JP2003064565A - Bound nonwoven fabric and colored nonwoven fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bound nonwoven fabric useful as a substitute for a woven fabric, having durability of washing without emitting toxic formaldehyde and without being broken even by severe dyeing such as jet dyeing and having a soft touch feeling with slight fluffing. SOLUTION: This bound nonwoven fabric is obtained by carrying out a water stream interlacing treatment of a fiber web containing polyester fibers, etc., providing a water stream interlaced nonwoven fabric, then applying an aqueous emulsion of an oxazoline cross-linkable acrylic resin having an area swelling ratio within the range of >=100 to <=110% in hot water at 60 deg.C to the nonwoven fabric, drying and curing the applied emulsion. Furthermore, the bound nonwoven fabric is dyed with a dye by using a jet dyeing machine to afford a colored nonwoven fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bonded non-woven fabric which does not generate harmful formaldehyde, has a soft texture, has washing durability and does not break even under severe dyeing and has little fuzz. More specifically, the present invention relates to a colored nonwoven fabric which is dyed with a dye and which is suitable for fashionable household goods, clothes, interiors and the like.

[0002]

2. Description of the Related Art In recent years, non-woven fabrics have been used in various applications as substitutes for woven fabrics because of the ease of selection of materials to be used, the ease of production, and the merit in terms of price. In particular, a hydroentangled nonwoven fabric entangled by a columnar flow of high-pressure water is used in a wide range of fields such as household goods, clothes, and interiors because it is the closest to a woven fabric in terms of thickness and texture. However, since these non-woven fabrics do not use an adhesive positively, they are vulnerable to physical external forces such as washing and rubbing, and are easily torn or fluffed, and are practically limited to disposable applications. . Also, if you try to obtain a colored non-woven fabric without using an adhesive, the current dyeing machine will cause tearing and fuzzing during the process, so it is limited to pad dyeing, beam dyeing, printing methods, etc. A colored non-woven fabric having high flexibility was not obtained. Furthermore, dyeing using a jet dyeing machine, which is the most versatile and has good levelness, was impossible because of its strong kneading effect.

On the other hand, in recent years, awareness of the environment has increased, and the disposition of disposable items to be discarded after one-time use has become stronger. At the same time, consumers' awareness of fashion has also increased, and the need for differentiation by dyeing has increased. There is. Therefore, for the purpose of improving the mechanical strength of the non-woven fabric for long-term use, for example, in Japanese Patent Laid-Open No. 5-209349, a cotton-based hydroentangled non-woven fabric is provided with a polyamide-amine-ebichlorohydrin (PAE) resin. A non-woven fabric impregnated with and dried is proposed. Japanese Unexamined Patent Publication No. 7-102462 proposes a non-woven fabric in which the surfaces of entangled fiber webs are partially bonded by a binder. Japanese Patent Laid-Open No. 11-217710 proposes a method of dyeing after increasing mechanical strength by applying an adhesive. Japanese Patent Application Laid-Open No. 10-72764 proposes rubbing with a jet dyeing machine after applying an adhesive to a hydroentangled nonwoven fabric using cotton to increase mechanical strength. In Japanese Patent Publication No. 55-3466, at least one binder selected from acrylic acid-based, methacrylic acid-based, and acrylonitrile-based polymers and a polyamine obtained by crosslinking dipropylenetriamine with epichlorohydrin and / or
Alternatively, there has been proposed a method for producing a nonwoven fabric which is impregnated with a liquid containing polyamidoamine and heated.

Further, among various binder resins, acrylic resins are widely used because they have strong binding force, are easy to process, and are inexpensive. Acrylic resin, or methylol melamine cross-linking acrylic resin is known as the binder resin of the bonded nonwoven fabric that can obtain the strongest cross-linking, has washing durability, and can withstand severe dyeing such as jet dyeing. There is.

