JP2005220463A - Method for producing air-permeable fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a fabric of improved air permeability while maintaining its quality in terms of mechanical strength and appearance without changing specifications on the arrangement density, thickness, etc. of multifilament yarns constituting a fabric conventionally used as a motor vehicle internal trim material or the like. <P>SOLUTION: The method for producing the air-permeable fabric comprises the following way: An original fabric to be comprised of multifilament yarns insoluble or sparingly soluble to a specific solvent is woven with multifilament yarns readily soluble to the specific solvent to make a new original fabric, which is then imparted with the specific solvent to dissolve the soluble multifilament yarns, thus developing air-permeable voids corresponding to the fineness(thickness) of the soluble multifilament yarns dissolved at weaves formed by the insoluble multifilament yarns in the original fabric. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for producing a breathable fabric used for vehicle interior materials and the like.

The vehicle interior fabric is required to have a required air permeability in order to increase the sound absorption effect of the other interior fabric so as not to give a feeling of stuffiness to the chair upholstery. In a chair-covered area, in addition to the sound absorbing effect, breathability is also required so as not to give a feeling of stuffiness (for example, see Patent Document 1).
Patent No. 3114920 Patent Publication (Claims)

  If it is only to improve the air permeability of the woven fabric, it is only necessary to make the multifilament yarns thin, and to make the warp density and the weft density coarse, and no special device is required. However, this only lowers the physical strength of the fabric, making it difficult to weave a fabric with uniform warp density and weft density, making it difficult to obtain a fabric with durability and high commercial value suitable for vehicle interior materials. In particular, in pile woven fabrics, pile standing (upright state) is deteriorated, and pile pull-out strength is reduced.

  The present invention provides the physical strength and appearance quality without changing the specifications such as the thickness, warp density, and weft density of the multifilament yarns that are conventionally used for the vehicle interior materials. It aims at improving air permeability while maintaining the above.

  The method for producing a breathable woven fabric according to the present invention allows easy dissolution in a specific solvent in a raw fabric that should be constructed using insoluble or hardly soluble insoluble multifilament yarns in a specific solvent. Weaving the melted fiber yarns to form the original fabric, then applying the specific solvent to dissolve the soluble fiber yarns woven into the fabric, and the insoluble The first characteristic is to generate a breathable gap corresponding to the fineness (thickness) of the dissolved soluble multifilament in the weave formed in the woven fabric.

  The second feature of the method for producing a breathable fabric according to the present invention is that, in addition to the first feature, a soluble multifilament is combined with all insoluble multifilaments that should constitute the raw fabric. A semi-soluble multifilament is formed, and the soluble multifilament is woven into the raw fabric as a semi-soluble multifilament.

  A third feature of the method for producing a breathable fabric according to the present invention is that, in addition to the first feature, a soluble multifilament is combined with a part of the insoluble multifilament that should constitute the raw fabric. By forming the semi-soluble multifilament yarn, the insoluble multifilament yarn that should constitute the raw fabric is converted into a completely insoluble multifilament yarn that is not combined with the soluble multifilament yarn, It is divided into the semi-soluble multi-filaments combined with the yarns, and the soluble multi-fibers are woven into the raw fabric as the semi-soluble multi-fibers.

  The fourth feature of the method for producing a breathable fabric according to the present invention is that, in addition to any one of the first to third features, the raw fabric is a pile fabric, and can be used as a base fabric for locking the pile. It is in the point of weaving the melt fiber yarn.

  A fifth feature of the method for producing a breathable fabric according to the present invention is that, in addition to any of the first to fourth features, the raw fabric is a pile fabric, and the pile is formed by insoluble multifilaments. There is in point to do.

  A sixth feature of the method for producing a breathable woven fabric according to the present invention is that, in addition to any of the first to fifth features, an insoluble multifilament yarn is allowed on at least one side of the front and back of the raw fabric. It is in the point which comprises an original fabric by the woven structure exposed more than a melt fiber yarn.

