JP5442985B2 - Method for producing dyed car seat fabric and dyed car seat fabric - Google Patents

Description

  The present invention is a fabric that contains ultrafine fibers and is dyed, and has a good light fastness as well as an excellent design, and is produced by the method. The invention relates to a dyed fabric.

  In recent years, fabrics using ultrafine fibers called nanofibers with a single fiber diameter of 1000 nm or less have been proposed (see, for example, Patent Document 1). Such a fabric has a soft surface touch unique to ultrafine fibers. However, if such fabric is dyed and then used as a car seat fabric or the like, it is difficult for dyes to enter into the ultrafine fibers, so the color development and fastness to light of the fabric are reduced. There was a problem that the sex was not enough.

As a countermeasure, for example, Patent Document 2 proposes dyeing a fabric with a dye recycle containing an anthraquinone dye and an ultraviolet absorber.
However, according to such a method, although the light fastness of the fabric is improved, since the fabric described in Patent Document 2 is a nonwoven fabric, it is not sufficient in terms of design.

JP 2007-291567 A JP 2007-262627 A

  The present invention has been made in view of the above-mentioned background, and the object thereof is a fabric containing and dyeing ultrafine fibers, which has not only good light fastness but also excellent design. Another object of the present invention is to provide a method for producing a fabric and a dyed fabric.

  As a result of intensive studies to achieve the above-mentioned problems, the present inventors have found that when a fabric containing ultrafine fibers is dyed with a dye recipe containing an anthraquinone dye and an ultraviolet absorber, a fabric or knitted fabric is used as the fabric. It has been found that a dyed fabric not only having good light fastness but also excellent in design can be obtained by adopting a fabric having a light resistance, and the present invention has been completed by further intensive studies. It was.

Thus, according to the present invention, “a polyester filament yarn A having a single fiber diameter of 10 to 1000 nm and a cloth containing a fiber having a single fiber diameter larger than 1 μm and having a woven or knitted structure, an anthraquinone dye and an ultraviolet ray There is provided a method for producing a dyed car seat fabric, characterized in that after dyeing with a dye recipe containing an absorbent, back coating is performed using an acrylic resin .

  At that time, the number of filaments of the polyester filament yarn A is preferably 500 or more. The polyester filament yarn A is a filament yarn obtained by dissolving and removing a sea component of a sea-island type composite fiber formed of a sea component and an island component having a diameter of 10 to 1000 nm with an alkaline aqueous solution. It is preferable. The polyester filament yarn A is preferably twisted. Moreover, it is preferable that the said polyester filament yarn A is contained 20 to 80weight% with respect to the fabric weight. Further, the blending ratio of the anthraquinone dye and the non-anthraquinone dye is preferably in the range of 50:50 to 100: 0 by weight ratio (the anthraquinone dye: non-anthraquinone dye). The total weight of the anthraquinone dye and the non-anthraquinone dye is preferably in the range of 0.25 to 6.0% by weight with respect to the fabric weight. Moreover, it is preferable that the weight of the said ultraviolet absorber exists in the range of 0.5 to 5.0 weight% with respect to the fabric weight.

  Moreover, according to this invention, the dyed fabric manufactured by the said manufacturing method is provided. In that case, it is preferable that the fabric is for a car seat, a chair, or a sofa.

  According to the present invention, there is obtained a dyed fabric production method and a dyed fabric which are ultrafine fibers and are dyed and have not only good light fastness but also excellent design. It is done.

Hereinafter, embodiments of the present invention will be described in detail.
In the present invention, first, a fabric including a polyester filament yarn A having a single fiber diameter of 10 to 1000 nm and having a woven or knitted structure is prepared.
Here, in the said polyester filament thread | yarn A (henceforth "nanofiber"), the single fiber diameter (diameter of a single fiber) is 10-1000 nm (preferably 100-800 nm, Especially preferably, 550-500). It is important to be within the range of 800 nm). When the single fiber diameter is converted into a single fiber fineness, it corresponds to 0.000001 to 0.01 dtex. When the single fiber diameter is smaller than 10 nm, the fiber strength is lowered, which is not preferable for practical use. On the other hand, when the single fiber diameter is larger than 1000 nm, the fabric may not exhibit a soft texture peculiar to the ultrafine fibers, which is not preferable. Here, when the cross-sectional shape of the single fiber is an atypical cross section other than the round cross section, the diameter of the circumscribed circle is defined as the single fiber diameter. The single fiber diameter can be measured by photographing the cross section of the fiber with a transmission electron microscope.

