out stably. In the stretching process, heat setting may be performed in the temperature range of 60°C to 150°C as needed.

[0065] In the case of a two-step method, the stretching temperature is preferably in the range of 100°C to 230°C, more preferably in the range of 120°C to 210°C, and even more preferably in the range of 160°C to 200°C. When the stretching temperature in the two-step method is 100°C or higher, the running yarn becomes more stable, which can further suppress the occurrence of yarn breakage. When the stretching temperature in the two-step method is 230°C or lower, the occurrence of yarn breakage can be further suppressed.

[0066] The stretching ratio in the stretching process can be selected according to the elongation of the fibers before stretching, the strength and elongation of the fibers after stretching, etc. From the viewpoint of further improving colorfastness and dyeability, the stretching ratio is preferably in the range of 1.02 times or more and 7.0 times or less, more preferably in the range of 1.2 times or more and 6.5 times or less, and even more preferably in the range of 1.5 times or more and 6.0 times or less.

[0067] The stretching speed in the stretching process can be selected according to the one-step method, two-step method, etc. The stretching speed in the one-step method corresponds to the speed of the second take-up roller, so the explanation is omitted. In the case of the two-step method, the stretching speed is preferably in the range of 30 m / min or more and 1000 m / min or less, more preferably in the range of 50 m / min or more and 900 m / min or less, and even more preferably in the range of 100 m / min or more and 800 m / min or less. When the stretching speed is above the lower limit, the running yarn is stabilized, which can suppress the occurrence of yarn breakage. When the stretching speed is below the upper limit, the occurrence of yarn breakage can be suppressed. Furthermore, there are no particular restrictions on the winding speed, but it is preferably in the range of 500 m / min or more and 6000 m / min or less.

[0068] <Operation and Effects of This Embodiment> Next, the operation and effects of this embodiment will be described. (B) The polyester copolymer is used to obtain a polyester resin composition for melt spinning by mixing it with (A) polyester. (B) The polyester copolymer has constituent units derived from (B1) polyalkylene glycol. The average molecular weight of the constituent units derived from (B1) polyalkylene glycol in (B) the polyester copolymer is in the range of 400 or more and 4000 or less. The content of constituent units derived from (B1) polyalkylene glycol in (B) the polyester copolymer is in the range of 15% by mass or more and 60% by mass or less. (B) The polyester copolymer is used by mixing it with (A) polyester in an amount of 0.5 parts by mass or more and 15 parts by mass or less per 100 parts by mass of the total of (A) polyester and (B) polyester copolymer.

[0069] This configuration makes it possible to suppress the decrease in dyeability and colorfastness when dyeing conditions are relaxed in polyester fibers obtained from the above-mentioned polyester resin composition for melt spinning.

[0070] Because the (B) polyester copolymer has a more flexible molecular structure than (A) polyester, when polyester fibers are heated during the dyeing process, the (B) polyester copolymer undergoes more active molecular motion than (A) polyester. For this reason, the low molecular weight components contained in the (B) polyester copolymer tend to precipitate on the surface of polyester fibers during the dyeing process. An increase in the amount of these low molecular weight components precipitated during the dyeing process of polyester fibers leads to greater uneven dyeing of the polyester fibers.

[0071] In the polyester copolymer (B) of this embodiment, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less, which makes it possible to reduce the amount of low molecular weight components precipitated during the dyeing treatment of polyester fibers. This makes it possible to reduce uneven dyeing of polyester fibers.

[0072] <Examples> Next, examples and comparative examples will be described. <(B) Synthesis of polyester copolymers> (Synthesis example A) In Synthesis Example A, 12.1 parts by mass of (B1) polyalkylene glycol, 49.5 parts by mass of (B21) dimethyl terephthalate (DMT), 38.4 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel. The transesterification reaction was carried out by gradually raising the temperature of the raw materials in the reaction vessel from 150°C to 240°C while distilling off the water. The reaction time T for the transesterification reaction in Synthesis Example A was 450 minutes. This reaction time is the time it takes to raise the temperature from 150°C to 240°C, and the temperature was raised at a nearly constant rate so that it reached 240°C after 450 minutes.

