JP2590661B2 - Manufacturing method of ultra-fine fiber woven or knitted fabric - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a dense woven or knitted fabric mainly composed of ultrafine fibers, which is super soft, has a swelling feeling, and has an extremely soft texture.

[0002]

2. Description of the Related Art Ultra-fine fibers vary depending on the material (polymer) used and the method for producing them. It has many extreme and wonderful properties, such as space, large surface area per weight, and large interfacial properties. Until now, various products such as artificial leather, moisture-permeable and waterproof fabrics have been developed. Was. In recent years, with the spread of wiping cloths and the new synthetic fiber boom, ultra-fine fibers have received a great deal of attention, and it is no exaggeration to say that synthetic fiber manufacturers are aiming for the field of ultra-fine fibers in this field. Finally, even the largest synthetic fiber companies in the United States and Europe have begun to promote ultra-fine fiber products, and the United States and Europe are in a boom.

[0003] Various techniques have been developed for filamentizing such ultrafine fibers, but at present, they are categorized into four types: direct spinning, sea-island spinning, split or peel spinning, and multilayer spinning. As a method of obtaining a dense woven or knitted fabric using the ultrafine fibers obtained by such a method, a method of highly shrinking a woven or knitted fabric with a solvent (drug) such as benzyl alcohol or phenylphenol (Japanese Patent Application Laid-Open No. 56-1981) 154546, JP-A-61-14
No. 6840) and a method of densification by a so-called water jet punching method in which a stream of high-pressure water is jetted onto a woven or knitted material (Japanese Patent Publication No. 61-58573). However, in the former method,
The strength has been reduced by chemical treatment,
In the latter case, a streak pattern due to water spots is generated, or the product has a slightly hard texture.

[0004]

SUMMARY OF THE INVENTION In view of the drawbacks of the art, the present invention is directed to obtaining a very fine ultra-fine fiber woven or knitted fabric having a soft and swelling texture and an optimum method for obtaining such a woven or knitted fabric. It is intended to provide a simple manufacturing method.

[0005]

In order to achieve the above-mentioned object, as a result of various studies for many years, the present invention has finally been reached. The present invention has the following configuration.

[0006] The method for producing a microfiber woven or knitted fabric of the present invention comprises:
Mainly polyamide and polyester of 0.3-0.001 denier
The two or more microfiber components of the ester substantially
Disperse and array without forming groups to form island components,
Sea component is hot water soluble type or weak alkali soluble type
After forming a woven or knitted fabric using the sea-island composite fiber formed from the synthetic polyester component , the sea component is dissolved and / or dissolved.
After shrinking the woven or knitted fabric while removing or removing it,
This is a method for producing a microfiber woven or knitted fabric characterized by further shrinking the woven or knitted fabric by performing a dry heat-wetting treatment .

[0007]

Hereinafter, the present invention will be described in more detail.

In order to densify a cloth such as a woven or knitted fabric, a method of weaving during knitting and weaving, a method of finely weaving or knitting the knitting itself, a method of applying tension, and a method of applying benzyl alcohol or the like are used. A method of contracting by using a drug, a method of causing contraction by a water jet punch, and the like have hitherto been known. On the other hand, the present invention provides two or more ultrafine fibers of polyamide and polyester.
The fibers are dispersed and arranged substantially without forming groups.
Make island component and sea component is hot water soluble or weak
Formed from alkali-soluble copolyester component
After forming into a woven or knitted fabric using the sea-island composite fiber, the woven or knitted fabric is shrunk while the ultrafine fibers are generated and shrinked, and then subjected to a dry heat-wet treatment to further shrink the woven or knitted fabric. By this manufacturing method, the yarn constituting the woven or knitted fabric is obtained by opening the ultrafine single fibers finely and obtaining a woven or knitted fabric having a very dense and ultrasoft texture. It is characterized by the following .

