JPH0347354B2 - - Google Patents

Description

[Detailed description of the invention] (a) Industrial application field The present invention is directed to a woven or knitted fabric which has a soft textured bulky spun yarn, so-called non-twisted yarn, on its surface, has a soft touch, and has excellent abrasion resistance. Regarding manufacturing methods.

(b) Conventional technology Spun yarn maintains its shape and strength by twisting short fiber bundles and the entanglement generated by filament migration and the frictional force generated by the lateral pressure caused by the twisting. ing.
Therefore, it was thought that cloth foil made from spun yarn would be extremely weak if the spun yarn was not twisted. However, in recent years, spun yarns made by hardening short fiber bundles with adhesives have come to be produced, and the properties of the fabrics when the adhesives are removed after they have been made are becoming known. According to the results, the cloth foil made of untwisted spun yarn is stronger than expected, close to that of cloth foil made of ordinary spun yarn, and has sufficient strength for practical use, and has good air permeability and water permeability. It is small and the texture changes easily depending on the fabric density.
High-density woven fabrics made of untwisted spun yarn from which the adhesive has been removed are harder than woven fabrics made of ordinary spun yarn, while low-density woven and knitted fabrics are significantly softer, and have a softness that cannot be obtained with ordinary spun yarn. It's going to be. The softness of low-density untwisted fabrics is not due to the weak binding force between the fibers, which results in no resistance to elongation, shearing, or bending, but rather due to the increased spacing between the fibers, which reduces the compressive resistance. The reason seems to be that it becomes soft to the touch. Therefore, it is difficult to make a woven fabric similar to a low-density non-twisted woven fabric from conventional spun yarn, and the same is thought to be true for knitted fabrics.

In response, proposals have been made to create yarns similar to non-twisted spun yarns from conventional spun yarns. It involves aligning a spun yarn with water-soluble vinylon yarn, twisting it in the direction of untwisting the spun yarn, and creating a yarn with very little twist in the spun yarn and water-soluble vinylon yarn wrapped around it. This is a method in which the water-soluble vinylon thread is removed with warm water after making cloth foil using the thread.

The problem with this method is the difficulty in dissolving and removing water-soluble vinylon. Water-soluble vinylon dissolves in hot water to produce polyvinyl alcohol (PVA),
PVA has a strong affinity for various fibers, so
Difficult to remove and requires considerable amounts of hot water. If hot water washing is insufficient, the fabric will become hard due to adhesion between fibers, making it impossible to obtain the desired texture. Also
Disposal of large quantities of hot water containing PVA poses difficult environmental problems.

Another problem is that water-soluble vinylon is generally more difficult to handle than ordinary fiber materials. Water-soluble vinylon expands and contracts greatly depending on the humidity in the air.
At the same time, the Young's modulus changes significantly. Therefore, in the process of making yarn using water-soluble vinylon, various drawbacks occur unless temperature and humidity are controlled extremely precisely. Furthermore, if twisted cheese is subjected to thread steaming or dry heat treatment, it may become difficult to unravel or become difficult to dissolve in water, so as a general rule, such processes should be avoided. In cases where synthetic fibers are mixed in the yarn, the yarn obtained by plying and twisting exhibits strong torque properties, causing problems such as the formation of snarls, which significantly impairs processability.

In order to solve these problems,
No. 116829 discloses a method of producing a non-twisted woven or knitted fabric by using an alkali-ready polyester instead of water-soluble vinylon and subjecting it to alkali treatment. This method uses water-soluble vinylon because the alkali easily meltable thread is easy to handle and is inexpensive, and because the dissolution is hydrolysis, there is no hardening during treatment, and wastewater treatment is generally easy. Although it is considered to be superior to , it still has the following drawbacks.

In order to fully demonstrate its bulkiness, non-twisted woven and knitted fabrics have loops and piles (in the present invention) on the surface.
The combination of both is called a pile). In this case, the binding force due to twisting does not work between the fibers, so they do not come off as a fiber bundle, but if something gets caught on the single fibers, they tend to be pulled out relatively easily, and the fibers often fall off, especially during washing. , wear resistance also tends to be poor.

(c) Problems to be Solved by the Invention The purpose of the present invention is to improve the common drawbacks of non-twisted woven and knitted fabrics, which are that single fibers often fall off and the abrasion resistance is poor.