[0073] Next, 0.01 parts by mass of polycondensation catalyst were added to the reaction vessel, and prepolymerization was carried out over 50 minutes. Subsequently, the pressure inside the reaction vessel was gradually reduced, and finally, the polymerization reaction was carried out under the conditions of 0.1 kPa, 275°C, and 160 minutes to obtain (B) polyester copolymer.

[0074] The details of the raw materials for synthesis example A are as follows: (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 1540, manufactured by NOF Corporation, product name: PEG#1540 • (B21) Aromatic dicarboxylic acid: Dimethyl terephthalate, manufactured by Fujifilm Wako Pure Chemical Industries, Ltd. • (B22) Diol: Ethylene glycol (monoethylene glycol: MEG), manufactured by Fujifilm Wako Pure Chemical Industries, Ltd. • Esterification catalyst: Titanium tetran-n-butoxide • Polycondensation catalyst: Titanium tetran-n-butoxide (Synthesis example B) In Synthesis Example B, 13.0 parts by mass of (B1) polyalkylene glycol, 45.7 parts by mass of (B21) terephthalic acid (TPA), 41.3 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel. The esterification reaction was carried out by gradually raising the temperature of the raw materials in the reaction vessel from 150°C to 240°C while distilling off the water. The reaction time T for the esterification reaction in Synthesis Example B was set to 450 minutes. This reaction time is the time required to raise the temperature from 150°C to 240°C, and the temperature was raised at a nearly constant rate so that it reached 240°C after 450 minutes.

[0075] Next, 0.01 parts by mass of polycondensation catalyst were added to the reaction vessel, and prepolymerization was carried out over 50 minutes. Subsequently, the pressure inside the reaction vessel was gradually reduced, and finally, the polymerization reaction was carried out under the conditions of 0.1 kPa, 275°C, and 160 minutes to obtain (B) polyester copolymer.

[0076] The details of the raw materials for synthesis example B are as follows: (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 1540, manufactured by NOF Corporation, product name: PEG#1540 • (B21) Aromatic dicarboxylic acid: Terephthalic acid, manufactured by Fujifilm Wako Pure Chemical Industries, Ltd. • (B22) Diol: Ethylene glycol (monoethylene glycol: MEG), manufactured by Fujifilm Wako Pure Chemical Industries, Ltd. • Esterification catalyst: Titanium tetran-n-butoxide • Polycondensation catalyst: Titanium tetran-n-butoxide (Synthesis example C) In synthesis example C, 36.2 parts by mass of (B1) PAG, 37.5 parts by mass of (B21) dimethyl terephthalate, 26.3 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0077] (Synthesis example D) In synthesis example D, the synthesis of (B) polyester copolymer was carried out in the same manner as in synthesis example A, except that the reaction time T for the transesterification reaction was changed from 450 minutes to 200 minutes.

[0078] (Synthesis example E) In Synthesis Example 5, the synthesis of (B) polyester copolymer was carried out in the same manner as in Synthesis Example A, except that the reaction time T for the transesterification reaction was changed from 450 minutes to 180 minutes.

[0079] (Synthesis example F) In synthesis example F, the following (B1)PAG was used. (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 600, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-600 In synthesis example F, 12.3 parts by mass of (B1) PAG, 50.5 parts by mass of (B21) dimethyl terephthalate, 37.2 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0080] (Synthesis example G) In synthesis example G, the following (B1)PAG was used. Synthesis Example G (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 2000, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-2000 In synthesis example G, 12.0 parts by mass of (B1) PAG, 48.9 parts by mass of (B21) dimethyl terephthalate, 39.1 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0081] (Synthesis example H) In synthesis example H, the following (B1)PAG was used. Synthesis Example H (B1)PAG: Polypropylene glycol (PPG), average molecular weight: 2000, manufactured by ADEKA Corporation, product name: ADEKA Polyether P-2000 In synthesis example H, 12.0 parts by mass of (B1) PAG, 48.9 parts by mass of (B21) dimethyl terephthalate, 39.1 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0082] (Synthesis example I) In synthesis example I, the following (B1)PAG was used. Synthesis Example I (B1) PAG: Polytetramethylene ether glycol (PTMG), average molecular weight: 2000, manufactured by Mitsubishi Chemical Corporation, product name: PTMG2000 In Synthesis Example I, 12.0 parts by mass of (B1) PAG, 48.9 parts by mass of (B21) dimethyl terephthalate, 39.1 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in Synthesis Example A.

