CN110678093B - 功能性布帛及其制造方法 - Google Patents

功能性布帛及其制造方法 Download PDF

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CN110678093B
CN110678093B CN201880035768.9A CN201880035768A CN110678093B CN 110678093 B CN110678093 B CN 110678093B CN 201880035768 A CN201880035768 A CN 201880035768A CN 110678093 B CN110678093 B CN 110678093B
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synthetic resin
resin film
polyester
fabric
carbon black
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CN110678093A (zh
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谷口文伸
野原茂
筑山智
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AS CORP
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Abstract

功能性布帛是将混入有炭黑微粒的聚酯的合成树脂膜贴合于布帛而成的，合成树脂膜为无孔质的，厚度为10μm～20μm。通过制造混入有炭黑微粒的聚酯的合成树脂膜的工序和将合成树脂膜贴合于布帛的工序来制造功能性布帛，将该功能性布帛贴合于内衣或中衣用服装的全部面或单面来制造衣服。

Description

功能性布帛及其制造方法
技术领域
本发明涉及具有防风、防水、透湿和保温的功能的布帛及其制造方法。
背景技术
对于秋冬季的防寒用衣服而言，通过各种方法致力于保暖。作为众所周知的方法，为了提高保温性能，有绝热保温、利用远红外线吸收、反射的辐射热保温。另外，还有通过利用水分的吸湿所带来的动能释放作用的吸湿发热保温等方法来提高所要求的各功能的衣服。
这些在保持保温等功能的同时、进一步也重视外观的设计和颜色等审美性、轻量且运动性能也优良的、以所谓的“薄、轻、暖”为概念的秋冬用服装也已经大量上市。
日常生活中穿着时需要的是流行性和功能性，但在登山、户外等用途、以及运动用途中，有时需要另行进一步附加其它功能。这种情况下，要求与外部环境、用途相应的服装，每次都要加鞋、加衣服。要选择所谓的防寒、防风和防水之类的符合保护身体免受外界刺激的目的的衣服，但对于外衣、中衣和贴身衣(内衣)，也需要附加选择与各自的用途相符的功能。
对于上班、上学等不那么需要运动的用途而言，也有时需要例如登山用途那样可耐受暴风雨、极寒和积雪等恶劣天气的防风、防水及拒水功能的衣物。也有需要考虑在渔业、农耕等室外容易活动的功能的情况，考虑各种各样的用途展开。
关于这一点，例如专利文献1公开了一种衣物，其是包含起毛布帛或起绒布帛与透湿性高分子膜的层叠粘接体的衣物，其中，该透湿性高分子膜借助固化反应型粘接剂层叠粘接在该布帛的起毛面或起绒面上，该衣物的重量为每1m2 50～400g，该粘接剂的涂布量为每1m2 2～30g，且该透湿性高分子膜面位于衣物的表面侧。
现有技术文献
专利文献
专利文献1：日本特开2002-327310号公报
发明内容
发明所要解决的问题
