JP2003201681A - Highly stretchable dyed nonwoven fabric and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a dyed nonwoven fabric having a stable quality of dyeing, dyed color fastness, also uniform fabric touch, basis weight and thickness, and high stretchability, and capable of reducing its cost. <P>SOLUTION: This highly stretchable dyed non-woven fabric is the dyed or printed nonwoven fabric and characterized by having ≥30% fabric recovery rate at 50% elongation of the nonwoven fabric in its warp direction, and the method for producing the highly stretchable dyed nonwoven fabric is provided by heat shrinkage-treating a potentially crimping nonwoven fabric consisting of spun fibers of 2-components having different melting points to make the crimped nonwoven fabric and then dyeing continuously. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a dyed soft, bulky and highly stretchable crimpable nonwoven fabric and a method for producing the same. Furthermore, texture, basis weight, thickness, elasticity, and hue management are easy, and the base material for external medicine such as poultices and clusters, the base material for cuffs, simple clothing, cover material, packaging material,
The present invention relates to a high-quality crimpable nonwoven fabric suitable for synthetic leather base materials, core cotton, molding base materials such as masks and automobile ceiling materials, and a method for producing the same.

[0002]

2. Description of the Related Art As a base cloth used for a happen or a cluster, a short fiber non-woven fabric having knit or bulkiness is generally used because of its softness and elasticity. As the short fibers used in the short fiber non-woven fabric, a conjugate type is used mainly because the crimping property is easily obtained by heat treatment. These short fibers have a shape such as a side-by-side type, an eccentric type, or a flat two-layer type formed by a combination of polyester and a modified polyester having a large heat shrinkage and a low melting point, as disclosed in JP-A-8-269855. In general, the latent crimpable structure has a crimp structure that easily exhibits crimps by heat shrinkage treatment.

[0003] These short fibers have been formed into a web, and after that, Japanese Patent Publication No.
No. 14061, needle punch, or water punch, etc., as described in Japanese Patent Publication No. 8-19611 to form a non-woven fabric structure, and heat shrinking treatment reveals crimps of latently crimpable fibers. Let Such a non-woven fabric is generally processed in a continuous process from the raw cotton feeding to the production of the crimped non-woven fabric.

[0004] Conventionally, the base cloth used for the pad material and the cluster has generally been used as it is as a white cloth, but recently, there has been a strong demand for a base cloth dyed with a skin color or the like. A crimped original fabric dyed is used. In general, non-woven fabrics are dyed by the pad-roll method, which can be dyed in a spread pattern, as described in “Basics and Applications of Non-woven Fabrics” edited by Japan Textile Machinery Society Non-woven Fabric Research Group, P179 and P180, and the beam dyeing method which is a batch dyeing method. Used. In Example 1 of Japanese Examined Patent Publication No. 8-14061, the web is 18
After heat treatment at 0 ° C., dyeing at 130 ° C. for 60 minutes is shown, which is a batch type dyeing from the processing time. When dyeing a non-woven fabric, the reason why the Wins dyeing method or the jet dyeing method can be avoided is that the non-woven fabric dyed with these is excellent in bulkiness and softness, but the quality is poor due to wrinkles, rubbing and rubbing that occur during dyeing. It is thought that this is because the retention and wear resistance are poor.

On the other hand, the beam dyeing machine is suitable for dyeing non-stretchable non-woven fabric composed of single component fibers, which is free from fluffing due to rubbing friction, excellent in abrasion resistance and shape retention. However, in general, a crimpable non-woven fabric having stretchability has a mechanism of winding and dyeing these non-woven fabrics by applying tension to the beam while applying tension to the beam, starting and ending the winding of the beam of the non-woven fabric, so-called texture of the inner and outer layers of the beam, basis weight, and thickness. However, the hue difference is unavoidable, the difference between dyeing batches is large, and the thinner the fabric is, the more difficult it is to control the dyeing process. It is not suitable because it has the drawback that it cannot be solved, and that the difference between dyeing batches is large and that the thinner the fabric is, the more difficult it is to control the dyeing process. In the case where the latently crimped nonwoven fabric, which has not been crimped, is subjected to dyeing and crimping at the same time, there is a drawback that these differences are further fatally widened.