[0083] (Synthesis example J) In synthesis example J, the following (B1)PAG was used. Synthesis Example J (B1)PAG: Polyoxyethylene polyoxypropylene glycol (POEPOPG), average molecular weight: 2000, manufactured by ADEKA Corporation, product name: ADEKA Pluronic L-44 In synthesis example J, 12.0 parts by mass of (B1) PAG, 48.9 parts by mass of (B21) dimethyl terephthalate, 39.1 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0084] (Synthesis example K) In synthesis example K, the following two types of (B1)PAG were used. • Item 1 (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 3400, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-4000S • Second (B1) PAG: Polypropylene glycol (PPG), average molecular weight: 2000, manufactured by ADEKA Corporation, product name: ADEKA Polyether P-2000 In synthesis example K, 15.8 parts by mass of the first (B1)PAG, 3.2 parts by mass of the second (B1)PAG, 45.1 parts by mass of (B21)dimethyl terephthalate, 36.0 parts by mass of (B22)ethylene glycol, and 0.01 parts by mass of the esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0085] (Synthesis example L) In synthesis example L, the following (B1)PAG was used. Synthesis Example L (B1) PAG: Polyethylene glycol (PEG), average molecular weight: 3400, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-4000S In synthesis example L, 12.0 parts by mass of (B1) PAG, 48.9 parts by mass of (B21) dimethyl terephthalate, 39.1 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0086] (Synthesis example M) In synthesis example M, the following (B1)PAG was used. (B1) PAG: Polyethylene glycol (PEG, average molecular weight: 400, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-400) In synthesis example M, 12.4 parts by mass of (B1) PAG, 51.4 parts by mass of (B21) dimethyl terephthalate, 36.2 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and then the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0087] (Synthesis example N) In synthesis example N, the following (B1)PAG was used. (B1) PAG: Polyethylene glycol (PEG, average molecular weight: 1000, manufactured by Sanyo Chemical Industries, Ltd., product name: PEG-1000) In synthesis example N, 3.4 parts by mass of (B1) PAG, 54.0 parts by mass of (B21) dimethyl terephthalate, 42.6 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and then the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0088] (Synthesis examples O, P, Q) Synthesis examples O, P, and Q used the same starting materials as synthesis example A. In synthesis example O, 5.7 parts by mass of (B1) PAG, 52.7 parts by mass of (B21) dimethyl terephthalate, 41.5 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and then the (B) polyester copolymer was synthesized in the same manner as in synthesis example A.

[0089] In synthesis example P, 52.2 parts by mass of (B1) PAG, 29.5 parts by mass of (B21) dimethyl terephthalate, 18.3 parts by mass of (B22) ethylene glycol, and 0.01 parts by mass of esterification catalyst were added to the reaction vessel, and the (B) polyester copolymer was synthesized in the same manner as in synthesis example A. In synthesis example Q, the (B) polyester copolymer was synthesized in the same manner as in synthesis example A, except that the reaction time T of the transesterification reaction was changed from 450 minutes to 150 minutes.

[0090] <(B) Preparation of polyester copolymer samples> The (B) polyester copolymer obtained in each synthesis example A to Q was extruded into water in a strand shape, cooled, and then cut to produce chip (pellet)-shaped polyester copolymers. The chip-shaped polyester copolymers were dried at 80°C for 120 minutes to obtain samples. The shape of the samples was elliptical cylinder, with a cross-section of 4-5 mm in major axis, 2-3 mm in minor axis, and 4-5 mm in height.

[0091] <(B) Content of each constituent unit in the polyester copolymer> (B) The content of constituent units derived from (B1) polyalkylene glycol (hereinafter referred to as "PAG") in the polyester copolymer is shown in the "B1" and "Content [mass %]" columns in Table 1. (B) The content of constituent units derived from (B21) aromatic dicarboxylic acid and constituent units derived from ester-forming derivatives of aromatic dicarboxylic acid in the polyester copolymer is shown in the "B21" and "Content [mass %]" columns in Table 1. (B) The content of constituent units derived from (B22) diol in the polyester copolymer is shown in the "B22" and "Content [mass %]" columns in Table 1.