  In the polyester filament yarn A, the number of filaments is not particularly limited, but is preferably 500 or more (more preferably 2000 to 10,000) in order to obtain a texture peculiar to ultrafine fibers. The total fineness of the polyester filament yarn A (the product of the single fiber fineness and the number of filaments) is preferably in the range of 5 to 150 dtex.

  Although the fiber form of the said polyester filament yarn A is not specifically limited, In order to obtain the outstanding designability, it is preferable that it is a long fiber (multifilament yarn). The cross-sectional shape of the single fiber is not particularly limited, and may be a known cross-sectional shape such as a circle, a triangle, a flat shape, or a hollow shape. In addition, normal air processing and false twist crimping may be applied. In particular, it is preferable that the polyester filament yarn A is twisted because the rigidity of the fabric is improved and the wear resistance is improved. At that time, the twist number is preferably 100 T / m or more (particularly preferably 100 to 600 T / m).

  The type of polymer forming the polyester filament yarn A is not particularly limited as long as it is a polyester polymer, and is copolymerized with polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, stereocomplex polylactic acid, and third component. Preferred examples include polyesters and the like. Such polyester may be material recycled or chemically recycled polyester. Furthermore, the polyester obtained using the catalyst containing the specific phosphorus compound and titanium compound which are described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. In the polymer, a fine pore forming agent, a cationic dye dyeing agent, an anti-coloring agent, a heat stabilizer, a fluorescent whitening agent, a matting agent, a coloring agent may be added as necessary within the range not impairing the object of the present invention. 1 type (s) or 2 or more types of an agent, a hygroscopic agent, and inorganic fine particles may be contained. Polymers such as polyamide other than polyester are not preferable because the light resistance and wear resistance of the fabric are impaired.

  The polyester filament yarn A is a sea component of a sea-island type composite fiber formed of a sea component and an island component having a diameter of 10 to 1000 nm, as disclosed in JP 2007-2364 A. A filament yarn obtained by dissolving and removing with an alkaline aqueous solution is preferable.

  That is, as the sea component polymer, polyester, polyamide, polystyrene, polyethylene and the like having good fiber forming properties are prepared. For example, as an easily soluble polymer in an alkaline aqueous solution, polylactic acid, an ultra-high molecular weight polyalkylene oxide condensation polymer, a polyethylene glycol compound copolymer polyester, a copolymer polyester of polyethylene glycol compound and 5-sodium sulfonic acid isophthalic acid may be used. Is preferred. Among them, a polyethylene terephthalate copolymer polyester having an intrinsic viscosity of 0.4 to 0.6 obtained by copolymerizing 6 to 12 mol% of 5-sodium sulfoisophthalic acid and 3 to 10% by weight of polyethylene glycol having a molecular weight of 4000 to 12000. Is preferred.

On the other hand, as an island component polymer, a polyester such as a fiber-forming polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, or a polyester obtained by copolymerizing a third component is prepared. In the polymer, a fine pore forming agent, a cationic dye dyeing agent, an anti-coloring agent, a heat stabilizer, a fluorescent whitening agent, a matting agent, a coloring agent may be added as necessary within the range not impairing the object of the present invention. 1 type (s) or 2 or more types of an agent, a hygroscopic agent, and inorganic fine particles may be contained.
In the sea component polymer and the island component polymer, the melt viscosity of the sea component at the time of melt spinning is preferably larger than the melt viscosity of the island component polymer.

