JP2003027343A - Acrylic spun yarn and raised cloth - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an acrylic spun yarn useful for the production of a raised cloth having extremely soft touch and high bulkiness and provide an excellent raised cloth producible at a low cost by improving the card passing property in the manufacture of the acrylic spun yarn and decreasing the processing loss in the manufacture of the raised cloth using the acrylic spun yarn. SOLUTION: The acrylic spun yarn contains >=40% acrylic fiber having a fineness of >=0.6 dtex and <=2.2 dtex, a (b/a) ratio of 2-10 ((a) is the minimum diameter and (b) is the maximum diameter of the cross-section of the fiber) and a fiber length of >=70 mm and <=130 mm and has a yarn shrinkage percentage of 10-35%.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to an acrylic spun yarn and a napped fabric.

[0002]

2. Description of the Related Art Spinning methods are roughly classified into cotton spinning (cotton spinning) and wool spinning (wool spinning). Cotton spinning is a relatively fine and short fiber, and wool spinning is thicker than cotton spinning. Fine and long fibers are used. Here, woolen spinning (worse spinning, woolen spinning) is introduced on the homepage of a domestic blanket manufacturer as a spinning means of yarn for processing a Meyer blanket, which is a kind of standing blanket. As in this example, it is common to use relatively thick and long fibers for the manufacture of Meyer blankets.

In recent years, fine fibers have been used to obtain a napped fabric having a softer texture. As a method for spinning a fiber having a fineness and a long fiber length, Japanese Patent Laid-Open No. 6-158486 discloses a method for silospan spinning an acrylic fiber having a fineness of 1 d or less and an average fiber length of 38 to 102 mm.

However, when the present inventor spun an acrylic fiber having a circular cross-sectional shape, a fineness of 0.9 dtex, and an average fiber length of 99 mm, sinking occurred in the card process and it was difficult to make top. Similarly, when TOW spinning with a circular cross-sectional shape and an average fiber length of 92 mm was performed, wrapping occurred in the gil process, and top making was difficult.

[0005]

SUMMARY OF THE INVENTION It is an object of the present invention to provide an acrylic spun yarn useful for obtaining a napped fabric which is extremely soft and has excellent bulkiness, and further the acrylic spun yarn. It is possible to improve the card passing property during the production of the woven fabric, improve the yield by reducing the processing loss when producing the napped fabric using the acrylic spun yarn, and provide an excellent napped fabric at a low cost. To aim.

[0006]

The present invention has a fineness of 0.6.
dtex or more and 2.2 dtex or less, the shortest diameter a of the fiber cross section
And a ratio (b / a) of the longest diameter b of 2 to 10 and at least 40 wt% or more of acrylic fibers having a fiber length of 70 mm or more and 130 mm or less and a yarn shrinkage ratio of 10 to 35%. Acrylic spun yarn, and a napped fabric using the acrylic spun yarn.

In the present invention, the acrylic fiber is a fiber made of a polymer or copolymer of 40 to 100 wt% of acrylonitrile and 0 to 40 wt% of an unsaturated vinyl compound copolymerizable with acrylonitrile.

Examples of unsaturated vinyl compounds copolymerizable with acrylonitrile include acrylic acid, methacrylic acid, acrylic acid esters (methyl acrylate, ethyl acrylate, etc.), methacrylic acid esters (methyl methacrylate, methacrylic acid). Ethyl, etc.), acrylamide or methacrylamide and their monoalkyl-substituted products, styrene, vinyl acetate, vinyl chloride,
Vinylidene chloride, vinyl pyridine, and styrene sulfonic acid, vinyl sulfonic acid, allyl sulfonic acid,
Examples thereof include methallyl sulfonic acid and salts of these sulfonic acids. The compound may not be used, and one kind or two or more kinds may be used in combination.

When the acrylonitrile in the polymer or copolymer is in the above range, the obtained napped product has high bulkiness and is excellent in commercial property.

The method for producing fibers from the above-mentioned polymer or copolymer is not particularly limited, but the above-mentioned polymer or copolymer may be added to dimethylformamide, dimethylacetamide, dimethylsulfoxide, concentrated aqueous nitric acid solution, concentrated aqueous rhodan salt solution, It can be dissolved in a solvent such as a concentrated aqueous solution of zinc chloride and can be produced by a known method such as wet spinning or dry spinning.