在由于身体运动而出汗的情况下，需要将身体出的湿气(水蒸气)等尽快排出到衣服外、从而调节衣服内温度、皮肤表面温度。作为穿在身上的衣服的必要条件，要能够保持(维持)身体温度，在夏季时为了控制体温升高而排出汗水、通过水分气化来抑制皮肤表面温度，另一方面，防御由于出冷汗等而产生的不适也变得重要。另外，如马拉松选手、各种运动选手在正式比赛前的热身活动中可见的那样，有时也需要预热身体、放松肌肉。
但是，包括上述专利文献1的衣物在内，存在难以全部满足防风、防水、透湿和保温的各功能的问题。
因此，本发明是鉴于上述问题而完成的，其目的在于提供具有防风、防水、透湿和保温的功能的功能性布帛。另外，其目的在于提供具有这些功能的功能性布帛的制造方法。
用于解决问题的方法
为了解决上述课题，本发明的功能性布帛的特征在于，其是将混入有炭黑微粒的聚酯的合成树脂膜贴合于布帛而成的。
在此，上述合成树脂膜优选为无孔质的，上述合成树脂膜的厚度优选设为10μm～20μm。
另外，本发明的功能性布帛的制造方法的特征在于，包括制造混入有炭黑微粒的聚酯的合成树脂膜的工序和将上述合成树脂膜贴合于布帛的工序。
另外，如果制成特征在于将上述功能性布帛贴合于内衣或中衣用服装的全部面或单面而成的衣服，则可实现防风、防水、透湿和保温的功能优良的衣服。
发明效果
如上所述，根据本发明的功能性布帛，可以得到具有防风、防水、透湿和保温的功能的功能性布帛。
附图说明
图1是示出制造使用本发明的实施方式的功能性布帛的衣服的步骤的图。
具体实施方式
以下对本发明的功能性布帛及其制造方法进行说明。
本实施方式的功能性布帛通过在布帛上整面或局部地贴合聚酯100％组成的合成树脂膜而得到，发挥防风、防水、透湿和保温性能。合成树脂膜不是氨基甲酸酯树脂、聚四氟乙烯树脂，而完全为无孔质的膜，是聚酯100％组成的膜。
通过将合成树脂膜的厚度控制为10μm～20μm，可以保持上述性能。如果使膜的厚度小于10μm，则较薄，对向所连动的布帛上的运动、拉伸性的影响小，较良好，但另一方面，有时膜本身的强度产生问题而破裂、或对向布帛上粘贴的操作产生影响。另一方面，如果设为20μm以上的厚度，则即使强度得到保持也会使要穿着的服装(衣料)的穿着感变得硬邦邦，有时会阻碍舒适性。因此，关于膜的厚度，10μm～20μm的厚度是最合适的。
合成树脂膜不是聚氨酯树脂的层叠体的膜，而是聚酯100％组成。因此，对于紫外线、包含酸性或碱性等的化学物质的风雨的耐候性能优良，可以抑制如聚氨酯树脂制的膜那样由于暴露于紫外线、风雨而劣化、脆化的情况。另外，由于膜为无孔质的，还可以保持适当的膜强度。
合成树脂膜虽为无孔质的，但高透湿性也优良，可以将身体出的汗的水蒸气排出到外部。另外，防风、防水性也优良。据称雨等水滴为100～6000μm，已知水蒸气为
Figure GDA0003520682100000041
的大小，该合成树脂膜的防风性能为0.3cc/cm2/秒。已知通常的针织贴身衣物的透气性能为150～250cc/cm2/秒，高密度布帛的透气性为30～50cc/cm2/秒。另外，膜的耐水性为25000mm，可以保持一般的基准(标准)。顺便提一下，雨伞需要为250mm，小雨、小雪需要为5000mm，滑雪、高尔夫衣物需要为10000mm，登山用途需要为20000mm。该合成树脂膜超过上述任一基准值，透湿性可以保持26300g/m2·小时。
通过向该合成树脂膜中混入具有将红外线再辐射的功能的炭黑微粒，合成树脂膜进一步有效地发挥保温功能。将红外线再辐射是指将从人体发出的红外线辐射到人体侧。炭黑微粒将红外线再辐射而使其向内侧、即身体侧起作用，由此，可以使身体的热量不逸散而提高保温效果。
以下是示出向合成树脂膜中混入氧化钛时的膜性能与混入炭黑微粒时的膜性能的差异的实验结果。
[表1]
<膜性能>(混入氧化钛)白
Figure GDA0003520682100000051
＜热再辐射特性＞(混入氧化钛微粒)白
“试验方法”
(一般社团法人)远红外线协会认定规则再辐射特性
45度平行再辐射法适用
·测定部位、测定面 …表面
·重叠片数 …1片