  Next, melt spinning is performed using the sea component polymer and the island component polymer. As the spinneret used for melt spinning, any one such as a hollow pin group for forming an island component or a group having a fine hole group can be used. At that time, the diameter of the island component needs to be in the range of 10 to 1000 nm. When the diameter is not a perfect circle, the diameter of the circumscribed circle is obtained. The sea-island composite weight ratio (sea: island) is preferably in the range of 40:60 to 5:95, and particularly preferably in the range of 30:70 to 10:90.

  The discharged sea-island type composite fiber is solidified by cooling air, and is preferably wound after being melt-spun at 400 to 6000 m / min. The obtained undrawn yarn is made into a composite fiber having desired strength, elongation, and heat shrinkage properties through a separate drawing process, or is taken up by a roller at a constant speed without being wound once, and subsequently drawn. Any of the methods of winding after passing through may be used. Then, twisted yarn is applied as necessary.

  In the sea-island type composite fiber thus obtained, the single yarn fiber fineness, the number of filaments, and the total fineness are within the range of the single yarn fiber fineness of 0.5 to 10.0 dtex, the number of filaments of 5 to 75, and the total fiber of 30 to 170 dtex, respectively. It is preferable that

  The fabric used in the present invention may be composed only of the polyester filament yarn A, but the polyester filament yarn A and other fibers constitute a fabric, and the polyester filament yarn A is 20 with respect to the fabric weight. When it is set so as to be contained in an amount of ˜80% by weight, the rigidity of the fabric is increased, and it can be suitably used as a car seat fabric or the like.

  Here, in the other fibers, the single fiber diameter is preferably in the range of more than 1 μm (preferably 2 to 25 μm). If the single fiber diameter is 1 μm or less, the rigidity of the fabric may be lost. In addition, workability and handleability may also be reduced. Conversely, if the single fiber diameter is larger than 25 μm, the soft texture of the ultrafine fibers may be impaired. Here, when the cross-sectional shape of the single fiber is an atypical cross section other than the round cross section, the diameter of the circumscribed circle is defined as the single fiber diameter. The single fiber diameter can be measured by photographing the cross section of the fiber with a transmission electron microscope, as described above.

  In the other fibers, the number of filaments is not particularly limited, but is preferably in the range of 1 to 300 (preferably 40 to 200). The fiber form of the other fibers is not particularly limited, but is preferably a long fiber (multifilament yarn). The cross-sectional shape of the single fiber is not particularly limited, and may be a known cross-sectional shape such as a circle, a triangle, a flat shape, or a hollow shape. In addition, normal air processing and false twist crimping may be applied.

  The type of polymer forming the other fibers is preferably a polyester polymer, and is obtained by copolymerizing polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, stereocomplex polylactic acid, and a third component. Polyester and the like are particularly preferred. Such polyester may be material recycled or chemically recycled polyester. Furthermore, the polyester obtained using the catalyst containing the specific phosphorus compound and titanium compound which are described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. In the polymer, a fine pore forming agent, a cationic dye dyeing agent, an anti-coloring agent, a heat stabilizer, a fluorescent whitening agent, a matting agent, a coloring agent may be added as necessary within the range not impairing the object of the present invention. 1 type (s) or 2 or more types of an agent, a hygroscopic agent, and inorganic fine particles may be contained.

The polyester filament yarn A and other fibers may be included as a composite yarn such as an air-mixed yarn, or both may be included together, or both may be woven or knitted. It may be. In particular, it is preferable that both are woven or knitted. When both are woven or knitted, the polyester filament yarn A having a small single fiber diameter is dyed lightly and the other fibers having a large single fiber diameter are dyed deeply by dyeing. can get.
It is important that the fabric has a woven fabric or a knitted fabric. In the case of a nonwoven fabric structure, it is not preferable because it is inferior in design.

  Here, the structure of the woven fabric and the knitted fabric is not particularly limited, and if it is a woven structure, it is a three-dimensional structure such as plain weave, oblique weaving, satin weaving, etc. Examples thereof include a single double structure such as a weft double weave, and a vertical velvet. Examples of the weft knitting structure include flat knitting, rubber knitting, double-sided knitting, pearl knitting, tuck knitting, float knitting, one-sided knitting, lace knitting, and bristle knitting. Examples include, but are not limited to, knitting, single atlas knitting, double cord knitting, half knitting, half base knitting, satin knitting, half tricot knitting, back hair knitting, jacquard knitting and the like. The number of layers may be a single layer or a multilayer of two or more layers. In particular, a jacquard woven fabric or a jacquard knitted fabric is particularly preferable in terms of design.

