Stock material or miscellaneous articles – Pile or nap type surface or component
Reexamination Certificate
1996-11-07
2001-06-19
Cole, Elizabeth M. (Department: 1771)
Stock material or miscellaneous articles
Pile or nap type surface or component
C428S359000, C442S400000, C442S409000, C442S414000, C442S181000, C002S272000, C002S268000, C002S171000, C280S728100, C264S211220
Reexamination Certificate
active
06248418
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a polyester product excellent in shape stability, etc. and a process for producing the same. Furthermore, the present invention relates to interlinings and pads using polyester fibers with good resilient elasticity and shape stability, or polyester fibers with resiliency and shape retainability, and also to clothes and various applied products using them.
BACKGROUND ART
Since they have high performance, synthetic fibers such as nylon and polyester fibers have been used widely for clothing and in industrial areas. Fibrous sheets composed of nylons and polyesters are used frequently as three-dimensional products such as interlining cloths for clothes, brassieres, and pads for breasts and shoulders. Furthermore, recently, it has been the practice to stabilize the shape of the shirts composed of blended yarns consisting of a polyester and cotton.
On the one hand, nylons are very poor in dimensional stability in dry and wet conditions because hey expand when absorbing water, and contract when dried, and cannot be used in areas where dimensional stability is important. So, in recent years, as fibers for clothes, nylon fibers are mostly being replaced by polyesters.
On the other hand, polyesters are disadvantageously weak in resilient elasticity and liable to yield to repeated bending, even though good in dimensional stability in dry and wet conditions. For this reason, even though they are lower in cost than nylon 6 and nylon 66, they are little used for such applications as toothbrushes, artificial lawns, carpets, etc.
Japanese Laid-Open Patent Application (Kokai) No. 2-289101 (1990) discloses an interlining cloth using conjugate fibers having spiral crimps. Japanese Laid-Open Patent Application (Kokai) No. 3-130434 (1991) discloses an interlining cloth formed by a knitted/woven fabric using yarns having loops and fluffs. Japanese Laid-Open Patent Application (Kokai) No. 3-152203 (1991) discloses a bonded interlining cloth using crimped yarns.
However, the conventional polyester fibers are poor in resiliency, and for such applications as interlining cloths where good resiliency is required, they must be, for example, used in conjugation with highly resilient animal hair such as horse hair or human hair. Furthermore, since interlining cloths higher in resiliency can be less adapted to the forms of clothing, then disadvantageously a sophisticated sewing technique is required.
DISCLOSURE OF THE INVENTION
It is difficult to obtain materials composed of fibers good in both resiliency and dimensional stability and excellent in shape stability, using the conventional fibers. More especially, it is more difficult to obtain three-dimensional materials composed of fibers.
For example, interlining cloths for dresses are three-dimensionally shaped to have curved surfaces by overlapping many fiber sheets (which, when produced are flat), to retain the shape of the clothing and to beautifully express body lines. However, the sewing work is complicated, and since the fibers memorize their original shapes, forcibly deformed fibers return to their original shapes with the lapse of time, making it difficult to achieve durable shaping. This appears as deformation of products, to lower greatly the grade. As a feature of interlining cloth, even though the yarns with conventional properties can be used in the vertical direction, surfaces curved to protrude outwardly are required in the horizontal direction.
On the other hand, recently it has often been the practice to crosslink or modify cellulose, for improving the shape stability of shirts, but these products have problems in that, for example, the chemical compounds used for shape stabilization remain (formalin in particular is not suitable for clothes to be kept in contact with the skin), the strength is lower, and the effect of shape stabilization is small.
The object of the present invention is to overcome the above disadvantages, to provide a polyester product good in both resilient elasticity and dimensional stability and excellent in shape retainability, and a process for producing the same.
An embodiment of the process for producing the polyester product of the present invention is a process is for producing a polyester product comprising; heat-treating a product comprising polyester fibers or a polyester film prepared by taking up a molten polyester at a take-up speed of 2000 m/min to 4000 m/min, in wet heat and/or dry heat at not lower than 120° C. with the product maintained in a loose or constrained condition without being drawn.
Another embodiment of the process for producing the polyester product of the present invention is a process for preparing a polyester product comprising: heat-treating a product comprising polyester fibers or a polyester film prepared by taking up a molten polyester at a take-up speed of 2000 m/min to 4000 m/min, in wet heat and/or dry heat at 60° C. to 120° C. with the product maintained in a loose or constrained condition without being drawn, as a first step, and further heat-treating the product in wet heat and/or dry heat at a temperature not less than the treatment temperature of the first step and not more than the melting point of the polyester, as a second step.
A still further embodiment of the process for preparing the polyester product of the present invention is a process for preparing a polyester product comprising: heat-treating in wet heat and/or dry heat at not lower than 120° C. a product comprising polyester fibers which have a yield point and a natural draw range to allow the polyester fibers to be elongated at a stress within a range lower than the stress of the yield point, on the stress-strain curve prepared by measuring the tensile strengths and elongations of the polyester fibers, and which are less than 100% in elongation from the yield point to the end point of the natural draw range.
Yet another embodiment of the process for preparing the polyester product of the present invention is a process for preparing a polyester product comprising: heat-treating at least in two steps a product comprising polyester fibers which have a yield point and a natural draw range such as to allow the polyester fibers to be elongated at a stress within a range lower than the stress of the yield point, on the stress-strain curve prepared by measuring the tensile strengths and elongations of the polyester fibers, and which are less than 100% in elongation from the yield point to the end point of the natural draw range, with the heat-treating in the latter step being performed in wet heat and/or dry heat at a temperature higher than the temperature of the first step and lower than the melting point of the polyester, and yet higher than 120° C.
An embodiment of the molded polyester product of the present invention is a molded polyester product is such as a polyester fiber or a polyester film, which comprises a layer-line 4-point pattern in the scattering image obtained by small-angle X-ray scattering photography, is of 8 nm to 15 nm in the Dm value (one unit period of crystal lattice
on-crystal lattice in the fiber axis direction) of the long period determined from said photo, and 20 nm to 35 nm in the De value (one unit period of crystal lattice
on-crystal lattice in the cross-sectional direction of the fiber), and further satisfies the following conditions (1) to (5):
(1) 1.350 to 1.385 in specific gravity,
(2) 2.0 nm to 4.0 nm at Miller index (010), 2.3 nm to 4.0 nm at Miller index (100), and 1.5 nm to 4.2 nm at Miller index ({overscore (1)}05), as crystal sizes obtained by wide-angle X-ray diffraction measurement,
(3) 58% to 85% in the degree of crystal orientation obtained by wide-angle X-ray diffraction measurement,
(4) 0.088 to 0.450 in the amorphous orientation by polarized fluorescence method,
(5) 50×10
−3
to 120×10
−3
in birefringence.
Another embodiment of the molded polyester product of the present invention is a molded polyester product such as a polyester fiber or a polyester film, which comprises a 2-point image in the sc
Maeda Yukihiro
Okamoto Miyoshi
Taguchi Setsuo
Cole Elizabeth M.
Miller Austin R.
Toray Industries Inc.
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