The sea island type composite fiber [0009] The present invention method, refers to that island components to form the ultrafine fibers of the so-called polymeric cross array fibers surrounded by the sea component, in which case, the island components 2 It is important to use one consisting of more than one kind of island component. With respect to a die structure for producing such a polymer inter-arrayed fiber composed of three or more components (including a sea component), for example, Japanese Patent Publication No. 57-49653 and Japanese Patent Publication No. 58
Japanese Patent Application Publication No. -4087 discloses the basic structure.
However, in the prior art described in these publications,
In the method of the present invention, the intended purpose, very dense and soft, excellent various properties described later, for example, the water repellency effect that the sharpness of the print and water drops roll off at a surprising speed, etc. Was not suggested.

As the island component, for example, in the case of two components , polyester and nylon 6 are used instead.
Combinations with the represented polyamides are particularly preferred because of their particularly soft effects.

In a preferred embodiment of the present invention, the method for obtaining ultra-fine fibers using the polymer inter-array fibers is poor in compatibility, such as the combination of polyester and nylon 6.
In the split or peeling type or the multi-layer type method, even in a combination that is easy to peel at the time of spinning, in that it can be spun stably without being affected by the interaction between the polymers used, etc. It is more preferable than the technique of forming ultra-fine fibers by a multilayer method.

In this case, as the sea component, polystyrene, copolymerized polystyrene, a weak alkali-soluble polyester obtained by copolymerizing sodium sulfoisophthalic acid, a hot water-soluble type obtained by copolymerizing sodium sulfoisophthalic acid and polyethylene glycol are used. polyester such as Ru using.

Here, the arrangement of two or more types of island components in such a polymer inter-arrayed fiber may be distributed randomly at all without forming a group and forming a group. it is obtained by regularly distributed array. By such a dispersion arrangement, the obtained ultra-fine fibers can be obtained by mixing two or more kinds of ultra-fine fibers without coagulation. Such a mixed fiber state, after forming two or more kinds of ultrafine fibers in advance, is different from, for example, forming a mixed fiber using means such as air entanglement, without forming a large loop with the ultrafine fibers. The same ultra-fine fibers do not form a clump group and can be in a high mixed state. In particular, when the islands are alternately dispersed, when the ultra-fine fibers are ultra-fine, one ultra-fine single fiber is used. This opening is particularly preferable because the porosity in the fiber bundle is large and the effect of super softening is very large. The ratio between the island component and the sea component can be easily selected freely within the range of 5/95 to 95/5, but in the present invention for forming a dense woven or knitted fabric, the island ratio is set high. It is preferable that the range be 75/25 to 95/5.

The ratio between the island 1 and the island 2 can be set arbitrarily.
Preferably, the ratio is 70/30.

In the present invention, by using mainly a polymer cross-array textiles made of three or more components described above, it is possible to form a preferably woven or knitted fabric. The method for producing the woven or knitted fabric may be any conventional method.
In the case of woven fabrics, all woven fabrics such as plain weave, oblique weave, satin weave, double weave or those with variable texture are included. Also,
If it is a knit, all types of knitting (broad sense) such as horizontal knitting and vertical knitting are included. In the present invention, these woven and knitted fabrics are collectively referred to as a cloth. When forming such a fabric,
It is preferable that the woven or knitted material be formed at a high density in advance as much as possible without any hindrance.

According to the present invention, after such a woven or knitted fabric is formed, first , a treatment such as dissolving and / or decomposing and removing sea components to remove one component of the conjugate fiber is carried out. Perform At this time, treatment at a high temperature is efficiently and preferably performed, but the high-temperature treatment causes the woven or knitted material to shrink at the same time as being extremely fine. The woven or knitted fabric is densified by such shrinkage. In addition, in general, when the polymer mutual array fiber is used, since the polymer mutual array fiber which initially constituted the woven or knitted material becomes thin for the removal of the sea component, no matter how high the island component is, Conventionally, there is a limit to the densification of such a woven or knitted product, and the densification tends to be somewhat inferior to that of a method using an ultrafine fiber forming means such as a split / peeling type. Therefore, in particular, the woven fabric is further woven by using a sea-island composite fiber composed of two or more kinds of island (ultrafine fiber parts) components, and performing the dry heat-wet treatment after performing the sea component removal / shrinkage treatment. The method of the present invention for shrinking a knitted fabric has a particularly remarkable effect in the case of using a polymer inter-arrayed fiber , which reduces sea thinness and enables densification .

