Method for manufacturing commingled yarn, commingled yarn, wind-up article, and, woven fabric

Patent metadata

Field	Value
Publication number	US-9994976-B2
Application number	US-201515510205-A
Country	US
Kind code	B2
Filing date	Sep 3, 2015
Priority date	Sep 10, 2014
Publication date	Jun 12, 2018
Grant date	Jun 12, 2018

Abstract

Provided is a method for manufacturing a commingled yarn that is capable of keeping a high level of dispersion of the continuous reinforcing fiber and the continuous resin fiber, moderately flexible, and less likely to cause fiber separation, and a commingled yarn a wind-up article and a woven fabric. The method for manufacturing a commingled yarn includes commingling a thermoplastic resin fiber having a treatment agent for the thermoplastic resin fiber on a surface thereof, and a continuous reinforcing fiber having a treatment agent for the continuous reinforcing fiber on a surface thereof, and heating the commingled fibers at a temperature in a range from a melting point of the thermoplastic resin composing the thermoplastic resin fiber, up to 30K higher than the melting point.

First claim

The invention claimed is:

1. A method for manufacturing a commingled yarn comprising:
commingling a thermoplastic resin fiber having a treatment agent for the thermoplastic resin fiber on a surface thereof, and a continuous reinforcing fiber having a treatment agent for the continuous reinforcing fiber on a surface thereof, and
heating the commingled fibers at a temperature in a range from a melting point of the thermoplastic resin composing the thermoplastic resin fiber, up to 30K higher than the melting point,
wherein the thermoplastic resin has a product of the melting point thereof and a thermal conductivity thereof of 100 to 150 W/m·K (watts per meter-kelvin), where the thermal conductivity is measured in compliance with ASTM D177,
the continuous reinforcing fiber has an amount of the treatment agent therefor of 0.01 to 2.0% by weight thereof, and
the thermoplastic resin fiber has an amount of the treatment agent therefor of 0.1 to 2.0% by weight thereof;
where the melting point is given in kelvin (K).

2. The method for manufacturing a commingled yarn of claim 1 , wherein the heating at a temperature in the range from the melting point to 30K higher than the melting point is carried out by using a heating roller.

3. The method for manufacturing a commingled yarn of claim 1 , wherein the heating at a temperature in the range from the melting point to 30K higher than the melting point is carried out by using a one-side heating roller.

4. The method for manufacturing a commingled yarn of claim 1 , wherein the thermoplastic resin is at least one species selected from polyamide resin and polyacetal resin.

5. The method for manufacturing a commingled yarn of claim 1 , wherein the thermoplastic resin is a polyamide resin composed of a structural unit derived from a diamine and a structural unit derived from a dicarboxylic acid, and 50 mol % or more of the structural unit derived from a diamine is derived from xylylenediamine.

6. The method for manufacturing a commingled yarn of claim 1 , wherein the continuous reinforcing fiber is a carbon fiber or a glass fiber.

7. The method for manufacturing a commingled yarn of claim 1 , wherein the commingled yarn has an impregnation rate of thermoplastic resin fiber of 5 to 15%.

8. A commingled yarn comprising a thermoplastic resin fiber, a treatment agent for the thermoplastic resin fiber, a continuous reinforcing fiber, and a treatment agent for the continuous reinforcing fiber,
wherein the thermoplastic resin composing the thermoplastic resin fiber has a product of a melting point thereof and a thermal conductivity thereof of 100 to 150 W/m·K (watts per meter-kelvin), where the thermal conductivity is measured in compliance with ASTM D177,
the commingled yarn has a total amount of the treatment agent for the continuous reinforcing fiber and the treatment agent for the thermoplastic resin fiber of 0.2 to 4.0% by weight of the commingled yarn,
the commingled yarn has a tensile strength retention of 60 to 100%, where the tensile strength retention is a retention of the tensile strength of the commingled yarn which is measured by arranging the commingled yarns, forming the commingled yarns at a temperature 293K higher than the melting point, for 5 minutes, at 3 MPa, immersing the commingled yarns in water at 296K for 30 days, and then pulling the commingled yarns in compliance with ISO 527-1 and ISO 527-2, at 296K, a chuck-to-chuck distance of 50 mm, a pulling speed of 50 mm/min,
the commingled yarn has a dispersion of 60 to 100%, and
the commingled yarn has an impregnation rate of the thermoplastic resin fiber in the commingled yarn of 5 to 15%, where the melting point is given in kelvin (K).

9. The commingled yarn of claim 8 , wherein the thermoplastic resin is at least one species selected from polyamide resin and polyacetal resin.

10. The commingled yarn of claim 8 , wherein the thermoplastic resin is a polyamide resin composed of a structural unit derived from a diamine and a structural unit derived from a dicarboxylic acid, and 50 mol % or more of the structural unit derived from a diamine is derived from xylylenediamine.

11. The commingled yarn of claim 10 , wherein 50 mol % or more of the structural unit derived from a dicarboxylic acid is at least either of adipic acid and sebacic acid.

12. The commingled yarn of claim 8 , wherein the continuous reinforcing fiber is a carbon fiber or a glass fiber.

13. A wound article comprising the commingled yarn described in claim 8 , wound up into a roll.

14. A woven fabric using the commingled yarn described in claim 8 .

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Nakai Asami
• Ootani Akio
• Kaji Masataka
• Takagi Mitsuro
• Matsumoto Nobuhiko

Classifications

• D02G3/402

  the adhesive being one component of the yarn, i.e. thermoplastic yarn · CPC title

• D02G3/04 Primary

  Blended or other yarns or threads containing components made from different materials · CPC title

• D10B2401/041

  thermoplastic; thermosetting · CPC title

• D03D15/00

  Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used · CPC title

• D02J13/005

  by contact with at least one rotating roll · CPC title