  A seventh feature of the method for producing a breathable fabric according to the present invention is that the water-soluble multifilament is applied to the soluble multifilament in addition to any of the first to sixth features, and is specified. The point is to apply water to the solvent.

  The eighth feature of the method for producing a breathable fabric according to the present invention is that, in addition to any of the first to seventh features, thermoplastic fibers are applied to the multifilament yarns constituting the raw fabric. The raw fabric is heated to heat set the thermoplastic fiber and to apply a specific solvent.

  A ninth feature of the method for producing a breathable fabric according to the present invention is that, in addition to any one of the first to eighth features, a heat-fusible fiber is applied to the multifilament yarn constituting the raw fabric. In addition, the raw fabric is heated to heat-fuse the heat-fusible fibers or heat-fusible fibers and other fibers, and then apply the specific solvent.

  A tenth feature of the method for producing a breathable woven fabric according to the present invention is that, in addition to any of the first to ninth features, the fineness (thickness) of the soluble multifilament yarn is changed to that of the raw fabric. The fineness (thickness) of any insoluble multifilaments constituting the texture is 0.16 to 0.7 times.

  An eleventh feature of the method for producing a breathable fabric according to the present invention is a unit of the raw fabric of the soluble multifilament yarn woven into the raw fabric in addition to any of the first to tenth features. The mass (weight per unit area) of the soluble multifilament occupying the area is the mass (unit weight) of the insoluble polyfilament occupying the unit area of the original fabric of the insoluble multifilament constituting the weave of the original fabric. It is in the point which makes it 0.1 times-2.0 times.

  Specifications such as fineness (thickness), warp density, and weft density of the multifilaments constituting the woven fabric obtained by the present invention as a result of dissolution of the soluble multifilaments are conventionally used for vehicle interior materials, etc. Even if it is the same as the specification of the woven fabric, the insoluble multifilament used alone is the soluble multifilament, which is a single product of insoluble multifilament that does not use soluble multifilament alone. The yarn is woven with the amount of swelling that does not intervene, and bends in the swollen state to form a texture, so that the insoluble multifilament yarn is a monofilament single yarn or the insoluble polyfilament yarn. Unless there is a special circumstance such as a multifilament yarn whose swelling is suppressed by sizing treatment using a binder, it is said that there is a gap in the weave as much as the soluble multifilament does not intervene Absent. In other words, in a woven fabric constituted by a multifilament yarn composed of a large number of fibers such as spun yarn and multifilament yarn, the warp density and the weft density are precisely set for use in the vehicle interior material. That is, even if the fineness (thickness) of the multifilament yarn is slightly changed, the air permeability of the fabric does not change greatly in proportion to the thickness of the multifilament yarn.

  In this regard, when the insoluble multifilament is woven together with the soluble multifilament to form a bent weave, and when the soluble multifilament is dissolved and removed in a fixed state called the weave, Since the insoluble multifilament remaining after dissolution and removal maintains the fixed shape of the texture, the gap corresponding to the thickness of the dissolved and removed soluble multifilament has a texture. As a result, the air permeability of the woven fabric is improved by that amount, and the insoluble multifilaments are more likely to behave by the amount of the generated gap, and the texture is easily deformed. For this reason, according to the present invention, even if the specifications such as the fineness (thickness), warp density, and weft density of the multifilament are the same as those of the conventional product, it is possible to obtain a woven fabric rich in breathability and stretchability. .

  In this way, in order to obtain a woven fabric rich in breathability and stretchability, the warp density and the weft density are not increased, or the fineness of the multifilament is not reduced. Weaving the fabric by thickening the multifilament yarns by the thickness and making the warp density and weft density substantially dense, so that the weaving process does not become uneven and suitable for vehicle interior materials High quality fabrics.