The temperature of the dry heat treatment is preferably 150 ° C. or higher, particularly preferably 180 ° C. or higher. Although the processing time varies depending on the temperature, for example, in the case of 180 ° C., a sufficient effect can be obtained in about 1 minute. Here, it should be noted that such a dry heat treatment is different from a heat set which is generally processed in a greige stage. In order to enhance the dimensional stability of the woven or knitted fabric, the woven or knitted fabric is subjected to a certain degree of tension in order to enhance the dimensional stability of the woven or knitted fabric. It has that characteristic in contracting. After performing such a dry heat treatment, a wet treatment is performed and drying is performed. The wetting treatment may be merely immersion in water. Such wet treatment then dyes the greige as needed, but may be substituted by such dyeing treatment. It is not clear why, by performing such a wet treatment, for either woven or knitted fabric which is released restraint of the ultrafine fibers to each other having different shrinkage properties becomes very soft. Second stage shrinkage (area shrinkage) due to dry heat-wet treatment is 5%
The above is preferred. It is more preferably at least 10%.

By performing such a second-stage shrinking process, it becomes more dense and more flexible. In general,
It has been common sense that the texture becomes harder as the woven or knitted material becomes denser. However, in the present invention, the texture is softened by performing the second-stage shrinkage treatment. Change. This means that one extra-fine yarn is
It is considered that the porosity in the fiber bundle is increased due to the fine opening, and the fine fibers are provided between the tissue entanglement points of the woven or knitted material so that the constituent fibers can move freely without being constrained.

In the present invention, the first-stage shrinking treatment is to densify the fabric at the same time as the formation of ultra-fine fibers.
%, Preferably in the range of 20%.
Most preferably, it is within the range of ３０30%.
If it is less than 15%, the effect of densification of the obtained fabric is small, and if it exceeds 40%, the effect of densification is sufficient, but it becomes hard and inferior in terms of feeling. The second stage contraction process
The main purpose is to mainly open ultra-fine single fibers finely one by one and to form voids in the fiber bundle. According to the findings of the present inventors, Although not particularly limited, the content is preferably set to about 5 to 20% from the viewpoint of clarity of the obtained effect.

Therefore, the present invention is different from the one in which the shrinkage treatment is performed in two stages for the purpose of simply obtaining a high shrinkage rate, and in particular, two or more kinds of ultrafine fibers having different characteristics. After forming a woven or knitted fabric using the sea-island type composite fiber capable of generating the following, the sea component is dissolved and / or removed, and the woven or knitted fabric is shrunk. Two-stage shrinkage where the woven or knitted fabric shrinks, the voids in the fiber bundle increase, and the microfibers have minute voids between the tissue entanglement points of the woven or knitted fabric and can easily move freely without being restrained by each other. It is meaningful to do.

According to the method of the present invention, a dense fabric can be obtained without impairing the extremely soft feeling of the ultrafine fibers, and the unique effects described later can be obtained.

By the way, when using a woven or knitted fabric made of a single ultrafine fiber other than the present invention, the fabric hardly shrinks in the second-stage shrinkage treatment, and the effect of the present invention is never obtained. This point is also as shown in a comparative example described later.

The woven or knitted fabric obtained by the present invention may be further subjected to a dyeing treatment, a silicone-based or fluorine-based water-repellent treatment, a coating or laminating treatment, an impregnation treatment, a sewing treatment, a water absorption treatment utilizing a superfine fiber, a hydrophilic treatment, etc. It is preferable to carry out alone or in combination. In particular, excellent water repellency can be obtained by performing a fluorine-based water repellent treatment.
Its water repellency is far superior to previous ones in the speed at which water drops run down the surface of the cloth,
It shows surprising super water repellency.

[0024]

EXAMPLES The present invention will be described in more detail with reference to the following Examples, which by no means limit or limit the effectiveness and scope of the present invention. Rather, they bring about the following applications and developments. In the examples, all “ratio” is based on weight.