(d) Means for Solving the Problems The present invention is a method in which continuous yarns made of easily alkali-soluble polyester fibers are arranged in a spun yarn made of poorly alkali-soluble fibers, and the spun yarns are twisted in the direction in which the spun yarns are untwisted. A pile fabric is woven or knitted using the yarn as a pile yarn, and the vicinity of the tips of the fibers or yarn tufts protruding from the resulting fabric sheet (i.e., the pile portion of the pile yarn) is treated with alkali to remove the alkali near the tips. A method for producing a bulky spun yarn woven or knitted material with excellent abrasion resistance characterized by dissolving and removing easily soluble polyester fibers and leaving easily alkali soluble polyester fibers in the vicinity of thread intersections of the cloth, the method comprising: Near the thread intersection of the fabric, the extremely lightly twisted fiber bundles are twisted by the remaining alkali-soluble polyester fibers, making it difficult for the single fibers to slip off, causing them to lift up from the structure of the fabric fabric. In the twisted parts, the alkali-soluble polyester fibers are dissolved by the alkali and bulkiness is developed, resulting in a soft texture equivalent to that of conventional non-twisted woven or knitted fabrics.

The latent bulky composite yarn obtained by the method of the present invention is
It can be used alone to make bulky fabric foil, or it can be used only as a yarn forming loops or piles to make bulky fabric foil. Furthermore, by performing alkali treatment to form a pattern, it is possible to form a pattern based on bulk. Further, by using the composite yarn and ordinary yarn in combination, an uneven pattern can be formed due to the bulk.

There are two methods for removing easily alkali-soluble polyester fibers in the vicinity of the tips by treating the vicinity of the tips of the fibers or tufts protruding from the cloth of the present invention with alkali. The first method is to prepare a highly viscous solution by dissolving a thickener such as polyacrylic acid, water glass, or carboxymethyl cellulose (CMC) in an alkaline aqueous solution, and then apply the alkaline solution uniformly onto a rotating roller. The cloth foil of the present invention is brought into light contact with the cloth foil, the alkaline solution is applied only to the vicinity of the tips of the fibers or yarn tassels protruding from the cloth foil, and the cloth foil is heated by a method such as steaming to remove the fibers. Alternatively, a method is to dissolve and remove the easily alkali-soluble polyester fibers only near the tips of the yarn tassels, wash with water to dissolve and remove the alkaline solution, and then dry. The second method is to glue the cloth sheet with an alkali-resistant glue such as polyvinyl alcohol, CMC, etc., dry it, dissolve it in the solvent of the glue for a short time, and remove the fibers or thread tufts protruding from the cloth sheet. When only the glue attached to the tip has been dissolved and removed, dissolving the glue is stopped and dried, and then the cloth foil is dipped in an alkaline solution to remove the fibers or thread tufts protruding from the cloth foil. This method involves dissolving only the easily alkali-soluble polyester fibers in the area from which the glue has been removed, washing away the adhering alkali, and then dissolving and removing the remaining glue, followed by drying. No matter which method is used, the fiber bundle or yarn tuft protruding from the fabric becomes bulky, and near the thread intersection of the fabric, it is restrained by the remaining alkali-soluble polyester fibers, resulting in single fibers. A fabric foil with excellent abrasion resistance that is less likely to fall off is obtained.

When a spun yarn made of poorly alkali-soluble fibers and a continuous yarn made of easily alkali-soluble polyester fibers are aligned and twisted in a direction to release the spun yarns,
The less twist remains in the spun yarn made of poorly alkali-soluble fibers, the greater the bulkiness will be.However, since the twists that existed before forming the composite yarn are not uniform, even if the average number of twists is 0, there will be some local twists. is often not untwisted. In such cases, a slight change in the number of twists may cause a significant change in bulk. In such cases, it is better to leave a slight twist in the fabric to create a more uniform fabric. Also, in such a case,
It may be twisted to a slightly over-twisted state. Over-untwisted spun yarns tend to have greater torque properties than yarns with some twist remaining, and are preferred because they tend to be bulky despite the residual twist. The larger the twist remaining in the spun yarn, the smaller the swelling after alkali treatment, and if the residual twist coefficient (cotton count type) is greater than 2.0, it is preferable because it becomes difficult to recognize the difference from the conventional spun yarn. do not have.

As the slightly alkali-soluble fiber used in the spun yarn used in the present invention, cotton, hemp, rayon (especially polynosic), nylon, polyester (regular type), vinylon, acrylic, etc. can be used.
Silk, wool, and acetate cannot be used.