  When making the warp density or weft density coarse or reducing the fineness of the multifilament yarns so as to create a gap that allows the front and back of the fabric to be seen through, prevent misalignment and unevenness of the texture. For this reason, it is necessary to devise such as making the woven structure into a twisted woven structure or providing a non-slip resin to warps and wefts by sizing treatment. As a result, the specifications of the resulting woven fabric are also limited. However, in the present invention, a breathable woven fabric with uniform texture can be easily obtained without being restricted by the woven structure, the weaving apparatus, the physical properties of warp and weft, and the like.

In the present invention, a gap in a texture that is blocked by swelling of an insoluble multifilament composed of a large number of fibers such as spun yarn and multifilament yarn is used as the insoluble multifilament. The insoluble multifilaments are spun and multifilaments because they are unfolded by soluble polyfilaments of appropriate fineness and are made to manifest as vents by dissolving the soluble multifilaments. Although it should be composed of a large number of fibers such as yarn, it is not always necessary to reveal the air holes in all the weaves of the raw fabric, but by exposing the air holes in some of the weaves. Breathability can be imparted to the raw fabric.
Therefore, it is not necessary that all the insoluble multifilament yarns constituting the raw fabric are composed of a large number of fibers like spun yarns and multifilament yarns, and some insoluble polyfilament yarns do not swell. Filament single yarn can also be used.
In addition, even in the case of monofilament single yarn, in the case of monofilament flat yarn having a flat cross section that can be deformed in the width direction, it is deformed in the width direction at the texture by the soluble multifilament, and the soluble multifilament By dissolving the yarn, it is possible to reveal the air holes in the weave.
However, in order to effectively carry out the present invention, at least a part of the warp and weft constituting the raw fabric is a multifilament yarn composed of a large number of fibers such as spun yarn and multifilament yarn. To do.

The “weave” referred to in the present invention means a detailed structure of the raw fabric that is surrounded by the warp and the weft in a woven structure in which the warp and the weft constituting the raw fabric are bent and entangled. Accordingly, in order to effectively carry out the present invention, it is desired to dissolve the soluble multifilament after fixing the shape of the texture. The most effective way to fix the texture is to fix it by heat. Therefore, it is an effective embodiment to apply thermoplastic fibers, particularly heat-fusible fibers, to the warp and weft constituting the original fabric.
Thermoplastic fibers and heat-fusible fibers are not necessarily applied to semi-soluble multifilament yarns, and may be applied only to all insoluble multifilament yarns (insoluble multifilament yarns). This is because when the bent shape of the all insoluble multifilament yarn constituting the texture is fixed, the semi-soluble polyfilament yarn constituting the texture together with the all insoluble multifilament yarn. This is because the bent shape of (especially insoluble polyfilament) is maintained. For this purpose, it is not necessary to make all the fibers constituting the completely insoluble multifilament yarn or the semi-soluble multifilament yarn (in particular, the insoluble multifilament yarn) into thermoplastic fibers or heat-fusible fibers. In particular, the heat-fusible fiber may be applied to some of the fibers constituting the warp and the weft.

  As the thermoplastic fiber, ordinary synthetic fibers such as nylon, polyester fiber, acrylic fiber, polypropylene fiber, and vinylon are used. The heat-fusible fiber only needs to have a lower melting point than the other fibers constituting the multifilament yarn together with the heat-fusible fiber. The thermoplastic synthetic fiber may be used. However, a preferred heat-fusible fiber is a heat-fusible core-sheath composite synthetic fiber having a high melting point polymer as a core component and a low melting point polymer as a sheath component. When two or more types of semi-soluble multifilament yarns or two or more types of completely insoluble multifilament yarns are used, the thermoplastic fiber or the heat-fusible fiber is any one type of multifilament. It may be applied only to the yarn.