In the Thermozoll method, there is an example in which polyester fiber is dried and cured at 180 ° C. as described in the above-mentioned literature. However, it is a single component polyester or a high temperature type low melting point component from the processing temperature. It is judged that the two-component spinning type short fiber non-woven fabric, spun bond, etc. In Example 1 of Japanese Patent Laid-Open No. 8-269855, there is 1
A non-woven fabric which is dry crimp-developed at 50 ° C. and has an elongation recovery rate of 62% is shown. Further, in JP-A-10-219572, a stretchable fibrous web at 110 ° C. including beam dyeing is disclosed.
Dyeing at the following dyebath temperatures is disclosed. However, according to these, even if the undyed product is excellent in texture and stretchability, similar performance cannot be expected to the undyed product by the conventional dyeing method described above. It is not possible to expect a dyed non-woven fabric having a uniform texture, a cloth appearance, a basis weight, a thickness, etc., in which the stretchability in the warp direction is reduced and there is no difference between the inner and outer layers.

Further, in the thermosol method, the low melting point component is welded or the stretchability disappears due to hard hand, and when the pre-dyeing product is a manifest nonwoven fabric, it becomes a dyed product different from the pre-dyeing product. For this reason, as a practical countermeasure, a beam dyeing method is adopted, and a measure is taken to reduce the difference between the inner and outer layers of the beam at the time of dyeing by limiting the beam winding length. For this reason, the number of processing batches is increasing, and it is inevitable that the dyeing fabric will be expensive. As described above, no rational dyeing method for a crimpable nonwoven fabric using two-component spun fibers having different melting points is disclosed.

[0008]

The present invention provides a non-woven fabric which has stable dyeing quality and dyeing fastness, has a uniform texture, unit weight and thickness, has high elasticity, and is capable of cost reduction. It provides the manufacturing method.

[0009]

Means for Solving the Problems That is, the present invention is as follows. 1. A highly stretchable dyed non-woven fabric, which is a dyed or printed non-woven fabric and has a fabric recovery rate of 30% or more when stretched by 50% in the warp direction. 2. A method for producing a highly stretchable dyed nonwoven fabric, which comprises subjecting a latently crimpable nonwoven fabric composed of different two-component spun fibers to a heat shrinkage treatment to obtain a crimpable nonwoven fabric, and then continuously dyeing. 3. A method for producing a highly stretchable dyed nonwoven fabric, which comprises continuously dyeing a latently crimped nonwoven fabric composed of different two-component spun fibers and simultaneously developing crimps. 4. The method for producing a highly stretchable dyed nonwoven fabric according to the second or third aspect, wherein the crimpable nonwoven fabric is heat-embossed and then continuously dyed.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below. 1) Fibrous form used in the present invention A latent crimpable bicomponent spun fiber having a different area melting ratio in a nonwoven fabric form having a dry heat of 130 ° C. and 4% or more after 1 minute treatment is used. As these fibers, polyester and modified polyester, polyethylene or the like is preferably combined. The modified polyester is preferably a fiber mainly composed of polyethylene terephthalate and copolymerized with isophthalic acid, sulfoisophthalic acid, neopentyl glucose, adipic acid, sebacic acid, diethylene glycol or the like. As for the cross-sectional shape, a side-by-side type, an eccentric type, a flat two-layer type, etc., in which crimps can be easily developed due to different shrinkage are adopted. The melting point of the modified polyester is preferably in the range of 120 ° C to 180 ° C,
More preferably, it is 140 to 160 ° C. If the melting point is too low, crimps will appear at low temperatures, but the dyeing fastness will be reduced, which is not preferable. On the contrary, if the melting point is too high, the crimp development is poor,
It is not preferable because it damages the feeling. From the viewpoint of dyeing fastness, the modified polyester is preferably a high melting point type within the scope of the present invention, and a low melting point type is more preferably a cationic dyeable type. When a cationic dyeable fiber is used as the low melting point fiber, it is effective to carry out a steam color development treatment in order to obtain color development and fastness.