[0005]

However, the above-mentioned nonwoven fabric has the following problems. For example, Japanese Patent Laid-Open No. 5-
In JP-A-209349 and JP-A-7-102462, an adhesive is applied in order to increase the mechanical strength of the nonwoven fabric, and this surely withstands several or several tens of washings and is practically used to some extent. Although it has become possible to provide products that can withstand the above use, on the other hand, it is not possible to withstand the dyeing by the jet dyeing machine, which brings about the hardening of the texture by the adhesive and at the same time high temperature and strong rubbing. It was Japanese Patent Laid-Open No. 11-217710 discloses a method of dyeing after increasing mechanical strength by applying an adhesive, but does not disclose any dyeing method. Further, in Japanese Patent Application Laid-Open No. 10-72764, the purpose is to soften the nonwoven fabric by kneading and to form short-fluffy fluffs, and the amount of binder attached is 3 to 1 as well.
Since the amount is as small as 0%, if the dyeing conditions are higher and the time is longer, tearing may occur during dyeing. Even if fluffing by kneading and softening of the texture are possible, dyeing treatment is possible. It was difficult until. In particular, it was remarkable in the polyester fiber nonwoven fabric whose dyeing treatment is performed under high temperature and high pressure. Furthermore, since the acrylic resin alone has insufficient bonding strength, melamine resin is added, and there is a risk of releasing harmful formaldehyde. Also, Japanese Patent Publication No. 55-3466 discloses a method of dyeing after increasing mechanical strength by applying an adhesive, but in this case, dyeing without rubbing such as textile dyeing or pad dyeing. Only a method has been proposed, the texture is flexible, it does not break even with severe dyeing such as jet dyeing, and in the actual situation that a bonded non-woven fabric and a colored non-woven fabric with little fuzz are not obtained. is there.

Furthermore, urea-formaldehyde cross-linking type acrylic resin or methylol melamine cross-linking releases harmful formaldehyde, so that it is actually used for household goods, clothes, interiors and the like. .

Therefore, simply adding an acrylic resin in order to improve the mechanical strength of the non-woven fabric does not solve the above-mentioned problems, and the acrylic resin is highly heat resistant because it is exposed to high temperature during dyeing. However, even if it was applied, it was insufficient for jet dyeing, which was high-temperature dyeing and had a rubbing effect. INDUSTRIAL APPLICABILITY The present invention relates to a non-woven fabric useful as a substitute for a woven fabric, which has a durability to washing without generation of harmful formaldehyde, and is not broken by severe dyeing such as jet dyeing, so that it can be fashion-oriented for consumers. In order to respond, the object is to provide a non-woven fabric that is soft to the touch and has little fuzz.

[0008]

As a result of intensive studies, the present inventors have found that the crosslinked structure of an acrylic resin and the swelling ratio in hot water contribute to the jet dyeing property, and arrived at the present invention. . That is, the bonded nonwoven fabric of the present invention is a nonwoven fabric in which the constituent fibers are bonded by the oxazoline-crosslinked acrylic resin having an area swelling ratio of 100% or more and 110% or less in hot water at 60 ° C. By adopting such a configuration, it is possible to achieve not only the washing durability but also the purpose of softening the texture by rubbing the dyeing in the jet dyeing machine.

It is preferable that the acrylic resin is contained in an amount of 10 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the non-woven fabric, because washing durability and good feeling can be achieved.

The non-woven fabric is preferably a hydroentangled non-woven fabric composed of short fibers, since it is thin and has a good texture like a woven fabric.

The above-mentioned non-woven fabric is superior in dyeing a non-woven fabric containing polyester fibers which has a high temperature during dyeing and requires treatment with a strong alkali such as dyeing and reduction washing. In particular, a hydroentangled nonwoven fabric made of polyester fiber that is dyed at high temperature is preferable because dyeing with a jet dyeing machine is possible.