  In a pile fabric, the pile is locked to the base fabric, and even if it is a first pile complicatedly entangled with the base fabric, the so-called dead pile or back stitch portion entangled with the base fabric It is difficult to say that it constitutes the texture of the base fabric, and even if the shape of the pile is fixed, the shape of the ground warp and weft yarn that constitutes the texture of the base fabric is fixed. Must not. Therefore, in pile woven fabrics, it is not necessary to apply thermoplastic fibers or heat-fusible fibers to the pile in order to fix the shape of ground warp and weft yarns constituting the weave of the base fabric. The heat-fusible fiber is applied to ground warp and ground weft constituting the base fabric.

The specific solvent is set relatively in relation to the soluble multifilament. For example, for polyamide fibers (nylon), aliphatic saturated dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, maleic acid, fumaric acid, citraconic acid, mesaconic acid, Aliphatic unsaturated dicarboxylic acids such as itaconic acid, p-toluenesulfonic acid, concentrated formic acid, guanidine carbonate, guanidine acetate, guanidine hydrochloride, and phenols are specific solvents.
For polyester fibers, alkali metal hydroxides such as guanidine carbonate, guanidine acetate, guanidine hydrochloride, tetramethylammonium hydroxide, caustic soda and caustic potash, and alkaline earth metal hydroxides such as calcium hydroxide and magnesium hydroxide An alkaline substance solution such as
For acrylic fibers, ethylene carbonate and propylene carbonate are specific solvents.
For cellulosic fibers, sulfuric acid, sodium hydrogen sulfate, aluminum sulfate, ferrous sulfate, ferric sulfate, ammonium sulfate, zinc sulfate and other sulfates, hydrochloric acid, ferrous chloride, ferric chloride, aluminum chloride In addition, chlorides such as stannous chloride and stannic chloride, and acidic substance solutions such as alkyl naphthalene sulphonic acid serve as the specific solvent.
For vinylon fibers, concentrated formic acid, pyridine, cresol, and phenols are specific solvents.
For polyvinyl alcohol fibers, water is the specific solvent.

  Similarly, the insoluble multifilament is also set relatively in relation to the specific solvent. For example, when the specific solvent is phenols, nylon becomes a soluble multifilament, and polyester fiber, acrylic fiber, and cellulose fiber become insoluble multifilament. When sulfuric acid is used as the specific solvent, the cellulosic fibers become soluble multifilaments, and the polyester fibers and acrylic fibers become insoluble multifilaments. When ethylene carbonate is used as the specific solvent, acrylic fibers become soluble multifilaments, and polyamide fibers (nylon), polyester fibers, and cellulose fibers become insoluble multifilaments. Thus, the specific solvent, soluble multifilament yarn, and insoluble polyfilament yarn (totally insoluble polyfilament yarn) in the present invention are relatively set.

  As is apparent from the properties of the specific solvent exemplified above, water is a preferable specific solvent in terms of work safety and drainage treatment, and the soluble multifilament is a water-soluble multifilament (polyvinyl alcohol). It is recommended to use fiber). As water-soluble multifilament yarns, Nichibi Corporation product “Solbron”, Kuraray Co., Ltd. product “Mint”, etc. are known as commercial products.

  The semi-soluble multifilament may be constituted by any of the alignment of the soluble multifilament and the insoluble multifilament, blending, and twisting. When a semi-soluble multifilament is formed by blending or twisting a soluble multifilament and an insoluble multifilament, the soluble multifilament is overfeeded compared to the insoluble multifilament. When the soluble polyfilament yarns are 1.1 times or more of the insoluble polyfilament yarns, the insoluble polyfilament yarns (semi-dissolved) before and after the dissolution of the soluble polyfilament yarns. The length of the multi-filament yarn) does not change, and no dimensional change occurs in the raw fabric. Here, the “yarn foot” means the length of a soluble multifilament or insoluble multifilament contained in a certain length of a semi-soluble multifilament in a tension state. Since the soluble multifilament is applied as a means for forming a gap (air hole) in the weave by its dissolution, 16% to 70% of the fineness (thickness) of the semi-soluble multifilament, In general, the thickness (fineness) of the soluble multifilament and the thickness of the insoluble multifilament (thickness) so that the fineness (thickness) of the soluble multifilament occupies 30% to 50%. The ratio to the fineness is set to the latter 2 with respect to the former 1, that is, 1 to 2.

