Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/08—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyacrylonitrile as constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D1/00—Treatment of filament-forming or like material
  • D01D1/02—Preparation of spinning solutions
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/06—Wet spinning methods
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
  • D01D5/30—Conjugate filaments; Spinnerette packs therefor
  • D01D5/32—Side-by-side structure; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
  • D02G1/004—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by heating fibres, filaments, yarns or threads so as to create a temperature gradient across their diameter, thereby imparting them latent asymmetrical shrinkage properties
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
  • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
  • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
  • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
  • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
  • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
  • D02J1/228—Stretching in two or more steps, with or without intermediate steps
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
  • D04B1/18—Other fabrics or articles characterised primarily by the use of particular thread materials elastic threads
  • D04B1/20—Other fabrics or articles characterised primarily by the use of particular thread materials elastic threads crimped threads
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
  • D10B2401/046—Shape recovering or form memory
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/06—Load-responsive characteristics
  • D10B2401/061—Load-responsive characteristics elastic
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/16—Physical properties antistatic; conductive

Definitions

• the present invention relates to acrylic fibers with excellent crimp and anti-pill properties, and a method for manufacturing such acrylic fibers.
• the present invention also relates to spun yarns and knitted fabrics formed using such acrylic fibers.
• Acrylic fibers have bulkiness and heat-retention properties similar to those of wool, and are dyeable to distinct colors with excellent fastness, while having excellent properties such as lightfastness and anti-corrosion. Acrylic fibers are used in a wide range of apparel, interior and materials applications.
• Wool exhibits excellent bulkiness, compression resistance and elasticity, and acrylic fibers are said to have similar properties to those of wool.
• the compression resistance and elasticity of acrylic fibers have not reached the level of wool. Studies have been conducted accordingly to make acrylic fibers more similar to wool.
• JP S63-190019A Patent Literature 1
• JP H01-104825A Patent Literature 2
• Patent Literature 2 disclose technologies for forming a double- or multi-layer fiber structure through composite spinning of two or more copolymers having different copolymerization compositions. These bicomponent fibers are manufactured by layering spinning dopes using a multi-layer system, but it is difficult to achieve a stable side-by-side formation and sufficient bulkiness.
• JP H07-197323A discloses technology for forming an eccentric-radiated or parallel fiber structure through bicomponent spinning of two types of acrylonitrile polymers with different hydrophilic properties.
• Such bicomponent fibers are self-crimping fibers with crimps that are reversible depending on wet or dry conditions.
• the target texture has not been achieved as they do not exhibit bulkiness and resilience similar to those of wool.
• JP S59-192717A discloses technology to conduct side-by-side bicomponent spinning using two types of polymers with different shrinkage rates.
• Bicomponent fibers formed by such a method have bulkiness and are capable of producing bulky fabrics.
• shrinkage along the fiber axis direction tends to occur, causing the texture to harden after shrinkage.
• bicomponent fibers produced by conventional technology have a higher shrinkage rate in the fiber axis direction, it is necessary to use a skein when the yarn is dyed (hank dyeing).
• hank dyeing In the case of fabric dyeing, it is necessary to make a loosely-knitted fabric based on the calculated size of the shrunk fabric.
• the shrinkage rate is controlled during the dyeing process. Advanced processing technology is required.
• the objective of the present invention is to solve the aforementioned problems in conventional technology by providing acrylic fibers with excellent crimp and anti-pill properties.
• An acrylic fiber related to the present invention has a crimp rate of 15% or higher measured in accordance with JIS L1015 (2010), and bulkiness measured by the method below is 380 cm 3 /g or greater.
• Acrylic fibers related to the present invention are preferred to have a single fiber fineness of 1.7 dtex ⁇ 6.6 dtex, and the value obtained by multiplying knot strength (cN/dtex) and knot elongation (%) is preferred to be 10 ⁇ 25.
• the number of crimps in the acrylic fibers related to the present invention is preferred to be 20 per 2.54 cm ⁇ 50 per 2.54 cm.
• Acrylic fibers related to the present invention are preferred to have a side-by-side bicomponent structure of an acrylonitrile copolymer (A) with an acrylonitrile unit content of 90 mass% ⁇ 95 mass% and an acrylonitrile copolymer (B) with an acrylonitrile unit content of 93.5 mass% ⁇ 97.8 mass%, which are arranged in an area ratio of 1:3 ⁇ 3:1 at a fiber cross-section perpendicular to the fiber axis.