The bonded non-woven fabric is a colored non-woven fabric dyed with a dye, and when dyed with a jet dyeing machine having a great kneading effect, the texture becomes soft and has washing durability, so that it is fashionable. High-quality daily goods, clothing,
Suitable for applications such as interior. The contents of the present invention will be described below.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION The fibers constituting the non-woven fabric used in the present invention are not particularly limited, and may be appropriately set according to the purpose, use, etc., for example,
Examples of dyeable fibers include cellulosic fibers such as cotton, wool, hemp, and rayon, acrylic fibers, polyamide fibers, polyester fibers, and polyurethane fibers.

The non-woven fabric used in the present invention is not particularly limited as long as it is composed of dyeable fibers, but in the non-woven fabric obtained directly from the spinning process such as spunbond or meltblown, the fibers themselves are already bonded. Therefore, the effect of the present invention may be difficult to obtain. Further, as the thermal bond nonwoven fabric, a web obtained by passing short fibers through a card is used, but it is similar to spunbond or meltblown in that it contains binder fibers, and the binder fibers themselves have different dyeability or are not dyed. It is difficult to dye because there are many For the above reasons, a nonwoven fabric obtained by needle punching or hydroentangling a fibrous web obtained by passing short fibers through a card without using an adhesive is preferable. Among them, the hydroentangling method is preferable because it can be composed of only dyeable fibers without using binder fibers. Among the hydroentangling methods, it is more preferable that the fibers are entangled with a columnar flow of high-pressure water and the constituent fibers are dried without heat fusion. The fiber length of the short fibers is 3
The range of 5 mm or more and 75 mm or less is preferable because it is excellent in processability such as card passing property and can suppress fuzz in the bonded nonwoven fabric and the colored nonwoven fabric.

The weight of the non-woven fabric is 100 g / m ²
It is preferably less than. The more preferable upper limit of the basis weight is 80 g / m ² or less. The more preferable lower limit of the basis weight is
It is 30 g / m ² or more. When the basis weight of the non-woven fabric exceeds 100 g / m ² , the movement in the jet dyeing machine is not smooth during dyeing, and uneven dyeing is likely to occur. From this point of view, the hydroentangled nonwoven fabric, which has a relatively low basis weight, is suitable for the present invention.

The non-woven fabric has an area swelling ratio of 100% or more in warm water at 60 ° C., which is measured as follows.
The fibers composed of the oxazoline cross-linking acrylic resin in the range of 110% or less are bonded to each other. [Area swelling ratio] Acrylic resin was poured onto a flat glass plate partitioned by a frame of 15 cm x 15 cm so that the thickness after film formation would be 1 mm, dried at 80 ° C, and cured at 140 ° C for 30 seconds. Ring to obtain a resin coating. After immersing the obtained resin film in warm water at 60 ° C. for 10 minutes, the area thereof was determined,
The area swelling rate is calculated from the following formula (1). Area swelling ratio (%) = (S / S ₀ ) × 100 (1) S ₀ : Area (c) of resin film before being immersed in warm water at 60 ° C.
m ² ) S: Area of resin coating after immersion in hot water at 60 ° C (c
m ² ) In general, dyeing is applied with heat to fix the dye in the fiber, and the fiber is activated by molecular motion by the applied heat.
The intermolecular distance increases, that is, swells. When the dye enters the intermolecular spaces thus created, the dye is firmly fixed in the fiber. The swelling is the same in the binder resin used for binding the fibers, and the binder resin also swells due to heat. When this swelling exceeds a certain level, in other words, when the intermolecular distance of the resin exceeds a certain level, it is considered that the resin no longer functions as a binder, and the heat resistance and the binding force decrease. Therefore, when a crosslinked structure is introduced into the binder resin, the swelling can be suppressed, and it is used as an index showing the degree of crosslink strength, heat resistance, and bonding strength. Area swelling rate is 100% or more, 11
By setting the content in the range of 0% or less, a binder resin having a strong crosslinked structure, excellent heat resistance, and excellent binding resistance and dyeing resistance is selected, and the object of the present invention can be achieved. When the area swelling ratio of the acrylic resin is less than 100%, shrinkage occurs during dyeing, which not only causes unevenness on the surface but also causes wrinkles during winding after processing, which is not preferable. If the area swelling ratio exceeds 110%, washing durability is obtained, but the nonwoven fabric is damaged by jet dyeing, which is not preferable.