  In order to impart high stretchability to the raw fabric, it is preferable to use an elastic yarn having an elastic recovery rate of 99% or more after 5% elongation, such as a polyurethane elastic yarn, as the insoluble multifilament yarn. In such a case, the soluble multifilament is controlled to keep the elongation rate of the semi-soluble multifilament (elastic insoluble multifilament) within a certain range against the tension applied during the weaving process of the raw fabric. Acts as a means. Thus, the soluble multifilament is applied not only as a means for imparting air permeability to the raw fabric, but also as a means for imparting stretch properties (stretchability, flexibility) to the raw fabric. . In the present invention, “breathability” is used as a synonym for “moisture permeability” and “water permeability”.

  The raw fabric can be finished by raising the surface or applying an adhesive on the back. When applying a water-soluble multifilament to a soluble multifilament, the soluble multifilament can also be dissolved with the water | moisture content of the adhesive agent used for the backing finish of a raw fabric. Since the raising treatment is performed on all non-soluble multifilaments whose form does not change depending on the soluble multifilaments, either the before or after the dissolution of the soluble multifilaments Although it may be performed in stages, it is preferably performed before dissolution of the soluble multifilament. When the backing adhesive is applied to the back side of the raw fabric after the soluble multifilament is dissolved, the gaps (air holes) created in the texture due to the dissolution of the soluble multifilament In order not to be blocked by the adhesive, adjust the viscosity and amount of the backing adhesive so that the backing adhesive is absorbed inside the multifilament, or foam the backing adhesive, etc. The amount of coating is adjusted by applying the above process, or the coating film of the adhesive covering the texture is destroyed by applying vibration or air flow after applying the backing adhesive, and the texture gap (air vent) is revealed. Let

Combination of polyester fiber multifilament yarn (insoluble multifilament 14) having a total fineness of 310 dtex / 100f (single yarn fineness 3.1 dtex) and water-soluble polyvinyl alcohol fiber having a total fineness of 110 dtex / 24f (single yarn fineness 4.6 dtex) Twisted yarn (semi-soluble multifilament yarn 15) is used for ground warp yarn 21 and weft yarn 22, polyester fiber multifilament yarn (total non-dissolvable multifilament yarn) having a total fineness of 495 dtex / 216f (single yarn fineness of 2.3 dtex). 13) is used for the pile warp 23, and a moquette 24 having a ground warp density of 46 / 吋, a weft density of 46 / 吋 and a pile warp density of 23 / 吋 is woven, and the polyvinyl alcohol fiber is passed through warm water at 80 ° C. After dissolving and removing, and drying, a phosphoric flame retardant-containing urethane resin emulsion adhesive (dry coating amount 55 g / m ² ) was coated and finished. In the weave 26 surrounded by the ground warp yarn 21 and the weft yarn 22 of the base fabric 25 of the moquette 24 thus obtained, air holes (gap) 27 due to dissolution of water-soluble polyvinyl alcohol fibers are recognized, and the JIS of the moquette is recognized. -Air permeability by L-1096 (6.27.1.A method) (unit: cc / cm ² / sec), JIS-L-1096 (6.14.1.B method, measured after 96N weighting 10 minutes) The constant load elongation (unit:%) according to JIS-L-1096 (6.19.1.A method) was as shown in [Table 1].