• A acrylonitrile copolymer
• B acrylonitrile copolymer with an acrylonitrile unit content of 93.5 mass% ⁇ 97.8 mass%
• Acrylic fibers related to the present invention are preferred to have a difference of 2 or greater between the value of acrylonitrile unit content (mass%) in the copolymer (A) and the value of acrylonitrile unit content (mass%) in the copolymer (B).
• the copolymer (A) is preferred to be formed by copolymerizing 90 mass% ⁇ 95 mass% of an acrylonitrile unit and 5 mass% ⁇ 10 mass% of an unsaturated monomer copolymerizable with the acrylonitrile unit
• the copolymer (B) is preferred to be formed by copolymerizing 93.5 mass% ⁇ 97.8 mass% of an acrylonitrile unit, 2 mass% ⁇ 5 mass% of an unsaturated monomer unit copolymerizable with the acrylonitrile unit, and 0.2 mass% ⁇ 1.5 mass% of a sulfonic acid group-containing monomer unit.
• the monomer unit contained as an unsaturated monomer unit copolymerizable with the acrylonitrile unit in the copolymers (A) and (B) is preferred to be a vinyl acetate unit, and the sulfonic acid group-containing monomer unit is preferred to be a sodium methallyl sulfonate unit.
• the shrinkage rate of the acrylic fibers related to the present invention is preferred to be 2% ⁇ 7%.
• a method for manufacturing an acrylic fiber according to the present invention is to form a side-by-side bicomponent fiber by discharging the following dopes from a nozzle into a coagulation bath with a solvent concentration of 35% ⁇ 60%: a spinning dope (A') prepared by dissolving a copolymer (A) with an acrylonitrile unit content of 90 mass% ⁇ 95 mass% in a solvent, and a spinning dope (B') prepared by dissolving a copolymer (B) with an acrylonitrile unit content of 93.5 mass% ⁇ 97.8 mass% in a solvent.
• the difference between the value of acrylonitrile unit content (mass%) in the copolymer (A) and the value of acrylonitrile unit content (mass%) in the copolymer (B) is 2 or greater.
• the copolymer (A) is preferred to be formed by copolymerizing 90 mass% ⁇ 95 mass% of an acrylonitrile unit and 5 mass% ⁇ 10 mass% of an unsaturated monomer copolymerizable with the acrylonitrile unit
• the copolymer (B) is preferred to be formed by copolymerizing 93.5 mass% ⁇ 97.8 mass% of an acrylonitrile unit, 2 mass% ⁇ 5 mass% of an unsaturated monomer unit copolymerizable with the acrylonitrile unit, and 0.2 mass% ⁇ 1.5 mass% of a sulfonic acid group-containing monomer unit.
• the unsaturated monomer unit copolymerizable with the acrylonitrile unit in the copolymers (A) and (B) is preferred to be a vinyl acetate unit, and the sulfonic acid group-containing monomer unit is preferred to be a sodium methallyl sulfonate unit.
• the method for manufacturing an acrylic fiber related to the present invention is preferred to have a step for forming a side-by-side bicomponent fiber by discharging the spinning dope (A') and spinning dope (B') from a nozzle into a spinning bath; a step for conducting primary drawing at a draw ratio of 3.0 ⁇ 5.0 times; a step for conducting relaxation heat treatment under saturated steam pressure of 90 kPa ⁇ 230 kPa; and a step for conducting secondary drawing at a draw ratio of 1.05 ⁇ 1.20 times.
• the spun yarn related to the present invention contains the above acrylic fiber at 30 mass% or greater.
• the spun yarn related to the present invention is preferred to contain a conductive acrylic fiber in a range of 3 mass% ⁇ 15 mass%.
• the knitted fabric related to the present invention contains the spun yarn at 50 mass% or greater and has an anti-pill grade of 4 or higher.
• the dimensional change in the knitted fabrics related to the present invention is preferred to be ⁇ 3% or lower in both vertical and horizontal directions.
• the acrylic fibers related to the present invention have excellent anti-pill, bulkiness, compression resistance and elasticity properties, while s featuring a texture similar to that of wool.
• Apparel products manufactured by using the acrylic fibers have a bulkiness and texture similar to those in wool products, while exhibiting easy-care characteristics with an anti-pill property to compensate for drawbacks inherent in wool.
• Acrylic fibers of the present invention have a crimp rate of 15% or higher and bulkiness of 380 cm 3 /g or greater.