In the present invention, the fineness of the acrylic fiber is 0.6 dtex or more and 2.2 dtex or less, and preferably 1.1 to 2.2 dtex. When the fineness is within this range, the above-described top making (card process or gil process) is easy and a soft texture is obtained.

In the present invention, the degree of deformation b of the acrylic fiber
/ A is 2 to 10, and the cross-sectional shape is, for example, a flat cross section,
A cocoon-shaped section, a bean-shaped section, etc., not including a circular section
When the degree of irregularity b / a is in the above range, it is possible to obtain the above-mentioned spinning property improving effect and a soft texture at the same time.
The acrylic fiber itself is easy to produce.

In the top making of an acrylic fiber having a fine fineness and a long fiber length, when an acrylic fiber having a circular cross section was used, it was difficult to make the top making as described above, but according to the knowledge of the present inventor, it is surprising. In particular, it was found that top-making becomes easy by adding a certain amount or more of acrylic fibers having a specific degree of irregularity b / a.

In the present invention, the fiber length of the acrylic fiber is 70 to 130 mm. If the fiber length is in this range,
The napped product has a high yield in the processing step, a product with a high basis weight and a high volume is obtained, and top-making is easy.

In the present invention, there are two methods of top making for obtaining acrylic fibers, a card method and a tow spinning method, and either method can be used.
More preferably, a top sliver obtained by using the card system is used. The top sliver obtained by tow spinning has higher parallelism of acrylic fibers than the card type, and is not suitable for spinning acrylic fibers having a fine fineness and a long fiber length. This is because the pull-out force of the sliver is large and partial spots are generated, and it is advisable to adopt the card system for more efficient production.

The spun yarn of the present invention contains the acrylic fiber in an amount of 40 wt% or more. As a result, the effect of improving top making is obtained, sufficient hair elongation is obtained, and the texture and quality are excellent.

The acrylic spun yarn of the present invention has a yarn shrinkage ratio of 1
It is 0 to 35%, preferably 18 to 30%. When the yarn shrinkage ratio is in this range, the spread is good, the pile of the napped cloth does not have a straight hair shape, there is no gap between the piles, and a napped cloth with a soft texture and high quality is obtained. If the yarn shrinkage is 10 to 35%, it can be appropriately changed by blending two or more kinds of fibers having different raw cotton shrinkages.

The fibers constituting the spun yarn of the present invention include:
In addition to acrylic fibers, polyester-based synthetic fibers, polyamide-based synthetic fibers, polyvinyl alcohol-based synthetic fibers, polyolefin-based synthetic fibers, rayon fibers, acetate fibers, copper ammonia fibers, and other natural fibers such as cotton, hemp, wool, and silk. Can be used, but has a fineness of 3.3 dte
x or less, the average fiber length is 70 mm or more, and it is desirable to use fibers generally used in worsted spinning.

The use of the spun yarn and napped fabric of the present invention is not particularly limited, but it can be processed into conventionally known products such as bores, carpets and Meyer blankets.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be further described below with reference to Examples.

The evaluation method and measurement method are as follows.

(1) Yarn shrinkage ratio It was measured in accordance with JIS-L1013 (1999) "Hot water shrinkage ratio-skein shrinkage ratio (method A)".

(2) Shrinkage rate of raw cotton It was measured according to JIS-L1015 (1992) "Shrinkage rate of hot water".

(3) Deformedness (b / a) A fiber bundle was embedded in paraffin resin, a thin film was formed with a microtome perpendicular to the fiber axis, and the paraffin resin was melted with a dryer to obtain a fiber section. The obtained section is photographed (taken so that at least 10 sections are included), and the shortest diameter a and the longest diameter b are obtained from the obtained sections.
Then, the degree of atypicalness b / a was calculated. The measurement was performed at n = 10, and the average value was calculated.

(4) Average fiber length It was determined according to JIS-L1015 (1992) "Average fiber length B method (corrected staple diagram method)".

(5) Fiber length and ratio of fiber length The fiber length is determined by untwisting the target yarn according to JIS-L1015.
(1992) "Average fiber length C method (direct method)".