The following are suitable as the easily alkali-soluble polyester fiber of the present invention. Undrawn yarn made of polyalkylene terephthalate fiber spun at high speed with a birefringence of 0.07 or higher, a specific gravity of 1.365 or lower, and a boiling water shrinkage rate of 10% or lower. The main component is polyethylene, which is made by copolymerizing 2 to 25 mol% of a compound having a sulfonic acid group and two or more ester-forming groups, or a dicarboxylic acid other than terephthalic acid that does not have a sulfonic acid group. Fibers that are terephthalates. 2-5 mol% of a compound having a sulfonic acid group and two or more ester-forming groups and 2 mol% or more of a dicarboxylic acid having no sulfonic acid group other than terephthalic acid, and the main component is polyethylene terephthalate. Content of ethylene terephthalate units is 70
Fiber that is more than % by weight. Or molecular weight 200−
10000 polyether or its derivative 5-25
A fiber whose main component is polyethylene terephthalate, copolymerized by weight%. 2 mol% of a compound having a sulfonic acid group and two or more ester-forming groups
The above fiber is copolymerized with 2% by weight or more of polyether or its derivative having a molecular weight of 200 to 10,000, the main component of which is polyethylene terephthalate, and the content of ethylene terephthalate units is 70% by weight or more. 2-5 mol% of a compound having a sulfonic acid group and two or more ester-forming groups, molecular weight
The main component is polyethylene terephthalate, which is copolymerized with 2 mol% or more of a glycol compound of less than 200%, and the content of ethylene terephthalate units is 70%.
Fiber that is more than % by weight.

As a compound having a sulfonic acid group and having two or more ester-forming groups, an alkali metal salt of sulfoisophthalate is preferable from the viewpoint of cost and reactivity.
As the dicarboxylic acid having no sulfonic acid group other than terephthalic acid to be copolymerized, isophthalic acid and adipic acid are preferred from the viewpoint of cost.

Examples of polyethers or derivatives thereof having a molecular weight of 200 to 10,000 to be copolymerized include polyethylene glycol, polypropylene glycol, polytetramethylene glycol, random or block copolymers of polyethylene glycol and polypropylene glycol, and polyethers having an ester-forming group at the end thereof. It is blocked by an ether bond, an imide bond, etc. so that more than one bond remains.

Glycol compounds with a molecular weight of less than 200 to be copolymerized include 1,2 propanediol,
1,3 propanediol, 1,3 butanediol, 1,4 butanediol, diethylene glycol, triethylene glycol, and neopentyl glycol are preferred, and 1,4 butanediol and diethylene glycol are most preferred in consideration of stability in the polymerization process.

The continuous yarn body of the easily alkali-soluble polyester fiber used in the present invention may have a structure as a continuous yarn of multifilament, monofilament, spun yarn, or yarn obtained by slitting or splitting a film, or may be crimped. It may be a yarn that has been treated with a polyurethane or a mixture thereof. In order to increase the alkali dissolution rate, it is preferable that the single fibers be thin, and it is preferable that the fibers have an irregular cross section rather than a circular cross section.

In the present invention, the alkaline solution for dissolving the alkali-soluble polyester fiber has a concentration of 0.1-10%,
The solvent is water or a water-based solvent, or an alcohol or an alcohol-based solvent. Furthermore, various additives may be added as necessary. The appropriate treatment temperature is 60° C. or higher and lower than the boiling point of the solvent, but in order to promote dissolution, the treatment can be performed at a temperature higher than the boiling point of the solvent by applying pressure using a closed container.

Example 1 A copolymerized polyethylene terephthalate having an intrinsic viscosity of 0.48 measured at 30°C was melt-spun using a mixture of equivalent amounts of phenol and tetrachloroethane, which was copolymerized with 3 mol% of sodium sulfoisophthalate and 4.5 mol% of isophthalic acid. It was wound up at 1350m/min. This fiber was drawn by a conventional method to obtain a 40 denier/24 filament multifilament.

This thread and No. 16 combed cotton thread (number of twists: 520t/
The material was twisted with 480t/m of S twist and wound. The remaining twist was 1 t/in and the twist coefficient was 0.5. The composite yarn and No. 16 cotton single yarn are used alternately as the warp, and the cotton No. 16 single yarn is used as the weft, and weaving is carried out at a warp density of 38 threads/in and a weft density of 32 threads/in. Toweling was made by making only the threads form a pile.

This towel cloth was treated with the following treatment solution to dissolve the alkali-soluble polyester fibers. Sodium hydroxide 4% Ethylene glycol 1% Polyacrylic acid 20% Water Residual This alkaline solution was evenly applied on a rotating roll. The towel fabric was lightly pressed to apply the alkaline solution only to the pile part, then heated in saturated steam with a gauge pressure of 1.2 kg/cm ² for 30 minutes to dissolve the alkali-soluble polyester fibers in the pile part, and washed with water. The attached alkaline solution was removed using a tumble dryer. The pile portion of the resulting towel fabric was extremely bulky, and the area near the thread intersections was restrained by the remaining alkali-soluble polyester fibers, resulting in good abrasion resistance, and almost no single cotton fibers fell off during washing.