[0092] (B) The content of (B1) constituent units derived from polyalkylene glycol and (B22) constituent units derived from ethylene glycol in the polyester copolymer is: 1 It can be determined from the peak intensity of the 1H-NMR spectrum.

[0093] 1 The measurement conditions for the H-NMR spectrum are as follows: Nuclear magnetic resonance apparatus: Manufactured by JEOL Ltd., product name: ECZ-500R Deuterated solvent: Deuterated trifluoroacetic acid Total number of times: 16 (B) Sample concentration of polyester copolymer: 0.01 g of sample / 0.7 mL of deuterated solvent (B1) The polyalkylene glycol content was determined by setting the integral value of the chemical shift derived from terephthalic acid (8.4 ppm) to 4.0 and comparing it to the integral value of the chemical shift of (B1) polyalkylene glycol. The chemical shift of ethylene glycol was 5.1 ppm, and the chemical shift of polyethylene glycol (PEG) was 4.2 ppm. The chemical shift of polypropylene glycol (PPG) was 1.5 ppm. The chemical shift of polytetramethylene glycol (PTMG) was 2.0 ppm. The chemical shifts of polyoxyethylene polyoxypropylene glycol (POEPOPG) were 1.5 ppm and 2.0 ppm.

[0094] <(B1)Average molecular weight of PAG> The average molecular weight of (B1)PAG is shown in the “B1” column in Table 1. The average molecular weight of (B1)PAG shown in Table 1 is the average molecular weight of the raw material (B1)PAG. The average molecular weight of the constituent units derived from (B1) polyalkylene glycol in (B) polyester copolymer corresponds to the value obtained by subtracting the molecular weight of OH from the average molecular weight shown in Table 1.

[0095] (B) The average molecular weight of the constituent units derived from (B1) PAG in the polyester copolymer can be measured as follows. To a mixed solution of 5 ml of water and 10 ml of ethanol, 1 g of sample (B) polyester copolymer and 3 g of sodium hydroxide were added and heated at 120°C for 20 hours to induce alkaline decomposition. The alkaline decomposition product was neutralized, filtered to remove the neutralized salt, and the filtrate was allowed to dry. After extracting the dry material with chloroform, the chloroform was removed to obtain an extract of polyalkylene glycol.

[0096] The number-average molecular weight (Mn) of the extract was measured according to the following method. The extract (2 mg) was added to tetrahydrofuran (2 mL) and mixed. The tetrahydrofuran-soluble components of the resulting mixture were analyzed by gel permeation chromatography (GPC), and the Mn of polyalkylene glycol was determined in terms of polyethylene glycol. The GPC measurement conditions were as follows.

[0097] • Measuring device: HLC-8320GPC (product name, manufactured by Tosoh Corporation) • Detection device: RI detector (detector included with HLC-8320GPC) • Mobile phase: tetrahydrofuran • Column: Two TSKgel superMultipore HZ-M columns (manufactured by Tosoh Corporation) and one TSKgel superMultipore HZ-H column (manufactured by Tosoh Corporation) were connected in series.

[0098] • Sample injector and column temperature: 40°C • Temperature of RI detector: 35℃ • Sample injection volume: 5 μL ·Flow rate: 0.35mL / min • Measurement time: 20 minutes <(B) Content of low molecular weight components contained in polyester copolymers> (B) The content of low molecular weight components contained in the polyester copolymer is shown in the “Content of low molecular weight components [mass%]” column in Table 2.

[0099] (B) The content of low molecular weight components contained in the polyester copolymer was measured as follows: (B) 1.0 g of the polyester copolymer sample was immersed in 10 mL of THF (tetrahydrofuran) for 8 hours. Next, the immersion solution was filtered to collect a sample, and the amount of components dissolved in THF (THF-dissolved component amount) was calculated from the mass M1 of the sample before immersion and the mass M2 of the sample after immersion using the following formula.

[0100] THF dissolved component amount [%] = (mass M1 - mass M2) / mass M1 Next, the filtrate of the immersion solution was analyzed by gel permeation chromatography (GPC) to calculate the content of low molecular weight components. The GPC conditions were the same as those used for measuring the average molecular weight of PAG described above. The content of low molecular weight components was calculated using the following formula, based on the area ratio A of the peaks of components with a molecular weight (number average molecular weight) of 600 or less, when the total area of ​​all components contained in the filtrate of the immersion solution is set to 1.