As the acrylic resin used in the present invention,
An oxazoline-crosslinked acrylic resin is selected from the viewpoint of washing durability and binding strength without releasing harmful formaldehyde, and the area swelling ratio is in the range of 100% or more and 110% or less. However, it can withstand severe dyeing such as jet dyeing. For example, in the case of acrylic resin obtained by crosslinking by carbonyl dehydration condensation and glycidyl crosslinking, even if the area swelling ratio in hot water at 60 ° C. is 100% or more and 110% or less, jet dyeing cannot withstand, The non-woven fabric will be damaged. Urea-formaldehyde cross-links and methylol melamine cross-links are also excellent in binding strength, but formaldehyde is liberated, which is not preferable.

The oxazoline cross-linking acrylic resin is used in an amount of 10 parts by mass or more and 5 parts by mass or more per 100 parts by mass of the nonwoven fabric.
It is preferably in the range of 0 parts by mass or less. The more preferable lower limit of the content is 15 parts by mass or more. A more preferable upper limit of the content is 30 parts by mass or less. When the content of the oxazoline cross-linking acrylic resin is less than 10 parts by mass, washing durability may be obtained, but the dyeing may be broken during dyeing with a jet dyeing machine, and the content is 50 parts by mass. If it exceeds, both washing durability and jet dyeing durability can be obtained, but the feel becomes hard, and it becomes a little soft due to the rubbing action at the time of jet dyeing, but it cannot be said to be sufficient.

Particularly when the nonwoven fabric of the present invention contains polyester fibers, the polyester fibers are usually dyed under high temperature and high pressure, and after dyeing, further washing with a strong alkali is carried out, so that severe dyeing is required. It was being done,
By binding with the oxazoline crosslinkable acrylic resin, deformaldehyde, which was difficult in the past,
A polyester-based colored nonwoven fabric excellent in washing durability, feeling and dyeability can be obtained.

Next, an example of the method for producing the bonded nonwoven fabric of the present invention will be described. First, a dyeable staple fiber is prepared, and the fiber is opened using a card machine to produce a fiber web. The fibrous web is then hydroentangled.
The conditions of hydroentangling treatment may be set according to the strength, thickness, basis weight, feel, etc. of the nonwoven fabric to be finally obtained. For example, in the case of obtaining a nonwoven fabric with a basis weight of less than 100 g / m ^2. Has an orifice with a diameter of 0.05 to 0.5 mm from 0.3 to
Water pressure from 1 to 10 from nozzles provided at intervals of 1.5 mm
A columnar water stream of MPa may be jetted from at least one side of the fibrous web, preferably from both sides, 1 to 4 times each. After the constituent fibers are entangled, the constituent fibers are dried under the condition that the constituent fibers are not heat-sealed to each other to obtain a hydroentangled nonwoven fabric.

Next, an oxazoline cross-linking acrylic resin having an area swelling ratio in hot water of 60 ° C. of 100% or more and 110% or less is adhered to the nonwoven fabric as a water emulsion liquid. Examples of the method of attaching the oxazoline-crosslinked acrylic resin include an impregnation method and a coating method. Of these, the impregnation method is preferable from the viewpoint of uniformly applying the resin to the nonwoven fabric. The non-woven fabric to which the oxazoline cross-linking acrylic resin is applied is squeezed using a mangle or the like, and the resin content is adjusted to be in the range of 10 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the non-woven fabric. Next, using a known drier heated to a temperature at which the oxazoline-crosslinked acrylic resin is cured, it is dried and cured to obtain a bonded nonwoven fabric.