• a crimp rate of 15% or higher provides fiber products with excellent bulkiness and resilience. From such viewpoints, a crimp rate is preferred to be at least 17%, more preferably at least 20%, and its upper limit is preferred to be no greater than 30% because such a rate can prevent the texture of the fiber products from hardening.
• a degree of bulkiness of 380 cm 3 /g or greater provides fiber products with excellent bulkiness and resilience. From such viewpoints, the degree of bulkiness is more preferred to be at least 440 cm 3 /g, and its upper limit is preferred to be no greater than 600 cm 3 /g, because such a degree of bulkiness prevents the texture of the fiber products from hardening.
• Acrylic fibers related to the present invention are preferred to have a single fiber fineness of 1.7 dtex ⁇ 6.6 dtex, and the value obtained by multiplying knot strength (cN/dtex) and knot elongation (%) is preferred to be 10 ⁇ 25.
• a single fiber fineness of at least 1.7 dtex provides fiber products with excellent bulkiness and resilience similar to those of wool.
• a single fiber fineness of no greater than 6.6 dtex prevents fiber products from developing a hardened rough texture. From such viewpoints, the single fiber fineness is more preferred to be 2.2 dtex ⁇ 5.6 dtex.
• knot strength (cN/dtex) and knot elongation (%) are preferred to be 10 ⁇ 25, more preferably 15 ⁇ 25 in the acrylic fibers related to the present invention.
• knot strength (cN/dtex) may be referred to as "DKS,” and knot elongation (%) as “DKE.”
• DKS ⁇ DKE is 10 or greater, problems such as formation of fly waste in post-processing steps (for example spinning), and decrease in yarn strength are unlikely to happen. Moreover, if the value of DKS ⁇ DKE is no greater than 25, an excellent anti-pill property is maintained.
• DKS ⁇ DKE is used as an index of anti-pill property by those skilled in the art.
• the number of crimps is preferred to be 20-50 per 2.54 cm, more preferably 25 ⁇ 45 per 2.54 cm.
• acrylic fibers prefferably have at least 20 crimps per 2.54 cm so that fiber products can achieve a texture of elasticity, compression resistance and bulkiness, whereas a number of crimps no greater than 50 per 2.54 cm can prevent the fiber products from hardening.
• Acrylic fibers related to the present invention are preferred to have a side-by-side bicomponent structure of acrylonitrile copolymer (A) with an acrylonitrile unit content of 90 mass% ⁇ 95 mass% and acrylonitrile copolymer (B) with an acrylonitrile unit content of 93.5 mass% ⁇ 97.8 mass%, which are laid in an area ratio of 1:3 ⁇ 3:1 at a fiber cross-section perpendicular to the fiber axis.
• copolymers (A) and (B) are arranged to have a side-by-side bicomponent structure, fine crimps are formed. Elasticity, rate of crimps and degree of bulkiness tend to be higher.
• the area ratio is in a range of 1:3 ⁇ 3:1, fiber products exhibit excellent bulkiness and resilience without decreasing spinning stability. From these viewpoints, the area ratio is more preferred to be 2:3 ⁇ 3:2.
• the side-by-side bicomponent fiber formed with copolymers (A) and (B), which are arranged in an area ratio of 1:3 ⁇ 3:1 at a fiber cross-section perpendicular to the fiber axis direction, is preferred to be contained at 80 mass% or greater in a fiber bundle discharged from one nozzle.
• a side-by-side bicomponent fiber When a side-by-side bicomponent fiber is contained at 80 mass% or greater, fiber products have excellent bulkiness and resilience. From such viewpoints, the content of a side-by-side bicomponent fiber is more preferred to be 90 mass% or greater.
• the copolymer (A) is preferred to have an acrylonitrile unit content of 90 mass% ⁇ 95 mass% to maintain physical properties, especially dimensional stability necessary for apparel fibers ,and sufficient shrinkage.
• the copolymer (B) is preferred to have an acrylonitrile unit content of 93.5 mass% ⁇ 97.8 mass% so that the shrinkage difference with copolymer (A) is easier to be present to provide bulkiness and resilience.
• Acrylic fibers related to the present invention are preferred to have a difference of 2 or greater between the value of acrylonitrile unit content (mass%) in the copolymer (A) and the value of acrylonitrile unit content (mass%) in the copolymer (B).
• the content difference is more preferred to be 3 or greater.