The fiber length ratio (70 mm to 130 mm) means that the fiber length measured above is 70 mm to 130 m.
The fiber bundle (A) having a length of m or less and the fiber bundle (B) having other fiber lengths are divided, and the masses W (A) and W (B) of each fiber bundle are measured.

Fiber length ratio (wt%) = [W (A) / {W
(A) + W (B)}] × 100 (6) Hair-reduction rate in processing step Prepare a cloth knitted with a seal milling machine, about 10 m / strip, and measure the cloth mass (W0) after backing, Next, the mass of cloth (W1) which had been subjected to the processes of brushing-polishing-shearing was measured.

Hair loss rate (wt%) = {(W0-W1) / W0} × 100 (7) The product fabric of a unit weight is cut into a square of 1 m on each side, and the mass M (g) is
Was measured.

Basis weight (g / m ² ) = M (8) Card passability Kyowa 60 The condition when passing through a card with cardboard was evaluated by the following items.

◯: Spinning gel 8 g / m, spinning speed 30 m
Stable spinning is possible per minute.

Δ: Spinning gel 8 g / m, spinning speed 30 m
Spinning is not possible in / min. Can be spun with gelen or at a reduced speed.

X: Spinning is impossible even if the supply amount or speed is reduced.

(9) Volume Sensitive Cloth A five person skilled in sensory evaluation was evaluated, and it was judged as ◯ or × only when 4 or more people answered ◯ or ×. All others were marked as △.

A: There is a clear feeling of volume.

Δ: No difference is recognized.

X: There is no apparent volume feeling.

(10) Softness of texture 10 persons skilled in the sensory evaluation of fabrics performed a 5-step evaluation, and the average score was recorded.

[0039] 1: hard 2: Slightly hard 3: somewhat soft 4: Pretty soft.

5: Very soft

(11) Fineness ratio (mass ratio of 0.6 dtex or more and 2.2 dtex or less) The fineness was measured from the fiber cross section using a planimeter and calculated from the obtained results.

[Production Example] (a) Production of non-shrinkable acrylic fiber Acrylonitrile 94.5 wt%, methyl acrylate 5.0 wt%, sodium methallyl sulfonate 0.5
wt% is copolymerized, the obtained polymer is dissolved in 67 wt% nitric acid, the obtained stock solution is wet-spun, washed with water, drawn with hot water,
Drying, wet heat setting, mechanical crimping and cutting into a predetermined fiber length, short fiber fineness of 0.3 to 3.3 dtex,
Deformedness (b / a) = 1 to 10, average fiber length 38 to 152
mm, non-shrinkable acrylic fibers as shown in Table 1 were obtained.

(B) Production of shrinkable acrylic fiber The fiber produced in (a) above was subjected to wet heat setting and dry heat drawing to obtain a short fiber fineness, 0.3 to 3.3 dtex, and a degree of irregularity (b / a). = 1 to 10, shrinkage rate of raw cotton 4.3 to 31.4%
The shrinkable acrylic fibers shown in Table 2 were obtained.

Examples 1 to 5 and Comparative Examples 1 to 9 (Examples 1 to 5) The fibers obtained in (a) and (b) above were spun with the combinations shown in Tables 1 to 3. , No yarn count 1/32 Nm spun yarn, further twisted yarn count 2 /
A spun yarn of 32 Nm was obtained. The spun yarn was dyed with a cationic dye using a rotary bag dyeing machine.

Using the obtained dyed yarn as a pile yarn, a false twisted yarn of a polyester filament yarn of 165 dtex / 72 filament and an acrylic spun yarn of 1/52 Nm were used as a base yarn, and a pile length of 13 m was obtained with a seal milling machine.
I knit it to the m bore. Then, after backing the pile back surface, brushing, polishing, and shirring were performed to obtain a 13 mm even napped fabric.

Comparative Examples 1 to 9 In the same manner as in Example 1,
Spinning was performed with the combinations shown in Tables 1 to 3 and twisted to obtain a spun yarn with a yarn count of 2/32 Nm. However, spinning was difficult depending on the conditions. The spun yarn obtained was dyed using a rotary back dyeing machine, and bored in the same manner as in Example 1 to obtain a 13 mm even napped fabric.