[0101] Low molecular weight component content [%] = THF dissolved component amount [%] × Area ratio A <Measurement of intrinsic viscosity> (B) The intrinsic viscosity of the polyester copolymer is shown in the “Intrinsic Viscosity IV Value” column in Table 2.

[0102] (B) The intrinsic viscosity (IV value) of the polyester copolymer was measured in accordance with JIS K7367-1:2002, "Method for determining the viscosity of polymer dilution solutions using a plastic capillary viscometer." Specifically, (B) the polyester copolymer was dissolved in a mixed solvent of phenol and 1,1,2,2-tetrachloroethane to a concentration of 0.4 g / dl, and measured at 30°C. The volume ratio of phenol to 1,1,2,2-tetrachloroethane in the mixed solvent was 1:1.

[0103] (Example 1) (A) Polyethylene terephthalate (manufactured by Unitika Ltd., trade name: MA-6102-K, intrinsic viscosity: 0.6) was prepared as the polyester. A sample of the (B) polyester copolymer obtained in the above synthesis example A was dried at 140°C under a nitrogen stream of 100 mL / min for 8 hours. As shown in Table 3, a polyester resin composition for melt spinning was obtained by melt kneading 95 parts by mass of (A) polyester and 5 parts by mass of (B) polyester copolymer using an extruder.

[0104] The obtained polyester resin composition for melt spinning was supplied to a spinneret having 48 spinning holes using a gear pump. The filament extruded from the spinneret was stretched by the speed difference between the first take-up roller and the second take-up roller located downstream of the first take-up roller.

[0105] The conditions for the spinning process are as follows: Spinning temperature: 280℃ ·Cooling temperature: 20℃ ·Cooling air speed: 1.8m / s • Speed ​​of the first take-up roller (extension speed): 500 m / min • Temperature of the first take-up roller (stretching temperature): 100℃ • Speed ​​of the second take-up roller (extension speed): 2500 m / min • Temperature of the second take-up roller (stretching temperature): 115℃ ·Stretching ratio: 5.0 times · Winding speed: 2470m / min Through the above spinning process, raw silk (FDY) with 80 denier (approximately 88.8 dtex) and 48 filaments was obtained.

[0106] (Example 2) As shown in Table 3, in Example 2, a polyester resin composition for melt spinning was obtained in the same manner as in Example 1, except that a sample of the (B) polyester copolymer obtained in Synthesis Example B was used, and then the spinning process was carried out.

[0107] (Examples 3, 4) As shown in Table 3, in Examples 3 and 4, a polyester resin composition for melt spinning was obtained in the same manner as in Example 1, except that the content of the (B) polyester copolymer sample in the melt spinning polyester resin composition was changed, and then the spinning process was carried out.

[0108] (Examples 5-14) As shown in Tables 3 and 4, in Examples 5 to 14, a polyester resin composition for melt spinning was obtained in the same manner as in Example 1, except that samples of the (B) polyester copolymer obtained in Synthesis Examples C to L were used, and then the spinning process was carried out.

[0109] (Comparative Examples 1 and 2) As shown in Table 5, in Comparative Examples 1 and 2, the spinning process was carried out in the same manner as in Example 1, using only the samples of the (B) polyester copolymer obtained in Synthesis Examples A and B, without blending them with the (A) polyester.

[0110] (Comparative Examples 3, 4) As shown in Table 5, in Comparative Examples 3 and 4, except that the samples and mass amounts of (A) polyester and (B) polyester copolymer were changed, a polyester resin composition for melt spinning was obtained in the same manner as in Example 1, and then the spinning process was carried out.

[0111] (Comparative Examples 5-7) As shown in Table 5, in Comparative Examples 5 to 7, except that samples of the (B) polyester copolymer obtained in Synthesis Examples O to Q were used, a polyester resin composition for melt spinning was obtained in the same manner as in Example 1, and then the spinning process was carried out.

[0112] (Comparative Example 8) As shown in Table 5, in Comparative Example 7, the spinning process was carried out in the same manner as in Example 1, except that only (A) polyester was used.