Single yarn fineness is 1.0 dtex to 3.3 dt
Ex is preferable, and if it is out of these ranges, too thin, it becomes difficult to carry out two-component spinning, and if too thick, the texture is hardened, which is not preferable. The low melting point component in the fiber is 40 to 60 by weight.
% Is preferred. The cut length is preferably about 38 mm to 51 mm. An antibacterial deodorant, a matting agent, a heat storage exothermic agent, a moisture absorbent, an aromatic agent, other kneading agents, and a fiber surface-treating agent may be added to the fiber.

2) Non-woven fabric form The non-woven fabric of the present invention is a short-fiber non-woven fabric composed of a latent crimpable bicomponent short fiber alone, or a latent crimpable bicomponent spun fiber and other fibers such as polyester and cationic dyeable polyester fiber. It can be obtained by a known method such as needle punching, water punching, and stitch bonding after forming a web with a mixed cotton of In the case of mixed cotton, the mixture ratio of latently crimpable bicomponent spun fibers is 70% or more by weight. This is because if it is less than 70%, it becomes difficult to obtain crimpability, stretchability and soft feeling. The cross-layer method is preferable for forming the web in terms of strength and quality. In terms of the basis weight, the beam dyeing is restricted to a thin cloth in order to obtain an inexpensive dyeing processing cost per unit length due to the restriction of the dyeing length, but in the present invention, there is no particular restriction, and from a thin cloth of about 20 g / m ² to 300 g. Widely applied to thick ground of / m ² or more.

In the present invention, a long-fiber non-woven fabric may be formed by a spun bond using latently crimped bicomponent spun long fibers, melt blown, or flash spinning. In particular, the spunbond method is cheaper than a short fiber non-woven fabric, can be delivered in a short time and can be mass-produced, and is preferably used in the present invention in which the latent crimped fibers can be crimp-exposed and color-developed at the same time. Further, the long-fiber non-woven fabric may be formed into a multilayer structure by superposing a spun bond of polyester alone, a spun bond of latent crimping bicomponent spinning, and a melt blown or flash spinning.

In these non-woven fabric manufacturing steps, crimp development treatment may be carried out by dry heat, wet heat, or a combination of these treatments. Further, the non-woven fabric is not subjected to crimp development treatment,
Alternatively, for the purpose of imparting strength, a slight crimp expression may be performed and the dyeing step may be performed.

3) Dyeing Method When the nonwoven fabric is unwound from the roll and supplied to the dyeing step, it is desirable to prevent excessive tension on the fabric by using a positive drive roll. This is to prevent a decrease in fabric weight due to over tension in the warp direction, and a decrease in fabric quality, feel, physical properties, and the like, which are associated with the decrease.

In the present invention, the crimp-developing nonwoven fabric or the non-crimp-developing non-woven fabric is soaked in a dyeing solution in a spread state, squeezed with a mangle to obtain a desired pick-up rate, and dry heat treated,
Or it develops color by steam treatment. Alternatively, after printing, color is developed by dry heat treatment or steam treatment. The dyeing solution may be only the dye, or the dye solution may be used in combination with a solvent, a dyeing aid or the like. After dyeing or printing, wash, dry and wind on a paper tube. In the drying step, the non-woven fabric surface can be compressed with a heat roll having a temperature lower than the color development temperature to give a flat finish or can be dried with a setter or the like. In addition to disperse dyes and cationic dyes, inkjet printing using a pigment or the like is also suitably used for dyeing and printing.