• the copolymer (A) is preferred to be formed by copolymerizing 90 mass% ⁇ 95 mass% of an acrylonitrile unit and 5 mass% ⁇ 10 mass% of an unsaturated monomer unit copolymerizable with the acrylonitrile unit.
• the copolymer (B) is preferred to be formed by copolymerizing 93.5 mass% ⁇ 97.8 mass% of an acrylonitrile unit, 2 mass% ⁇ 5 mass% of an unsaturated monomer unit copolymerizable with the acrylonitrile unit, and 0.2 mass% ⁇ 1.5 mass% of a sulfonic acid group-containing monomer unit.
• an unsaturated monomer unit copolymerizable with the acrylonitrile unit examples include acrylic acid, methacrylic acid and their derivatives, vinyl acetate, acrylamide, methacrylamide, vinyl chloride, vinylidene chloride and the like. Among them, vinyl acetate is preferred due to its availability and cost.
• Examples of a sulfonic acid group-containing monomer unit are sodium vinylbenzenesulfonate, sodium methallylsulfonate, sodium acrylamide methyl sulfonate, sodium p-sulfophenyl methallyl ether and the like. Among them, sodium methallylsulfonate is preferred due to its availability and cost.
• the content of an unsaturated monomer copolymerizable with the acrylonitrile unit in the copolymer (A) is sufficient if it is 5 mass% ⁇ 10 mass%. When the content is 5 mass% or greater, sufficient shrinkage is maintained, and when the content is 10 mass% or less, physical properties, especially dimensional stability necessary for apparel fibers, are maintained.
• a content of 2 mass% ⁇ 5 mass% is sufficient. Such a range of content causes a difference in shrinkage between copolymers (A) and (B), and thus provides fibers with excellent bulkiness and resilience. Also, as for a sulfonic acid group-containing monomer unit, a content of 0.2 mass% ⁇ 1.5 mass% is sufficient. Such a range of content prevents an overly large difference in dyeability between copolymers (A) and (B), and color shades variations are prevented.
• the shrinkage rate of acrylic fibers related to the present invention is preferred to be 2% ⁇ 7%.
• a shrinkage rate of 2% or higher makes latent fine crimps to provide bulky texture, whereas a shrinkage rate of 8% or less prevents hardened texture after shrinkage. Considering these features, a shrinkage rate of 4% ⁇ 7% is more preferred.
• each of their specific viscosities is preferred to be 0.12 ⁇ 0.21 (when measured at 30°C by dissolving 0.5 grams of a polymer in 100 mL of dimethylformamide).
• each of their molecular weights is not limited specifically as long as the value is within a normal range for manufacturing acrylic fibers. It is usually preferred to be 10,000 ⁇ 1,000,000.
• Acrylic fibers related to the present invention are manufactured by the following method, for example.
• Copolymers (A) and (B) are each dissolved in a solvent normally used for spinning acrylic fibers, for example, dimethylacetamide, dimethylformamide, dimethyl sulfoxide, and the like, and are each made into a spinning dope with a solid content of 20 mass% ⁇ 28 mass%.
• the viscosity of the spinning dope is preferred to be 50-500 poise (measured at 50°C in accordance with JIS Z8803, using a falling ball viscometer.)
• a solid content of 20 mass% or greater prevents a decrease in quality of the spinning dope when it is spun out, and a solid content of 28 mass% or less prevents lowered spinnability, caused by insufficient chronological stability.
• Bicomponent fibers related to the present invention are manufactured when two types of spinning dope prepared as above are discharged simultaneously from a spinning nozzle.
• the spinning method may be selected appropriately from among known methods, but it is preferred to select a method for forming side-by-side bicomponent fibers.
• Acrylic fibers related to the present invention are formed by discharging two types of spinning dope from a side-by-side bicomponent spinning nozzle into a wet-spinning coagulation bath containing a solvent.
• the solvent concentration in the spinning bath is preferred to be 35 mass% ⁇ 60 mass%, more preferably 40 mass% ⁇ 55 mass%.
• the temperature of the spinning bath is preferred to be 20°C ⁇ 45°C. If the temperature of the spinning bath is 20°C or higher, it is relatively easy to control the temperature, and if the temperature is 50°C or lower, an efficient spinning process is maintained. Also, when the temperature of the spinning bath is in such a range, the value of DKS ⁇ DKE will be within a desired range, and an excellent anti-pill property is thereby achieved.
• the draw ratio is more preferred to be 4 ⁇ 5 times.
• the draw ratio of secondary drawing is 1.05 ⁇ 1.20 times, preferably 1.05 ⁇ 1.10 times.