“试验结果”
ΔT＝0.3℃(置信度95％(Pr：0.05)下有显著差异)
“试验试样”
·试样 单位面积重量：16.0g/m2 厚度：0.02mm(初始载荷23.5kPa)
·空白(比较) 单位面积重量：95.8g/m2 厚度：0.22mm(初始载荷23.5kPa)
[表2]
Figure GDA0003520682100000061
[表3]
Figure GDA0003520682100000062
[表4]
Figure GDA0003520682100000071
[表5]
Figure GDA0003520682100000072
＜热再辐射特性＞(混入炭黑微粒)黑
“试验方法”贴合布料与未贴合布料的比较
(一般社团法人)远红外线协会认定规则再辐射特性
45度平行再辐射法 适用
·测定部位、测定面 …表面
·重叠片数 …1片
“试验结果”
ΔT＝0.6℃ (置信度99％(Pr：0.01)下有显著差异)
“试验试样”
·试样 单位面积重量：175.6g/m2 厚度：0.75mm(初始载荷23.5kPa)
·空白(比较) 单位面积重量：164.1g/m2 厚度：0.85mm(初始载荷23.5kPa
一般财团法人 纺检品质评价机构
[表6]
Figure GDA0003520682100000091
[表7]
Figure GDA0003520682100000101
[表8]
Figure GDA0003520682100000111
[表9]
Figure GDA0003520682100000112
另外，以下示出关于光吸收保温特性的实验结果(由一般财团法人纺检品质评价机构提供)。
在试样(两种膜，15cm×15cm)的背面中央部设置热电偶温度传感器，在以下的条件下每1分钟测定对试样表面照射光时的温度变化，测定20分钟。
＜条件＞
使用灯：岩崎电机株式会社制造的护眼灯(PRF-500WD)
照射距离：30cm
测定条件：在用灯照射10分钟后切断灯的电源，在该状态下测定10分钟。
测定环境：20±2℃、65±4％RH
测定方法：将试样排列后同时测定(第一次)，更换试样位置后再次测定(第二次)，将两次的平均值作为试验结果。
＜试验结果1＞
A：(混入氧化钛微粒)白
B：(混入炭黑微粒)黑
[表10]
Figure GDA0003520682100000131
根据表10所示的混入氧化钛的膜(白)和混入碳的膜(黑)的基于上述试验方法的光吸收保温性试验结果明确可知，混入碳的膜是保温性更优良得多的膜。
＜试验结果2＞
A：粘合(碳膜贴合)布料
B：无贴合的布料
[表11]
Figure GDA0003520682100000141
根据表11所示的试验结果，在该服装布料上粘合、粘贴有混入碳的膜的该布料的保温性性能与无贴合的布料相比，显示出最大5℃的差异。
接着，对使用本发明的功能性布帛的衣服的制造步骤进行说明。
图1是示出制造使用本实施方式的功能性布帛的衣服的步骤的图。
首先，在制备功能性布帛时，首先需要制作合成树脂膜，在工序上为聚酯片(原材料颗粒)的熔融→挤出→T模方式(无拉伸)→卷取→电晕表面处理→膜厚度确认检查→异形物相机检查→制品保管这样的流程。特别是保存合成树脂膜时最大的注意点在于，需要不对极薄的合成树脂膜施加负荷的悬空之类的保管方法。在进行将合成树脂膜贴合于布帛的操作时，必须注意不要引起合成树脂膜的起皱、破裂、断裂。需要说明的是，为了维持宽度方向上的无拉伸状态的合成树脂膜的形态，通过将温度调整到比通常的纤维原材用的300℃热环境稍低的220℃～250℃，可形成包含聚酯高分子排列更为均匀的结晶区域和非结晶区域的聚酯树脂膜。
使用含有聚氨酯树脂的粘合剂，以涂布量为7g/m2来进行该合成树脂膜与布帛的贴合(粘合工序操作)。为了将厚度为10～20μm的合成树脂膜均匀地贴合于布帛上，5g～10g/m2是最佳的。如果小于5g/m2，则膜与布帛的结合(粘接力)不足，变得容易剥离，如果超过10g/m2，则虽然接合力提高，但合成树脂膜发硬，容易产生起因于粘合剂的粘接面的不均，也会对贴合有合成树脂膜的服装的布料手感产生影响，从而引起品质下降。