The crimp-expressing non-woven fabric or the non-crimp-expressing non-woven fabric may be embossed to give an uneven pattern to the surface of the fabric and then used for dyeing. The embossing temperature may be a temperature slightly higher than the melting point of the low melting point fiber, and may be appropriately set in consideration of the pattern effect and the feeling. When the embossed product is dyed by the beam dyeing method, a three-dimensional, soft, and uniform nonwoven fabric as in the present invention cannot be obtained.

The color development temperature in the present invention is set to a temperature higher than the temperature at which the dry shrinkage treatment of the non-woven fabric is 10% or more in free shrinkage per minute. This shrinkage rate is 10%
When it is less than 1, the crimp expression is insufficient, and the color developability and dyeing fastness are insufficient, which is not preferable. Preferred shrinkage is 15% or more, more preferably 25% or more, 50%
Is less than. This is because if the content is 50% or more, the material becomes hard and the elasticity is poor.

Shows a high shrinkage ratio on the low temperature side of 160 ° C. or less 2
As the component-spun fiber is obtained, a soft, highly crimped and highly stretchable nonwoven fabric is obtained, which is preferable for the present invention. As the coloring temperature exceeds the melting point of the low melting point fiber, the degree of adhesion of the fiber surface increases, the texture of the non-woven fabric after treatment is hardened, and the stretchability is hindered.
Temperature treatment above the melting point of the low melting point fiber is not preferred. The heat treatment time to develop color or develop crimp is about 1 minute in dry heat and 1 to 100 ℃ to 120 ℃ in high pressure steam treatment.
0 to 20 minutes, 12 in high temperature steaming
It may be about 5 to 10 minutes at 0 to 160 ° C., but it is appropriately set in consideration of fiber characteristics, dye concentration and the like.

In the present invention, it is preferable to use a net type conveyor air type or a conveyor belt type pin tenter for the purpose of preventing the unit weight from varying in the width direction due to its own weight. The draw-out ratio and the feed ratio are preferably about 0%, and are appropriately set according to the latent heat shrinkage ratio of the nonwoven fabric. Excessive drawing out and pulling in the longitudinal direction are not preferable because the texture is impaired, and the thin portion is conspicuous and the quality is remarkably impaired.

4) Product characteristics The dyed nonwoven fabric of the present invention has a stretchability of 50.
The recovery rate in the warp direction after% stretching is 30% or more, and more preferably 35% or more. If it is less than 30%, the texture of the non-woven fabric is hard and lacks elasticity, and it is unsuitable for applications requiring high elasticity such as poultices and plasters. In the present invention, a nonwoven fabric having a stretchability of about 50% can be easily obtained.
In beam dyeing, the non-woven fabric wrapped in the inner layer of the beam is flattened, thinner, harder and less stretchable than that of the outer layer. Also, differences in fabric quality and appearance are unavoidable. When the non-woven fabric is softly wound around the beam in order to make the inner layer portion bulky and soft, the fabric is stretched in the weft direction due to the liquid flow during dyeing, causing wrinkles, uneven widths, and uneven weight distribution. The present invention is characterized in that such inconvenience can be eliminated, and uniform cloth appearance, quality, uniform thickness, basis weight, and high stretchability can be easily obtained.

Defects such as glued fibers and unstretched fibers, which occur rarely in the raw cotton manufacturing process, and scattering of other polyester fibers, which occur in the non-woven fabric manufacturing process, occur as a density difference defect after dyeing. Since conventional exhaust dyeing methods such as beam dyeing are competitive dyeing, it is difficult to avoid these defects, but in the present invention, these density difference defects are drastically reduced, and there is an additional effect that a fabric quality improving effect is obtained. Greatly contributes to the improvement in the yield of dyed products.

5) Measuring method: Recovery rate at 50% elongation: JIS L 1096-19
In accordance with 90 6.14.2, a recovery rate was obtained when the sample was stretched by 50% at a gripping distance of 20 cm and a pulling speed of 20 cm / min using a constant elongation tensile tester, and was restored to the origin at the same speed. -Thickness: Based on JIS L1913 B method. -Unit weight: Based on JIS L1913. -Area shrinkage of non-woven fabric: thickness 0.6 mm obtained by dry heat drying at 100 ° C with a water punch cloth layer, basis weight 8
Using a non-woven fabric of 0 g / m ² , JIS L1913-19
Compliant with 98. -Fastness to sunlight: Based on JIS L0841-1998 (gray scale). Sweat fastness: in accordance with JIS L0848-1996. -Color crying: Based on JIS L0846-1996.