For the bonded nonwoven fabric, a known dyeing machine is used,
A colored nonwoven fabric is obtained by dyeing with a dye. According to the bonded nonwoven fabric, among the dyeing machines, using a known jet dyeing machine,
Even when jet dyeing is performed by a known method, since the constituent fibers are bonded by the oxazoline type acrylic resin, it has sufficient durability even with severe dyeing and rubbing action, and has a uniform dyeing property. In addition to being excellent, the softness of the texture is increased by the strong rubbing effect of the jet dyeing, and a flexible colored nonwoven fabric is obtained.

[0023]

The present invention will be described in more detail with reference to the following examples. The present invention is not limited to the examples below. The tensile strength, tensile elongation, and bending resistance of the nonwoven fabric were measured as follows.

[Tensile strength, tensile elongation] JIS-L-10
According to 96, a sample piece with a width of 5 cm and a length of 15 cm is grasped and held at an interval of 10 cm, and the ambient temperature is room temperature (23 ° C) and 13
It was adjusted to 0 ° C. and stretched at a tension rate of 30 cm / min using a constant-speed elongation type tensile tester, and the load value and elongation rate at cutting were taken as the tensile strength and the elongation rate, respectively.

[Bending flexibility] According to JIS-L-1096 Bending flexibility A method (41.5 ° cantilever method), the data was the average of vertical and horizontal measurement values.

[Examples 1 and 2, Comparative Examples 1 and 2] Fineness 0.
Polyester fiber with 9 dtex and 38 mm fiber length (Teijin Ltd.)
Manufactured by Toyobo Co., Ltd. and a polyester fiber having a fineness of 1.7 dtex and a fiber length of 51 mm (manufactured by Toyobo Co., Ltd.) in a mass ratio of 7: 3 to form a fiber web with a semi-random card. Placed on a 90-mesh plain weave net with diameters of 0.132 mm and orifices with hole diameters of 0.1 mm at intervals of 0.6 mm, water pressure 2MP
Water is jetted once at a pressure of 3.9 MPa and 3.9 MPa to entangle the constituent fibers and then dried at 110 ° C. to give a basis weight of 45 g /
A m ² hydroentangled nonwoven fabric was obtained. The obtained hydroentangled nonwoven fabric is impregnated with an acrylic resin water emulsion solution shown in Table 1 manufactured by Nippon Carbide Industry Co., Ltd., squeezed with a mangle, then dried at 80 ° C. for 30 minutes and then cured at 140 ° C. for 30 seconds. Then, a bonded nonwoven fabric whose acrylic resin content shown in Table 2 was adjusted was obtained. Table 2 shows the physical properties of the obtained bonded nonwoven fabric.

[0027]

[Table 1]

[0028]

[Table 2]

The bonded non-woven fabric obtained was JIS-L-104.
When it was washed 10 times by the 2G method (electric washing machine method), it was possible to wash without breaking any of the nonwoven fabrics and without significant dimensional change. Next, the bonded nonwoven fabric is FP
Dyeing was performed under the following conditions using a type Rapid Uniace dyeing machine (capacity 400 liter, manufactured by Nissen Corporation). [Dyeing] (1) Dye Dianix Blue UNSE (manufactured by Daistar Japan Ltd.) 2% owf Carazol ACE-41 (manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) 2 g / l Ammonium sulfate (for industrial use) 0.5 g / l acetic acid (Industrial use, 90%) 0.3cc / l (2) Dyeing time 130 ° C x 45 minutes [Washing (reduction washing)] (1) Washing 38 ° Be NaOH (industrial) 4.5cc / l Hydrosulfite ( Industrial, 88%) 4g / l (2) Washing time 80 ° C x 20 minutes

As a result, the non-woven fabrics of Comparative Examples 1 and 2 were torn during dyeing, but the non-woven fabrics of Example 1 and Example 2 were processed without any tearing and dyeing and subsequent reduction cleaning. We were able to. Of particular note, the nonwoven fabric of Example 1 had lower mechanical properties in the vertical direction at 130 ° C., which corresponds to the dyeing temperature, than Comparative Example 1, but 6
By controlling the area swelling rate with warm water of 0 ° C. in a desired range, it was possible to withstand jet dyeing. further,
The obtained non-woven fabric was considerably softened by the rubbing effect of jet dyeing.