• a draw ratio of secondary drawing is 1.05 times or higher, the fine crimps are set to be latent.
• a draw ratio of 1.20 times or lower does not cause excessive shrinkage, and a decrease in dimensional stability and hardened texture after shrinkage are prevented.
• the spun yarn contains the acrylic fiber at 100 mass%
• the obtained knitted fabric exhibits excellent bulkiness and resilience along with excellent anti-pill property.
• Fibers to be blended with the acrylic fiber in spun yarn are not limited specifically. Both synthetic fibers and natural fibers may be used. To enhance the anti-pill property, it is preferred to blend with anti-pill synthetic fibers.
• the rate of blending natural fibers is preferred to be 70 mass% or less, more preferably 30 mass% or less to prevent a decrease in the anti-pill property.
• the yarn count of the spun yarn related to the present invention is preferred to be 60 or lower in metric count because bulkiness is easier to obtain if the yarn is not too thin.
• the twist coefficient is preferred to be 70 ⁇ 120.
• a twist coefficient of 70 or higher makes it strong enough to not cause trouble during spinning.
• a twist coefficient of 120 or lower makes it easier to obtain bulkiness and prevents hardened texture in knitted fabrics.
• the spun yarn related to the present invention is preferred to contain a conductive acrylic fiber at 3 mass% ⁇ 15 mass%. Including a conductive acrylic fiber in such a range suppresses unpleasant sensations caused by static electricity when the fiber product is put on or taken off.
• the content of conductive acrylic fiber is more preferred to be 5 mass% ⁇ 12 mass% from the viewpoints of antistatic performance and cost effectiveness.
• Knitted fabrics related to the present invention contain the above spun yarn at 50 mass% or greater. To maintain an excellent anti-pill property and easy-care features, using the spun yarn of the present invention at 100% is preferable. However, it is also an option to interknit other spun yarn within a range that does not spoil the knitted texture, anti-pill property and easy-care features.
• a spun yarn that may be interknitted with the spun yarn of the present invention is not limited specifically; for example, it may be made of 100% natural fiber, 100% synthetic fiber, blended yarn of natural and synthetic fibers or the like. To obtain wool-like texture having an excellent anti-pill property of grade 4 or higher and easy-care features, it is preferred to contain an acrylic fiber related to the present invention at 30 mass% or greater of the entire knitted fabric.
• the dimensional change of the knitted fabric related to the present invention is preferred to be ⁇ 3% or lower in both vertical and horizontal directions.
• the fineness was determined in accordance with JIS L 1015 (vibration testing method). Testing was conducted on 50 fiber strands and the average value was used.
• the hot water shrinkage rate was determined in accordance with JIS L 1015.
• Shrinking treatment was conducted in boiling water.
• the crimp rate was determined in accordance with JIS L 1015 (2010).
• the number of crimps was determined in accordance with JIS L 1015 (2010).
• the knot strength was determined in accordance with JIS L 1015 (2010) (testing under normal conditions).
• the elongation rate at that time was determined as knot elongation, and the multiplication product was calculated.
• the anti-pill property was tested in accordance with pilling test method "A" specified in JIS L 1076 (2012) (ICI-type tester, running time: five hours), and classified as grades 1 ⁇ 5 based on the appearance of the fabric after testing.
• Spinning dopes were prepared by respectively dissolving copolymers (A) and (B) specified in Table 1 in a dimethylacetamide (DMAc) solvent to have a solid content of 24 mass%.
• DMAc dimethylacetamide
• the spinning dopes were discharged at a ratio of 50 mass% of copolymer (A) and 50 mass% of copolymer (B) from a bicomponent spinning nozzle and coagulated to be side-by-side.
• an oil agent was applied, dried by using a 150°C hot roller, and then the fiber was crimped.
• a fiber was obtained through the same process as that employed in Example 1 except that the solvent concentration, the spinning bath temperature and the single fiber fineness were changed to those specified in Table 1.
• the fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• a fiber was obtained through the same process as that employed in Example 1 except that the composition of copolymer (A) and single fiber fineness were changed to those specified in Table 1.