Example 1 An easily alkali-soluble copolymerized polyester was used as the sea component, polyethylene terephthalate was used as the island 1 component, nylon 6 was used as the island 2 component, and the ternary composite base was used. / Sea component ratio 90/10, number of islands 7
0 (36 islands consisting of one island component, 34 islands consisting of two island components, and islands 1 and 2 are alternately dispersed), 10 filaments, and a polymer of 150 denier total fineness The arrayed fiber is spun and then stretched at a hot roller temperature of 100 ° C. and a hot plate temperature of 140 ° C. at a draw ratio of 3 to obtain a conjugate fiber consisting of three components having a boiling water shrinkage (boil recovery) of 10%. Was.

Next, by using such a conjugate fiber as a warp yarn and a weft yarn, 160 warps / inch and 108 wefts / i are used.
A high density taffeta with nch greige density was obtained.

Next, using a 1.2% aqueous solution of NaOH, a treatment was carried out at a treatment temperature × time = 95 ° C. × 45 minutes to dissolve and remove sea components and to carry out shrinkage treatment. A dense fabric with a shrinkage of 25% was obtained.

Thereafter, the cloth is dried at 180 ° C. for 1 hour.
After performing a free shrinking treatment for 5 minutes, it was immersed in water and further dried. Due to such shrinkage, the fabric is further 13%
Shrinkage (area shrinkage) was observed.

The woven fabric made of the obtained ultrafine fibers was very flexible and dense. 1.4m thickness of fabric
m, the basis weight was 79 g / m ² , the density was 0.56 g / cm ³ , the weaving density was 210 lines / inch, and the width was 128 lines / inch.

The woven fabric was dyed with ultrafine fibers on the polyester side using a disperse dye, and then subjected to reduction washing to finish. The finished fabric had no color spots, though the nylon side was not dyed at all.

Thereafter, a water repellent treatment was performed using a fluorine-based water repellent.

The water-repellent cloth thus obtained was very flexible and dense. When water droplets were dropped on the cloth, the water drops ran vigorously on the cloth.

An umbrella was prepared using such a fabric as an umbrella ground, and the umbrella was immersed in the rain.

In order to check the water repellency, the conventional method was used. However, since it was too good to be evaluated, as a new method, the cloth was slightly slanted, and a drop of water was dropped on the cloth. As a result of the evaluation, it was found that the sample rolled down a little faster than the conventional water-repellent cloth.

Incidentally, when both the island 1 and the island 2 components are polyethylene terephthalate components (in this case, ultra-fine fibers of the polyethylene terephthalate component alone are obtained), and both the island 1 and the island 2 components are the nylon-6 component alone. If
The respective shrinkage rates under boiling water of the composite fibers obtained by spinning under the same conditions as in the above examples were 8.5% and 15%.
The shrinkage ratios of the polyethylene terephthalate ultrafine fibers and the nylon-6 ultrafine fibers were significantly different.

Incidentally, the boiling yield was measured under the following conditions.

Boiling yield: Initial load = D / 30 (g), treated in boiling water free for 20 minutes, where D = total fiber fineness.

The woven fabric composed of the ultrafine fibers of the polyethylene terephthalate component alone and the ultrafine fibers of the nylon-6 component alone was prepared in the same manner as in Example 1 (Comparative Examples 1 and 2). In any case, almost no shrinkage occurred in the second-stage shrinkage treatment.

A comparison between the woven fabric of the above-described example and the woven fabric obtained in the comparative example shows that the softness of the woven fabric is as follows.
Despite being a woven fabric of ultrafine fibers of the same fineness, those of the examples have a very supple, swelling feeling and a soft touch, and also in their denseness, the polyethylene terephthalate component The ultra-fine fiber woven fabric (Comparative Example 1) was significantly superior to that of the single woven fabric, and even though the fluorescent light was seen through, the light of the fluorescent light did not show through at all even though it was a thin woven fabric. On the other hand, the woven fabric of the comparative example (Comparative Example 2) composed of nylon-6 component alone and ultrafine fibers is dense, but the ultrafine fibers are hard to disperse, and the texture is considered to be composed of ultrafine fibers. It was surprisingly hard.