[Examples 3 to 7, Comparative Examples 3 to 8] Fineness 1.
A polyester web having a fiber length of 7 dtex and a fiber length of 51 mm (manufactured by Toyobo Co., Ltd.) was formed into a fiber web with a semi-random card, and the fiber web was placed on the plain weave net of Example 1 so that the surface of the fiber web had a pore size of 0. 1mm orifice is 0.
Water pressure 2MPa, 3.9MP from nozzles provided at intervals of 6mm
a Water flow is sprayed once at 3.9MPa, the fiber web is turned inside out, and water pressure is 3.9MPa using the same nozzle on the back side.
A single jet of water was used to entangle the polyester fibers, followed by drying at 110 ° C. to obtain a hydroentangled nonwoven fabric having a basis weight of 70 g / m ² . The obtained hydroentangled nonwoven fabric was impregnated with an acrylic resin water emulsion liquid shown in Table 1 manufactured by Nippon Carbide Industry Co., Ltd., squeezed with a mangle, and then at 80 ° C. for 30 minutes.
After drying for 30 minutes, cure at 140 ° C for 30 seconds, and
And the bonded nonwoven fabric adjusted to the acrylic resin content shown in Table 4 was obtained. Physical properties of the obtained bonded nonwoven fabric are shown in Tables 3 and 4.

[0032]

[Table 3]

[0033]

[Table 4]

When the bonded non-woven fabrics of Examples 3 to 7 and Comparative Examples 3 to 8 were washed 10 times in the same manner as in Example 1, none of the non-woven fabrics were torn and they could be washed without a large dimensional change. However, when these non-woven fabrics were dyed by the same method as in Example 1, the non-woven fabrics of Comparative Examples 3 to 8 were torn during the dyeing. On the other hand, although the non-woven fabrics of Examples 3 to 4 were resistant to dyeing, they were torn by the subsequent reduction washing, but the non-woven fabrics of Examples 5 to 7 were not damaged by dyeing and the subsequent reduction washing, and were flexible. A dyed non-woven fabric was obtained.

[0035]

As described above, according to the present invention, the area swelling ratio in hot water at 60 ° C. is 100 ° C. or more and 110% or less even if the mechanical strength at high temperature is low. By combining the constituent fibers with an oxazoline cross-linking acrylic resin, a bonded nonwoven fabric that can withstand 10 or more times of washing and at the same time does not break even with jet dyeing, which has a strong rubbing effect at high temperatures, and has little fuzz can get.

The bonded non-woven fabric is most effective when jet dyeing is performed by using a jet dyeing machine, and particularly, the temperature at the time of dyeing is high and it is necessary to carry out reduction washing after dyeing with a strong alkali. Even a non-woven fabric containing a polyester fiber as described above can be obtained as a colored non-woven fabric having a soft texture without tearing during dyeing.

The bonded nonwoven fabric and the colored nonwoven fabric of the present invention do not generate harmful formaldehyde, have a soft texture, have washing durability, and are suitable for fashionable household goods, clothes, interiors and the like. .

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Claims (5)

[Claims] 1. The area swelling ratio in hot water at 60 ° C. is 1.
A bonded non-woven fabric in which fibers composed of an oxazoline-crosslinked acrylic resin in a range of 00% or more and 110% or less are bonded to each other. 2. The bonded nonwoven fabric according to claim 1, wherein the oxazoline-crosslinked acrylic resin is contained in the range of 10 parts by mass or more and 50 parts by mass or less with respect to 100 parts by mass of the nonwoven fabric. 3. The bonded nonwoven fabric according to claim 1, wherein the nonwoven fabric is a hydroentangled nonwoven fabric composed of short fibers. 4. The bonded nonwoven fabric according to claim 1, wherein the constituent fibers include polyester fibers. 5. A colored nonwoven fabric, wherein the bonded nonwoven fabric according to claim 1 is dyed with a dye.