• the fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• a fiber was obtained through the same process as that employed in Example 3 except that only the copolymer (A) of Example 3 was used. The fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• a fiber was obtained through the same process as that employed in Example 1 except that only the copolymer (B) of Example 1 was used and the solvent concentration was set at 30 mass%. The fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• the copolymers (A) and (B) of Example 1 were made into spinning dopes respectively and homogenously mixed. The mixture was then discharged from a spinning nozzle and coagulated so as to obtain a heterogeneous polymer composite acrylic fiber. The fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• a fiber was obtained through the same process as that employed in Example 1 except that the solvent concentration was changed as specified in Table 1. The fiber was spun, knitted and dyed in the same way as in Example 1. The results are shown in Table 1.
• Example 1 AN: 93% - 55% / 40°C 1.2 5.6 0 265 8.7 10.6 35.9 3 - AV: 7% Comp.
• Example 3 AN: 91% AN: 95% 55% / 40°C 3.8 5.6 65.5 350 16.5 13.9 28.8 3.5 + AV: 9% AV: 4.5% MS: 0.5% Comp.
• Example 4 AN: 91% AN: 95% 30% / 40°C 12.6 2.2 90.5 305 20.4 14.8 18.7 3.5 - AV: 9% AV: 4.5% MS: 0.5% AN: acrylonitrile, AV: vinyl acetate, MS: sodium methallyl sulfonate
• a spun yarn with a metric count of 1/30 was prepared by blending 70 mass% of the acrylic fiber obtained in Example 1 and 30 mass% of wool (66's). The spun yarn underwent a boiling water treatment at 100°C ⁇ 30 minutes by using a cheese dyeing machine. Then, two strands of the spun yarn were aligned and put onto a 12G flat knitting machine to form a knitted fabric.
• the knitted fabric exhibited wool-like texture, showed hardly any dimensional change after washing, and had an excellent anti-pill grade of 4.0.
• the results are shown in Table 2.
• a spun yarn with a metric count of 1/30 was prepared by blending 40 mass% of the acrylic fiber obtained in Example 1, 30 mass% of an anti-pill acrylic fiber with a single fiber fineness of 2.2 dtex (item type: H616, made by Mitsubishi Rayon), and 30 mass% of wool (66's). After the spun yarn underwent a boiling water treatment by using a cheese dyeing machine the same as in Example 4, the spun yarn was put onto a 12G flat knitting machine to form a knitted fabric.
• the knitted fabric exhibited a wool-like texture, showed hardly any dimensional change after washing, and had an excellent anti-pill grade of 4.5.
• the results are shown in Table 2.
• a spun yarn with a metric count of 1/30 was prepared by blending 90 mass% of the acrylic fiber obtained in Example 1, and 10 mass% of a conductive acrylic fiber with a single fiber fineness of 3.3 dtex (item type: TB10, made by Mitsubishi Rayon). After the spun yarn underwent a boiling water treatment by using a cheese dyeing machine the same as in Example 4, the spun yarn was put onto a 12G flat knitting machine to form a knitted fabric.
• a spun yarn with a metric count of 1/30 was prepared to have a 100% wool (66's) content. After the spun yarn underwent a boiling water treatment by using a cheese dyeing machine the same as in Example 4. Then, two strands of the spun yarn were aligned and put onto a 12G flat knitting machine to form a knitted fabric.
• Example 2 Composition of spun yarn Blending ratio Anti-pill grade Dimensional change rate (vertical / horizontal) Texture
• Example 4 acrylic fiber of Example 1 wool 70% 4 -1.9% /-1.2% ++ 30%
• Example 5 acrylic fiber of Example 1 anti-pilling acrylic fiber wool 40% 4.5 -1.2% /-0.9% ++ 30% 30%
• Example 6 acrylic fiber of Example 1 conductive acrylic fiber 90% 4.5 -0.9% /0.5% ++ 10%
• the acrylic fibers related to the present invention have excellent crimp and anti-pill properties, and are preferable for apparel such as sweaters and jackets along with handcraft yarn.

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• Engineering & Computer Science (AREA)
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• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
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• Knitting Of Fabric (AREA)
• Artificial Filaments (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Multicomponent Fibers (AREA)

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• 2015
  • 2015-04-28 WO PCT/JP2015/062863 patent/WO2015166956A1/fr not_active Ceased
  • 2015-04-28 US US15/307,053 patent/US20170044693A1/en not_active Abandoned
  • 2015-04-28 JP JP2015523315A patent/JP6065976B2/ja not_active Expired - Fee Related
  • 2015-04-28 EP EP15786320.0A patent/EP3138940A4/fr not_active Withdrawn
  • 2015-04-28 CN CN201580022144.XA patent/CN106460242A/zh active Pending

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