[0024]

EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited thereto. Example 1 Polyester (melting point 262 ° C.) and modified polyester (melting point 150 ° C.) fiber containing neopentyl glycol in polyethylene terephthalate, having a side-by-side round cross-sectional shape with a component ratio of 1: 1 and a fineness of 2.2 dtex,
After forming a web composed of latently crimpable fibers having a fiber length of 51 mm, it was entangled with a water punch, followed by drying and crimping at 130 ° C. for 1 minute to obtain an area shrinkage ratio of 2
Recovery rate in the longitudinal direction at 5% and 50% elongation 48%, basis weight 80
A non-woven fabric of g / m ² was obtained. Then, the non-woven fabric was treated with a disperse dye 1.0 g / l (Dianix manufactured by Dystar Japan Co., Ltd.
Blue HF-G, Dianix Red HF-G,
(Dianix Yellow HF-4G is used equally)
It was dipped in a mixed solution of a dispersant and a dispersant to obtain a dough having a squeezing ratio of 100%, a tentering ratio and a feed ratio of 0%, and a net type pin tenter was used to perform a treatment at a coloring temperature of 135 ° C for 70 seconds. Continue soaping, width, feed rate 0
%, And the color development temperature was 120 ° C. for 60 seconds for pin tenter drying. As a result, a uniform non-woven fabric was obtained which was bulky and rich in raised suede-like soft texture and high stretchability, and had little difference in unit weight, thickness and texture at the beginning and end of dyeing. The dyeing fastness was also practical.

Example 2 A polyester having a fineness of 2.2 dtex and a fiber length of 51 mm (melting point 262 ° C.) and a modified polyester (melting point 170 ° C.) fiber containing neopentyl glycol in polyethylene terephthalate in an amount smaller than that in Example 1 were used. Side-by-side round cross-section with a 1: 1 ratio and a fineness of 2.2 dt
After forming a web composed of latently crimpable fibers having a length of 51 mm and a fiber length of 51 mm, it was entangled with a water punch, followed by drying and crimp development for 1 minute at 160 ° C, and an area shrinkage ratio of 26% (130 ° C). Area shrinkage 6% in 1 minute treatment), 5
A nonwoven fabric having a warp recovery rate of 31% at 0% elongation and a basis weight of 80 g / m ² was obtained. Then, the same procedure as in Example 1 was carried out except that only the coloring temperature was changed to 160 ° C. As a result, although the performance was slightly inferior to that of Example 1, a non-woven fabric of sufficient quality was obtained as compared with the comparative example.

Comparative Example 1 A polyester having a fineness of 2.2 dtex and a fiber length of 51 mm (melting point 262 ° C.) and a modified polyester fiber (sodium melting point 180 ° C.) containing sodium 5-sulfoisophthalate and isophthalic acid in polyethylene terephthalate were used. 1: 1 side-by-side type round cross-sectional shape, fineness of 2.2 dtex, fiber length of 51 mm, formed from a web of latent crimpable fibers, entangled with a water punch, followed by drying and crimping. The development was carried out at 180 ° C. for 1 minute to obtain a nonwoven fabric having an area shrinkage rate of 11% (2% shrinkage rate at 130 ° C. treatment), a recovery rate in the machine direction of 9% at 50% elongation, and a basis weight of 80 g / m ² . Then, the same procedure as in Example 1 was carried out except that only the color development temperature was set to 180 ° C. As a result, it was a non-woven fabric which was hard to touch and was inferior in bulkiness and elasticity.