  Next, the fabric is subjected to an alkaline aqueous solution treatment, and the sea component of the sea-island composite fiber is dissolved and removed with an alkaline aqueous solution, whereby the sea-island composite fiber is made into a polyester multifilament yarn A having a single fiber diameter of 10 to 1000 nm. . At that time, the alkaline aqueous solution treatment may be performed at a temperature of 55 to 65 ° C. using a 3 to 4% NaOH aqueous solution.

  In the present invention, the fabric is dyed with a dye recycle containing an anthraquinone dye and an ultraviolet absorber. In this case, it is preferable to use a non-anthraquinone dye in combination with the other dye since the color developability of the fabric is improved.

  Here, anthraquinone dyes are excellent in light fastness. On the other hand, non-anthraquinone dyes (for example, azo dyes, methine dyes, naphthoprinone dyes, quinophthalone dyes, solvent dyes) are excellent in color development. By optimizing these blending ratios, a dyed fabric having both good color development and light fastness can be obtained. At that time, the blending ratio of the anthraquinone dye and the non-anthraquinone dye is 50:50 to 100: 0 (more preferably 50:50 to 95: 5) in a weight ratio (the anthraquinone dye: non-anthraquinone dye). It is preferable to be within the range. The total weight of the anthraquinone dye and the non-anthraquinone dye is preferably in the range of 0.25 to 6.0% by weight with respect to the fabric weight.

  Moreover, the said ultraviolet absorber is required in order to improve the light fastness of a fabric, As a kind, a hindert type, a benzotriazole type, a benzotriazine type, a benzophenine type etc. are illustrated suitably. Moreover, it is preferable that the weight of the said ultraviolet absorber contained in a dye recipe exists in the range of 0.5 to 5.0 weight% with respect to the fabric weight.

In the present invention, the fabric is dyed with the dye recipe. In that case, except for using the dye recipe, conventional methods such as temperature conditions and auxiliary agents to be used may be used.
Then, if necessary, conventional buffing, brushing, backside coating, water repellent, UV shielding or antistatic agent, antibacterial agent, deodorant, insect repellent, phosphorescent agent, retroreflective agent In addition, various processings that impart functions such as a negative ion generator may be additionally applied.

Further, in such a fabric, the basis weight is preferably in the range of 100 to 700 gr / m ² (more preferably 150 to 650 gr / m ² ). If the basis weight is less than 100 gr / m ² , the rigidity becomes small and there is a possibility that it cannot be used as a fabric for a car seat. On the other hand, if the basis weight is larger than 700 gr / m ² , the basis weight is too large, and the handleability when producing a car seat or the like may be impaired.

  Since the dyed fabric thus obtained contains the polyester filament yarn A having a single fiber diameter of 10 to 1000 nm, it exhibits a soft texture peculiar to ultrafine fibers. Moreover, since it has a woven structure or a knitted structure, it is excellent also in design property. Furthermore, since it is dyed with a dye recycle containing an anthraquinone dye and an ultraviolet absorber, it has good light fastness. Further, when a non-anthraquinone dye is included in the dye recycle, the fabric exhibits good color developability.

  Such a fabric is a fabric that contains and dyes ultrafine fibers and has not only good light fastness but also excellent design, so that it is a car seat fabric, a chair fabric, a sofa fabric, etc. Is preferably used.

Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.
<Dissolution rate>
The yarn is wound at a spinning speed of 1000 to 2000 m / min with a base of 0.3φ-0.6L × 24H for each of the sea and island polymers, and further drawn so that the residual elongation is in the range of 30 to 60%. Thus, a 84 dtex / 24 fil multifilament was produced. The weight loss rate was calculated from the dissolution time and the dissolution amount at a bath ratio of 100 at a temperature at which the solvent was dissolved in each solvent.
<Texture>
Three testers sensory-evaluate the texture of the fabric surface, and grade 3: presents a soft, slimy texture peculiar to ultra-fine fibers (nanofibers), grade 2: normal, grade 1: peculiar to ultra-fine fibers. It was evaluated in three stages: not present.
<Designability>
Three testers visually judged the design properties, and grade 3: grade difference between warp and weft was different and excellent in design properties, grade 2: normal, grade 1: inferior in design properties.
<Light fastness>
Measurement was performed according to JIS L0843 B method (for xenon arc method, 38 cycles), and the determination was performed using the gray scale for color fading according to JIS L0804. Grade 3 or higher is acceptable.
One cycle mentioned here is a light cycle (black panel temperature 89 ± 3 ° C., relative humidity 50 ± 5%, cycle time 3.8 hours) and dark cycle (black panel temperature 38 ± 3 ° C., relative humidity 95 ± 5%). , Cycle time 1.0 hour).
<Single fiber diameter>
After the fabric was photographed with an electron microscope, the single fiber diameter was measured with an n number of 5, and the average value was obtained.

[Example 1]
Using polyethylene terephthalate as the island component, polyethylene terephthalate copolymerized with 6 mol% of 5-sodium sulfoisophthalic acid and 6% by weight of polyethylene glycol having a number average molecular weight of 4000 as the sea component (dissolution rate ratio (sea / island) = 230), A sea-island type composite unstretched fiber having sea: island = 30: 70 and number of islands = 836 was melt-spun at a spinning temperature of 280 ° C. and a spinning speed of 1500 m / min, and wound up once. The obtained undrawn yarn was roller-drawn at a drawing temperature of 80 ° C. and a draw ratio of 2.5 times, and then heat-set at 150 ° C. and wound up as a sea-island type composite drawn yarn for polyester filament yarn A. The obtained sea-island type composite drawn yarn was 56 dtex / 10 fil and the cross section of the fiber was observed with a transmission electron microscope TEM. As a result, the shape of the island was round and the diameter of the island was 700 nm.
Subsequently, four of the drawn yarns were aligned to form a twisted yarn (Z direction, 250 T / m), and heat set was performed at a temperature of 70 ° C. for 30 minutes as a countermeasure against snare to obtain a warp.
On the other hand, a polyethylene terephthalate multifilament (total fineness: 167 dtex / 48 fil, manufactured by Teijin Fibers Ltd., single fiber diameter: 18 μm) was prepared as another fiber and used as a weft.

Next, using the warp and the weft, a plain fabric was woven at a warp density of 162 / 2.54 cm and a weft density of 90 / 2.54 cm by a conventional method.
Next, the woven green machine is subjected to a 30% weight reduction process at 50 ° C. for 20 minutes with a 50 g / liter NaOH aqueous solution, whereby the sea-island type composite drawn yarn is made into a polyester filament yarn A having a single fiber diameter of 700 nm. The dyeing process described below was performed.
Azo and quinone (50:50) Harmony Light Yellow HAL 1.05%
Anthraquinone Harmony Light Red MS-4 0.63%
Anthraquinone Harmony Light Blue HAL 1.36%
UV absorber Sunlife LPX50 1.00%
Azo: quinone = 17.3: 82.7
Here, the azo series refers to non-anthraquinone series dyes, and the quinone series refers to anthraquinone series dyes.

After dyeing, it was dried, heat set at 150 ° C., and then buffed as surface processing. Finally, back coating was performed using an acrylic resin on the back surface to prevent fraying, and a car seat fabric was obtained. At that time, the amount of acrylic resin at the time of back coating was 100 g / m ² .
The obtained fabric exhibited a soft and slimy texture (class 3) peculiar to ultrafine fibers (nanofibers). Moreover, since the single fiber diameters of the warp and the weft were different, the color difference was different and the design was excellent (class 3). Further, the light fastness was class 3 and excellent in light fastness. The basis weight was 300 g / m ² . Further, the obtained fabric contained 63% by weight of the polyester filament yarn A having a single fiber diameter of 700 nm in the total fiber weight of 200 g / m ^{2 and} 37% by weight of the other fibers. The single fiber diameter of the other fibers was 18 μm.
Next, when a car seat was produced using the fabric, it exhibited a soft and slimy texture peculiar to ultrafine fibers (nanofibers) (Class 3), and was excellent in design (Class 3). ). Moreover, the workability was also good.