[0113] (Spinning properties) The above spinning process was used to check for yarn breakage during one hour of continuous spinning. No breakage was judged as excellent, breakage occurring between 30 minutes and 1 hour was judged as good, and breakage occurring in less than 30 minutes was judged as poor. In Tables 3-5, the "Spinability" column is indicated by "a" for excellent, "b" for good, and "c" for poor.

[0114] (Dyeability) Test pieces for dyeing were prepared by knitting the raw silk obtained in each example and comparative example using a single-tube test knitting machine (manufactured by Eiko Sangyo Co., Ltd., product name: model NCR-E) at a 20 gauge.

[0115] The obtained test specimens were placed in a scouring bath with a bath ratio of 1:15. The scouring bath was heated from 40°C to 80°C at a heating rate of 3°C / min, and then held at 80°C for 20 minutes. Next, the scouring bath was cooled to 70°C, and the test specimens were removed from the scouring bath. Subsequently, the removed test specimens were washed with water and dehydrated to obtain scouring-processed test specimens.

[0116] Next, the test specimens were placed in the staining bath. In Examples 1-14 and Comparative Examples 1-7, the test specimens were stained according to the following <Staining Condition 1>.

[0117] <Staining Condition 1> Under staining condition 1, the staining temperature was set to a low temperature. Under staining condition 1, the staining bath was heated from 60°C to 100°C at a heating rate of 2°C / min, and then held at 100°C for 60 minutes. Next, the staining bath was cooled to 70°C, and then the test specimen was removed from the staining bath.

[0118] In Comparative Example 8, the test specimens were stained according to the following <Staining Condition 2>. <Staining conditions 2> In staining condition 2, the staining temperature was set to a high temperature. In staining condition 2, the staining bath was heated from 60°C to 130°C at a heating rate of 2°C / min, and then held at 130°C for 30 minutes. Next, the temperature was lowered to 70°C, and the test specimens were removed from the staining bath.

[0119] Each test specimen stained under the above conditions <Staining Condition 1> and <Staining Condition 2> was subjected to reduction washing using a reduction washing bath at 80°C for 15 minutes with a bath ratio of 1:15. After reduction washing, the test specimens were rinsed with water, dehydrated, and dried to obtain stained test specimens.

[0120] Table 6 shows the compositions of the scouring bath, dyeing bath, and reducing wash bath. For the stained test specimens, the K / S values ​​were determined at 10 nm intervals from 400 to 700 nm using a spectrophotometer (Konica Minolta Sensing, Inc., product name: CM-3600d), and then the integral value of these K / S values ​​was calculated. The integral value for the test specimens of each example and comparative example other than Comparative Example 8 was set to 100, and the integral values ​​for the test specimens of each example and comparative example other than Comparative Example 8 were calculated. This integral value was taken as the staining rate for the test specimens of each example and comparative example other than Comparative Example 8. The results are shown in Tables 3 to 5.

[0121] A higher dye penetration rate indicates a deeper color, meaning superior dye penetration. For dye penetration, a rate of 60 or higher was considered acceptable. In the "Judgment Result" column of Tables 3-5, "a" indicates an acceptable result and "c" indicates a non-acceptable result.

[0122] (Uneven dyeing) The stained test pieces were visually inspected to check for faint streaks or uneven staining. In the "Uneven Staining" column of Tables 3-5, if no faint streaks or uneven staining were observed, it was judged as having a superior effect in reducing uneven staining. If a small amount of faint streaks or uneven staining was observed, it was judged as having a good effect in reducing uneven staining. If many faint streaks or uneven staining were observed, it was judged as having a poor effect in reducing uneven staining. In the "Uneven Staining" column of Tables 3-5, "a" indicates a superior effect in reducing uneven staining, "b" indicates a good effect in reducing uneven staining, and "c" indicates a poor effect in reducing uneven staining.

[0123] (Washfastness) Wash fastness tests were conducted according to the A-5 method of JIS L0844:2011, and the wash fastness grade was determined using a grayscale for staining (JIS L0805:2005). The results are shown in Tables 1-3. A higher wash fastness grade indicates better fastness. For wash fastness, a grade of 3 or higher was judged as passing. In the "Judgment Result" column of Tables 1-3, "a" indicates passing and "c" indicates failing.