Comparative Example 2 The nonwoven fabric of 500 m of Example 1 was wound into a beam with a winding tension of 18%, dyed with a disperse dye (the dye used was the same as in Example 1) at 100 ° C. for 30 minutes, and after drainage, the form was maintained. It was dried with warm air. The result is a dyed product with a non-uniform quality with a large difference between the inner and outer layers of the beam such as basis weight, thickness, hue, stretchability, etc. Met.

Comparative Example 3 The procedure of Example 1 was repeated except that the color development temperature was 180 ° C. The result is bulky,
Due to excessive heat shrinkage, it has a hard texture and inferior elasticity,
The non-woven fabric is remarkably lacking in practicality.

Example 3 A modified polyester (melting point 150 ° C.) fiber containing polyester (melting point 262 ° C.) and polyethylene terephthalate and neopentyl glycol in the same amount as in Example 1 and having a component ratio of 1: 1 is a side-by-side type. Round cross-section shape,
1.6 dtex spunbond was obtained, and then crimp development was carried out at 130 ° C. for 1 minute to obtain a nonwoven fabric having an area shrinkage of 53%, a recovery in the machine direction of 47% at 50% elongation, and a basis weight of 30 g / m ² . Then, a dyed cloth was obtained under the same conditions as in Example 1. As a result, a very soft and delicate texture and high elasticity are provided, and as in Examples 1 and 2, the unit weight and thickness of the dyeing start and end portions,
A uniform nonwoven fabric with a slight difference in texture was obtained. The dyeing fastness was also practical.

Example 4 A dyed fabric was obtained in the same manner as in Example 3 except that the spunbond obtained in Example 3 was embossed at 120 ° C. for 10 tons. The embossed product before dyeing had an area shrinkage rate of 39% and a recovery rate in the longitudinal direction at 50% elongation of 38%. As a result, a thin non-woven fabric having a large unevenness, softness, delicacy, bulkiness, and elasticity was obtained.

Comparative Example 4 The nonwoven fabric obtained in Comparative Example 1 was subjected to Example 4 at 180 ° C. and 10 tons.
A dyed cloth was obtained in the same manner as in Example 1 except that the embossing having the same pattern as in Example 1 was applied. Area shrinkage of embossed product before dyeing is 5
%, The longitudinal recovery rate at 50% elongation was 6%. Compared to Example 4, it was flat and the pattern effect was weak, and the texture and stretchability were poor, and it was remarkably lacking in practicality.

[0032]

[Table 1]

[0033]

EFFECTS OF THE INVENTION According to the present invention, a dyed non-woven fabric having high stretchability, stable dyeing quality and dyeing fastness, uniform texture, basis weight, thickness and stretchability and capable of cost reduction Is easily obtained.

Continued front page    (72) Inventor Eiki             Toyobo, 2-8, Dojimahama, Kita-ku, Osaka-shi             Koki Co., Ltd. (72) Inventor Tetsuya Shirai             255 Oka, Ritto City, Shiga Prefecture F-term (reference) 4H057 AA01 BA08 DA01 DA17 GA25                       HA01 HA13 JA10 JB03                 4L047 AA21 AB09 AB10 BA04 DA00

Claims (4)

[Claims] 1. A highly stretchable dyed nonwoven fabric, which is a dyed or printed nonwoven fabric and has a fabric recovery rate of 30% or more when the nonwoven fabric is stretched by 50% in the warp direction. 2. A method for producing a highly stretchable dyed nonwoven fabric, which comprises subjecting a latently crimped nonwoven fabric composed of bicomponent spun fibers having different melting points to a heat shrinkage treatment to obtain a crimped nonwoven fabric, and then continuously dyeing. 3. A method for producing a highly stretchable dyed nonwoven fabric, which comprises continuously dyeing a latently crimped nonwoven fabric composed of bicomponent spun fibers having different melting points and simultaneously developing crimps. 4. The method for producing a highly stretchable dyed nonwoven fabric according to claim 2 or 3, wherein the latently crimped nonwoven fabric is heat-embossed and then continuously dyed.