Example 2 A mixture of equivalent amounts of phenol and tetrachloroethane in which 6 mol% of sulfoisophthalic acid was polymerized produced 30
Copolymerized polyethylene terephthalate with an intrinsic viscosity of 0.42 measured at °C is melt-spun, and the spinning draft is
It was wound at 5800m/min at 1200x. This fiber was drawn in a conventional manner to obtain a 75 denier/36 filament fiber.

This fiber and cotton No. 30 single yarn (twist number 680t/m, Z
A composite yarn was made by aligning the strands (twist) and applying S twist at 650t/m. The composite yarn and No. 30 cotton single yarn were used alternately as the warp, and the cotton No. 30 single yarn was used as the weft, with a warp density of 65 threads/in and a weft density of 35 threads/in, so that only the composite thread of the warp thread was used. Make a terry cloth that will form a pile, and use the same alkaline treatment solution as in Example 1.
The alkali easily soluble polyester was dissolved only in the pile portion. After 30 minutes of steam treatment, the easily alkali-soluble polyester fibers in the pile part are completely dissolved and removed, resulting in a pile made of extremely soft cotton yarn, with a firm structure near the yarn intersections.
A non-twisted fabric was obtained which was extremely bulky and had a soft feel. This fabric had good abrasion resistance, and almost no single cotton fibers fell off during washing.

Example 3 A copolymerized polyethylene terephthalate having an intrinsic viscosity of 0.47 measured at 30°C with 10 mol% sodium sulfoisophthalate copolymerized with a mixture of equivalent amounts of phenol and tetrachloroethane was melt-spun to obtain 1300
It was wound up at m/min. This fiber was drawn in a conventional manner to obtain a 40 denier/24 filament multifilament.

This thread and cotton No. 16 combed thread (number of twists 520t/m,
A composite yarn was made by combining the yarn with a Z twist and applying an S twist of 480t/m. The composite yarn and No. 16 cotton single yarn were used alternately as the warp, and the No. 16 cotton single yarn was used as the weft, with a warp density of 36 threads/in and a weft density of 30 threads/in, so that only the composite thread of the warp thread was used. I made towels that can be piled up.

This towel fabric was immersed in a 7% polyvinyl alcohol aqueous solution, squeezed with Nipprol to a squeeze rate of 150%, and dried. Next, this towel cloth was immersed in hot water at 90° C. for 1 minute to dissolve the polyvinyl alcohol only in the pile portion, and then dried.
Next, the easily alkali-soluble polyester fibers were subjected to dissolution treatment using the following alkaline treatment solution. Bath ratio 200:
1. The alkali easily soluble polyester fibers were completely dissolved and removed at a temperature of 90°C and a treatment time of 10 minutes.

Sodium hydroxide 4% Ethylene glycol 1% Sodium terephthalate Saturated water Residual Next, the towel fabric was washed with water to remove the alkaline solution adhering to it, and then immersed in hot water at 98°C to remove the remaining polyvinyl alcohol. It was dissolved and removed and dried. The resulting towel fabric was extremely bulky, and was bound by the easily alkali-soluble polyester fibers remaining in the vicinity of the tissue points, so it had good abrasion resistance, and almost no single cotton fibers fell off during washing.

Example 4 A copolymerized polyethylene terephthalate with an intrinsic viscosity of 0.66 measured at 30°C was melt-spun into a 1350 m /min. This fiber was drawn by a conventional method, and 40
I got a multifilament of denier/24 filament.

This fiber and cotton No. 30 single yarn (twisted yarn 680t/m Z
A composite yarn was made by aligning the strands (twisted) and applying an S twist of 650t/m. Using this composite yarn, a towel fabric was made under the same conditions as in Example 1 and treated with alkali. As in Example 1, a fabric with excellent bulk and good abrasion resistance was obtained.

(f) Effects of the invention Bulky spun yarn woven and knitted fabrics produced by the present invention,
In particular, woven and knitted fabrics with looped piles include terry cloth,
Suitable for underwear and knitwear, the tips of the loops are bulky and soft to the touch, have excellent water absorption, are tightly packed inside the woven structure, and have excellent abrasion resistance and washing resistance.

Claims (1)

[Claims] 1 A spun yarn consisting of poorly alkali-soluble fibers and a continuous yarn consisting of easily alkali-soluble polyester fibers are aligned, and the spun yarns are twisted in a direction in which they are untwisted so that the yarns become at least pile yarns. After weaving or knitting the pile fabric, the pile is treated with alkali to remove the alkali easily soluble polyester fibers near the tip of the pile,
A method for producing a bulky spun yarn woven or knitted fabric having excellent abrasion resistance, characterized in that alkali-soluble polyester fibers are left in the vicinity of yarn intersections of the fabric.