[0124] [Table 1]

[0125] [Table 2]

[0126] [Table 3]

[0127] [Table 4]

[0128] [Table 5]

[0129] [Table 6] As shown in Tables 3 and 4, Examples 1 to 14 passed both the dyeability and wash fastness tests. Furthermore, Examples 1 to 14 showed excellent or good results in reducing uneven dyeing.

[0130] On the other hand, as shown in Table 5, Comparative Example 1 did not contain (A) polyester, resulting in poor spinability. Comparative Example 2 did not contain (A) polyester, but used (B) polyester copolymer with a (B2) PAG content of less than 15% by mass. In Comparative Example 2, spinability was good and the dyeability was satisfactory, but the wash fastness was unsatisfactory and the effect of reducing uneven dyeing was inferior.

[0131] In Comparative Example 3, the dyeability result was unsatisfactory because the content of (B) polyester polymer was less than 0.5 parts by mass relative to the total of 100 parts by mass of (A) polyester and (B) polyester copolymer. In Comparative Example 4, the spinnability result was poor because the content of (B) polyester polymer exceeded 15 parts by mass relative to the total of 100 parts by mass of (A) polyester and (B) polyester copolymer. In Comparative Example 5, the dyeability result was unsatisfactory because the content of (B1) PAG was less than 15% by mass. In Comparative Example 6, the spinnability result was poor because the content of (B1) PAG exceeded 60% by mass. In Comparative Example 7, the effect of reducing uneven dyeing was poor because the content of low molecular weight components in (B) polyester copolymer exceeded 15% by mass.

Claims

1. (A) A polyester copolymer used for the purpose of obtaining a polyester resin composition for melt spinning by mixing with polyester, (B1) Having constituent units derived from polyalkylene glycol, The average molecular weight of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less. The content of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less. In the polyester copolymer (B) mentioned above, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less. A polyester copolymer used by mixing it with the polyester (A) in an amount of 0.5 parts by mass or more and 15 parts by mass or less, relative to a total of 100 parts by mass of the polyester (A) and the polyester copolymer (B).

2. The polyester copolymer according to claim 1, wherein the (B1) polyalkylene glycol comprises at least one selected from polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and polyethylene glycol-polypropylene glycol copolymer.

3. The polyester copolymer according to claim 1 or claim 2, wherein the (B) polyester copolymer further comprises a structural unit derived from at least one of (B21) an aromatic dicarboxylic acid and an ester-forming derivative of an aromatic dicarboxylic acid, and a structural unit derived from (B22) a diol.

4. A polyester resin composition for melt spinning containing (A) polyester and (B) a polyester copolymer, The (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, The average molecular weight of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less. The content of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less. In the polyester copolymer (B) mentioned above, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less. The polyester resin composition for melt spinning, wherein the content of the (B) polyester copolymer in the melt spinning polyester resin composition is within the range of 0.5 parts by mass or more and 15 parts by mass or less, based on 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

5. A method for producing polyester fibers, comprising the step of melt-spinning a polyester resin composition for melt spinning, The aforementioned polyester resin composition for melt spinning is (A) contains polyester and (B) polyester copolymer, The (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, The average molecular weight of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less. The content of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less. In the polyester copolymer (B) mentioned above, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less. A method for producing polyester fibers, wherein the content of the (B) polyester copolymer in the melt-spinning polyester resin composition is within the range of 0.5 parts by mass or more and 15 parts by mass or less, based on 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

6. A polyester fiber containing (A) polyester and (B) a polyester copolymer, The (B) polyester copolymer has constituent units derived from (B1) polyalkylene glycol, The average molecular weight of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 400 or more and 4000 or less. The content of the constituent units derived from the (B1) polyalkylene glycol in the (B) polyester copolymer is in the range of 15% by mass or more and 60% by mass or less. In the polyester copolymer (B) mentioned above, the content of low molecular weight components having a molecular weight of 600 or less is 15% by mass or less. The polyester fiber wherein the content of the (B) polyester copolymer in the polyester fiber is within the range of 0.5 parts by mass or more and 15 parts by mass or less, based on 100 parts by mass of the total of the (A) polyester and the (B) polyester copolymer.

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