[Example 2]
Example 1 was the same as Example 1 except that the dye recipe was changed as follows.
Azo / quinone (50:50) Harmony Light Yellow HAL 2.13%
Anthraquinone Harmony Light Red MS-4 0.59%
Anthraquinone Harmony Light Blue HAL 0.29%
UV absorber Sunlife LPX50 1.00%
Azo series: quinone series = 35.4: 64.6
The obtained fabric exhibited a soft and slimy texture (class 3) peculiar to ultrafine fibers (nanofibers). Moreover, since the single fiber diameters of the warp and the weft were different, the color difference was different and the design was excellent (class 3). Further, the light fastness was class 3 and excellent in light fastness. The basis weight was 300 g / m ² . Further, the obtained fabric contained 63% by weight of the polyester filament yarn A having a single fiber diameter of 700 nm in the total fiber weight of 200 g / m ^{2 and} 37% by weight of the other fibers. The single fiber diameter of the other fibers was 18 μm.
Next, when a car seat was produced using the fabric, it exhibited a soft and slimy texture peculiar to ultrafine fibers (nanofibers) (Class 3), and was excellent in design (Class 3). ). Moreover, the workability was also good.

[Comparative Example 1]
The same procedure as in Example 1 was performed except that ordinary polyethylene terephthalate multifilaments (total fineness: 167 dtex / 48 fil, manufactured by Teijin Fibers Ltd., single fiber diameter: 18 μm) used for the wefts in Example 1 were arranged on the warp and the wefts.
In the obtained fabric, the design properties were normal (second grade), and the fabric did not exhibit the texture peculiar to ultrafine fibers (first grade).

  According to the present invention, a method for producing a dyed fabric that contains ultrafine fibers and is dyed and has not only good light fastness but also excellent design, and produced by the method. And dyed fabrics are provided, the industrial value of which is enormous.

Claims (10)

A fabric containing a polyester filament yarn A having a single fiber diameter of 10 to 1000 nm and a fiber having a single fiber diameter larger than 1 μm and having a woven or knitted structure is a dye recycle containing an anthraquinone dye and an ultraviolet absorber. A method for producing a dyed car seat fabric, characterized by back coating using an acrylic resin after dyeing. The method for producing a dyed car seat fabric according to claim 1, wherein the number of filaments of the polyester filament yarn A is 500 or more. The polyester filament yarn A is a filament yarn obtained by dissolving and removing a sea component of a sea-island type composite fiber formed of a sea component and an island component having a diameter of 10 to 1000 nm with an alkaline aqueous solution. A method for producing a dyed car seat fabric according to claim 1 or 2. The method for producing a dyed car seat fabric according to any one of claims 1 to 3, wherein the polyester filament yarn A is twisted. The method for producing a dyed car seat fabric according to any one of claims 1 to 4, wherein the polyester filament yarn A is contained in an amount of 20 to 80 wt% based on the fabric weight. The method for producing a dyed car seat fabric according to any one of claims 1 to 5, wherein the dye recipe includes a non-anthraquinone dye as another dye. The blending ratio of the anthraquinone dye and the non-anthraquinone dye is in a range of 50:50 to 100: 0 by weight ratio (the anthraquinone dye: non-anthraquinone dye). A method for producing a dyed car seat fabric as described. The dyed car seat according to any one of claims 1 to 7, wherein the total weight of the anthraquinone dye and the non-anthraquinone dye is in the range of 0.25 to 6.0% by weight based on the fabric weight. For producing a fabric for use. The method for producing a dyed car seat fabric according to any one of claims 1 to 8, wherein a weight of the ultraviolet absorber is in a range of 0.5 to 5.0 wt% with respect to a fabric weight. A dyed car seat fabric produced by the production method according to claim 1.