As described above, the technical idea of the present invention is to use ultra-fine fibers in a woven or knitted fabric composed of a fiber structure in which fibers exist very densely, and to show the characteristics thereof. It is unique.

[0041]

As described above, according to the method for producing a woven or knitted fabric of the present invention, it is possible to develop the following excellent functions and effects.

B ) In the prior art, it was generated by deseaching.
Ultrafine fibers have the property that each single fiber converges,
Although there was a disadvantage that it did not easily act as ultra-fine fibers, the present invention
In the above, the ultra-fine
Fibers are two or more kinds of ultrafine fibers
It can be made into a mixed fiber.
For example, it is possible to form a mixed fiber using means such as air entanglement.
Differently, the same ultrafine fibers do not form a mass
It can be made into a highly mixed state,
In this case, the ultrafine fibers are opened one by one, and the porosity is large.
In addition, the effect of super softening in the fiber bundle becomes very large. Ma
And, b) In general, when using a polymer cross-array fiber, initial
The polymer inter-array fiber that constituted the woven or knitted fabric was the sea component
How high is the island component to make it thinner for removal
However, there has been a limit to the densification of such woven or knitted materials.
Method using ultra-fine fiberizing means such as splitting / peeling type
In comparison, it is inevitable that its densification is slightly inferior.
, Especially sea-island complex consisting of two or more island components
Using fiber and applying such sea component removal / shrinkage treatment
After that, a dry heat-wet treatment is applied to further shrink the woven or knitted fabric.
The method of the present invention has less sea thinness and can be densified. Sa
In addition, c) In general, the denser the woven or knitted fabric, the harder its texture
It was common sense so far, but the invention of the present application
By performing the second stage of shrinkage processing,
Ultrafine fibers with different shrinkage characteristics are unwound
The ultra-fine single yarn is finely opened one by one, and the space inside the fiber bundle is
Rate at the tissue entanglement point of the woven or knitted fabric
With a gap, the constituent fibers are free to move without being restrained
Therefore, the feeling becomes softer.

( D) Since the ultrafine fibers are not grouped and are mixed in a very high mixed state, even one-sided dyeing (dying of any one of two or more types of ultrafine fibers) can be performed by whole dyeing. It looks as if there is no irritability or color spots.

( E) Since the ultrafine fibers are finely spread, a woven or knitted fabric having a good touch can be obtained, which is suitable for underwear, underwear, and silk-like clothing such as blouses.

( F) Since the ultra-fine fibers act one by one and the characteristics of the ultra-fine fibers are exhibited without regret, the cleaning properties are excellent.
It can be preferably used for various wiping materials including industrial use.

(G ) Since it is very dense and flexible even on thin fabrics and hardly wrinkles, it is also suitable as a compact cloth for windbreakers.

(H ) Since a very high performance can be obtained by performing the water repellent treatment, it is most suitable as an umbrella base including water-repellent clothing, waterproof clothing, and moisture-permeable clothing. Indeed, as an umbrella that can drain water with a single stroke, an umbrella that can be immediately stored in a bag or the like without getting wet at all becomes possible.

(4 ) Since the surface is smooth and dense, by printing an optically readable mark on the surface of the fabric,
It can be used as an optically read mark recording fabric and also as an image printing and copying fabric since clear images can be formed.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location D03D 15/00 D03D 15/00 F D06C 29/00 D06C 29/00 Z D06M 11/05

Claims (1)

(57) [Claims] (1) Mainly 0.3 to 0.001 denier po
Two or more microfiber component of the polyamide and polyester
Island components are arranged in a distributed manner without forming groups.
And the sea component is hot water soluble or weakly alkaline
Sea-island type duplex formed from soluble copolyester component
After forming a woven or knitted fabric using the composite fiber, the sea component is dissolved.
A method for producing an ultrafine fiber woven / knitted fabric, which comprises subjecting the woven / knitted material to shrink by shrinking and / or shrinking the woven / knitted material, followed by performing a dry heat-wet treatment.