最后，将贴合合成树脂膜而得到的功能性布帛根据其用途贴合于外衣、中衣和贴身衣等衣服。
以下使用实施例和比较例进行说明。
(实施例1)
将混入有1重量％的炭黑微粒的PET片在温度200℃～220℃的范围内熔融，通过T模法制作片状的膜。使该膜从20℃～25℃的冷却辊通过，进一步通过T模法制造薄的膜状覆膜。关于膜卷取速度，以15～25m/分钟来进行。
然后，将通过T模法制造的合成树脂膜通过粘合加工与布料贴合，所使用的粘接树脂为乙酸乙烯酯树脂、丙烯酸酯树脂、氯乙烯树脂、环氧树脂、硅系树脂等各种树脂。在此，考虑到布料手感、伸缩性和拉伸性，使用7g/m2的聚氨酯粘接树脂。进一步优选使用湿气固化型的聚氨酯树脂。可以在80℃～150℃的温度范围内进行加工，但在120℃±5℃下进行粘合加工。为了不损害拉伸性，通过打点进行粘接，为了保持布料和膜本来所具有的适度的伸缩性，进行粘合加工。
需要说明的是，关于混入聚酯片中的炭黑微粒的直径，从瑞利光散射理论的应用来看，在红外线/远红外线波长的1/10～1/2的范围的粒径是适宜的。粒径在该范围的炭黑微粒可以将从生物体(包括人类)发出的红外线/远红外线最有效地再辐射。
顺便提一下，已知红外线的波长为0.78μm～1.5μm、远红外线的波长为3.0μm～1000μm。因此，认为炭黑的粒径的最佳范围为0.08μm～500μm。但是，实际上通过炉法制造的炭黑的粒径在3～500nm的范围，因此，任何粒径的炭黑都可以将从身体发出的红外线/远红外线有效地再辐射。
另外，作为可促进聚酯高分子树脂的结晶化的结晶化促进剂，可列举苯甲酸金属盐、草酸金属盐、硬脂酸金属盐、高熔点PET、炭黑、金属氧化物、金属硫酸盐等。以这些促进剂物质作为结晶核，聚酯(对苯二甲酸与乙二醇的缩聚物)的分子链折叠排列，因此，晶体生长(高分子取向)，引起聚酯树脂内的结晶区域(硬段)的增大。
另外，与此相反地，通过将熔融的聚酯高分子树脂冷却到其玻璃化转变温度以下，从而构成作为非结晶塑料、即非结晶区域的链段(软段)。
形成虽为无孔质聚酯的合成树脂膜、但使湿气从该非结晶区域的间隙通过的结构。分子量大的水、空气无法通过，但可以使湿气(水蒸气)水平的物质通过。形成所谓的具有透湿、防水和防风功能的聚酯膜。作为其它的聚酯树脂结晶化促进剂，存在脂肪酸有机酯、磷酸三烯丙酯、聚亚烷基二醇及其衍生物，但由于该聚酯膜中混杂有炭黑，因此不需要重新添加上述促进剂。
将含有炭黑的聚酯片熔融，将该熔融的聚酯高分子用玻璃化转变温度以下的冷却辊冷却，可以恰好在聚酯树脂膜内构成非结晶区域。
对于这样得到的合成树脂膜，通过(一般社团法人)远红外线协会认定规则45度平行再辐射法，以数据(Data)的形式在上文中记载各膜的热再辐射特性。
接着，利用湿气固化型聚氨酯树脂在120℃±5℃的温度环境下通过粘合加工操作将规定的纤维布料与膜贴合。
将对75d/144f的极细纤维束的纱条进行双罗纹编织而成的布帛的皮肤侧(里侧)进行薄起毛，将所得布料作为面料(身生地)主体，进一步将作为垫布的、对50/1聚酯短纤纱与棉60％聚酯40％的50/1混纺纱进行双罗纹编织而成的布帛的单侧进行薄起毛，在其上粘贴混入有炭黑的合成树脂膜，将所得布帛仅用于前身，制作长袖圆领T恤衫。
(实施例2)
将对75d/144f的极细纤维束的纱条进行双罗纹编织而成的布帛的皮肤侧(里侧)进行薄起毛，将所得布料作为面料主体，进一步将作为垫布的、对50/1聚酯短纤纱和棉60％聚酯40％的50/1混纺纱进行双罗纹编织而成的布帛的单侧进行薄起毛，在其上粘贴混入有炭黑的合成树脂膜，将所得布帛仅用于前身，制作长袖高领衬衫。
(实施例3)