With respect to the above Examples and Comparative Examples, the card passing property, the hair reduction rate in the bore processing step, the unit weight of the product, etc. were measured, and the feeling of volume and softness of the obtained napped fabric was sensed. evaluated. The results are shown in Table 3.

Comparative Examples 1 and 2 are spun yarns obtained by using a general spinning method for processing fine fibers, but the yield is poor and a volume feeling cannot be obtained.

Examples 1 to 3 satisfy the card passing property by making the fine fibers atypical and increasing the fiber length.
The yield in the processing step was improved, and a napped fabric with a soft feel having a volume feeling was obtained.

From Examples 1 to 3 and Comparative Examples 6 to 9, it is understood that when the cross-sectional shape of the short fibers is modified (Examples 1 to 3), the card passing property and the texture of the napped fabric are improved. .

From Examples 4 and 5, when the mixing ratio of acrylic fiber specified in the present invention is 40 wt%, the card passing property,
It can be seen that the texture is improved.

[Examples 6 to 10 and Comparative Examples 10 to 16] In this example, the influence of the fineness was examined.

Examples 6 to 10 are similar to Example 1,
Comparative Examples 10 to 16 were processed in the same manner as Comparative Example 1 to obtain spun yarn and napped cloth. Table 4 shows a summary of the study contents and results.

In Examples 6 to 8, since the fineness and other requirements are within the ranges specified in the present invention, the spun yarn and the napped cloth having the desired excellent performance were obtained.

It can be seen from Comparative Example 11 that the desired texture cannot be obtained even when the fineness is large, even with a modified cross section.

From Comparative Examples 12 to 16, it can be seen that even with a circular cross section, spinning is possible only when the fineness is relatively large, but a napped fabric with a soft texture cannot be obtained.

From Examples 9 and 10, it can be seen that the intended effect can be obtained when the mixing ratio of the acrylic fibers specified in the present invention is 40 wt% or more.

[Examples 11 to 14] In this example, the influence of the degree of atypicalness was examined.

A spun yarn and a napped fabric were obtained in the same manner as in Example 1. Table 5 summarizes the examination contents and results.

As shown in Examples 11 to 13, when the degree of irregularity b / a of the acrylic fiber is 2 to 10 and other requirements are within the range specified by the present invention, stable card passing property is obtained. A napped cloth having a feeling of volume and a soft texture is obtained.

As shown in Example 14, the same effect can be obtained by using fibers having a dogbone cross section.

[Examples 15 to 18, Comparative Example 17] In this example, the influence of the yarn shrinkage ratio was examined.

Examples 15 to 18 were the same as Example 1, and Comparative Example 17 was the same as Comparative Example 1 to obtain spun yarn and napped cloth. Table 6 summarizes the study contents and results.

From Examples 15 to 17, it can be seen that when the yarn shrinkage ratio is within the range specified in the present invention, the desired volume feeling and soft texture can be obtained.

In Comparative Example 17, the yarn shrinkage ratio is too small, so that the feeling of volume is insufficient. However, since the card passing property is good, it is understood that the yarn shrinkage ratio does not affect the card passing property.

As shown in Example 18, the modified raw cotton has the same excellent effect even when used as a shrinkable acrylic fiber.

[0067]

[Table 1]

[0068]

[Table 2]

[0069]

[Table 3]

[0070]

[Table 4]

[0071]

[Table 5]

[0072]

[Table 6]

[0073]

Industrial Applicability According to the present invention, an acrylic spun yarn useful for obtaining a napped fabric having an extremely soft texture and excellent bulkiness can be provided, and further, it can be passed through a card when producing the acrylic spun yarn. Of the acrylic spun yarn, the yield is improved by reducing the processing loss when producing a napped fabric using the acrylic spun yarn, and an excellent napped fabric can be efficiently provided at low cost.

Claims (2)

[Claims] 1. A fineness of 0.6 dtex or more and 2.2 dte
x or less, ratio of shortest diameter a and longest diameter b of fiber cross section (b / a)
Of 2 to 10 and at least 40 wt% or more of acrylic fibers having a fiber length of 70 mm or more and 130 mm or less and a yarn shrinkage rate of 10 to 35%. 2. A napped cloth formed by using the acrylic spun yarn according to claim 1.