对75d/144f的极细纤维束的纱条和20d聚氨酯纱进行平织而成的平纹的裸汗布(ベア天竺布帛)的里面单侧进行薄起毛，制成主体面料，在对50/1聚酯短纤纱与棉60％、聚酯40％的50/1混纺纱进行双罗纹编织而得到的布帛上贴合混入有炭黑的合成树脂膜，将该布帛仅贴合在下身的两膝部分的前身(粘合加工)，制作前开式五分紧身裤。
(实施例4)
对将75d/144f的极细纤维束的纱条和20d聚氨酯纱进行平织而成的平纹的裸汗布的里面单侧进行薄起毛，制成主体面料，在对50/1聚酯短纤纱与棉60％、聚酯40％的50/1混纺纱进行双罗纹编织而得到的布帛上贴合混入有炭黑的合成树脂膜，将该布帛仅贴合在下身的两膝部分的前身(粘合加工)，制作前开式长紧身裤。
(比较例1)
将考虑到膜的透明性而混入有5～6％的氧化钛微粒的PET片在温度200～220℃的范围内熔融。
(其它比较例)
将消费者等对本实施例1～4与现有商品的区别进行确认而得到的结果示于下述表中。
[表12]
Figure GDA0003520682100000181
可见，本实施例1～4得到了良好的评价。
(实施例5)
将对75d/144f的极细纤维束的纱条和20d聚氨酯纱进行平织而得的平纹的裸汗布的里面单侧进行薄起毛，制成主体面料，在对棉60％、聚酯40％的50/1混纺纱进行双罗纹编织而得到的布帛上贴合混入有炭黑的厚度18μm的合成树脂膜，制作布帛A。同样地制作贴合有混入有炭黑的厚度15μm的合成树脂膜的布帛B。对于布帛A及布帛B，以下示出透湿防风性的试验结果。
[表13]
Figure GDA0003520682100000191
关于透气性，两者在几乎不透气这一点上没有变化，但根据表13的试验结果可知，贴合有15μm的合成树脂膜的布帛B与贴合有18μm的合成树脂膜的布帛A相比，透湿性提高10％以上，该性能有差异。
以上，基于实施方式对本发明的功能性布帛进行了说明，但本发明不限于此，可以在能够实现本发明的目的且不脱离发明的主旨的范围内进行各种设计变更，这些也全部包含在本发明的范围内。
产业上的可利用性
本发明的功能性布帛作为具有防风、防水、透湿和保温的功能的布帛有用，若使用本布帛，不仅适合于日常生活中穿着的衣服，而且也适合于登山用衣物、运动衣物等衣服。

Claims (3)

1.一种功能性布帛，其特征在于，其是将混入有炭黑微粒的聚酯的合成树脂膜使用涂布量为5g～10g/m2的含有聚氨酯树脂的粘合剂贴合于布帛而成的，
所述炭黑微粒的粒径为3～500nm，
所述聚酯的合成树脂膜为无孔质的，具备将含有1重量％的所述炭黑微粒的聚酯片熔融并冷却到玻璃化转变温度以下而构成的非结晶区域，
所述合成树脂膜是聚酯100％组成的膜，
所述合成树脂膜的厚度为10μm～20μm。
2.一种功能性布帛的制造方法，其特征在于，包括：
制造混入有炭黑微粒的无孔质的聚酯的合成树脂膜的工序；和
将所述合成树脂膜使用涂布量为5g～10g/m2的含有聚氨酯树脂的粘合剂贴合于布帛的工序，
在所述制造聚酯的合成树脂膜的工序中，
使所述合成树脂膜为聚酯100％组成的膜，使所述合成树脂膜的厚度为10μm～20μm，
使所述炭黑微粒的粒径为3～500nm，将含有1重量％的该炭黑微粒的聚酯片熔融并冷却到玻璃化转变温度以下而构成非结晶区域。
3.一种衣服，其特征在于，其是将功能性布帛贴合于内衣或中衣用服装的全部面或单面而成的，
所述功能性布帛是将混入有炭黑微粒的聚酯的合成树脂膜使用涂布量为5g～10g/m2的含有聚氨酯树脂的粘合剂贴合于布帛而成的，
所述炭黑微粒的粒径为3～500nm，
所述合成树脂膜为无孔质的，具备将含有1重量％的所述炭黑微粒的聚酯片熔融并冷却到玻璃化转变温度以下而构成的非结晶区域，
所述合成树脂膜是聚酯100％组成的膜，
所述合成树脂膜的厚度为10μm～20μm。
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