[Comparative example]
A polyester fiber / rayon blended spun yarn (average single yarn fineness 2.3) having a total fineness of 380 dtex with a fineness unit converted to dtex is used for the ground warp and the weft, and the total fineness is 495 dtex / 216f (single yarn fineness 2.3 dtex). Polyester fiber multifilament yarn (all non-dissolvable multifilament yarn) is used for pile warp, and weaving moquette with a ground warp density of 46 / 吋, a weft density of 46 / 吋, and a pile warp density of 23 / 吋, An acrylic resin emulsion adhesive (dry coating amount 55 g / m ² ) was coated and finished. The air permeability (unit: cc / cm ² / sec) according to JIS-L-1096 (6.27.1.A method) of the moquette thus obtained, JIS-L-1096 (6.14.1.B method. The constant load elongation (unit:%) by 96N load 10 minutes) and the bending resistance (unit: mm) by JIS-L-1096 (6.19.1.A method) are as shown in [Table 1]. Met.

It is a back view after melt | dissolution of the soluble multifilament of the moquette which concerns on the Example of this invention. It is a back view before melt | dissolution of the soluble multifilament of the moquette which concerns on the Example of this invention.

Explanation of symbols

13: Totally insoluble polyfilament 14: Insoluble polyfilament 15: Semi-soluble polyfilament 21: Ground warp 22: Weft 23: Pile warp 24: Moquet 25: Base fabric 26: Weave 27 : Vent (gap)

Claims (11)

  An original fabric woven by incorporating soluble multifilaments that are easily soluble in the specified solvent into the original fabrics that should be constructed using insoluble or hardly soluble insoluble filaments in the specified solvent. And then dissolve the soluble multifilament yarn woven into the raw fabric by applying the specific solvent, and the insoluble multifilament is formed in the raw fabric. A method for producing a breathable fabric in which a breathable gap is generated in accordance with the fineness (thickness) of the dissolved soluble multifilament.   All insoluble multifilaments that should constitute the raw fabric are combined with soluble multifilaments to form semi-soluble multifilaments, and the soluble multifilaments are made into semi-soluble multifilaments. The method for producing a breathable woven fabric according to claim 1, wherein the woven fabric is woven into a raw fabric.   The insoluble multifilament yarn that should constitute the raw fabric is formed by composing the soluble multifilament yarn with a part of the insoluble multifilament yarn that should constitute the raw fabric to form a semi-soluble multifilament yarn. The strip is divided into a totally insoluble multifilament yarn that is not combined with the soluble multifilament strip and a semi-soluble multifilament strip that is combined with the soluble multifilament strip. The method for producing a breathable fabric according to claim 1, wherein the fabric is woven into a raw fabric as a soluble multifilament yarn.   The breathable woven fabric manufacturing method according to any one of claims 1 to 3, wherein the raw fabric is a pile woven fabric, and a soluble multifilament is woven into a base fabric that holds the pile.   The method for producing a breathable fabric according to any one of claims 1 to 4, wherein the raw fabric is a pile fabric, and the pile is formed by insoluble multifilaments.   In each of claims 1 to 5, the raw fabric is composed of a woven structure in which the insoluble multifilament is exposed more than the soluble multifilament on at least one side of the front and back of the raw fabric. The method for producing a breathable fabric as described.   The method for producing a breathable fabric according to any one of claims 1 to 6, wherein a water-soluble multifilament is applied to the soluble multifilament and water is applied to the specific solvent.   Each of the above-mentioned claims 1 to 7, wherein the thermoplastic fibers are applied to the multifilaments constituting the raw fabric, and the thermoplastic fabric is heated to heat-set the thermoplastic fibers, and then the specific solvent is applied. A method for producing a breathable fabric according to claim.   After applying heat-fusible fibers to the multifilaments that make up the raw fabric, heat the original fabric and heat-bond the heat-fusible fibers together or heat-fusible fibers and other fibers. The method for producing a breathable fabric according to any one of claims 1 to 8, wherein the specific solvent is added.   The fineness (thickness) of the soluble multifilament is 0.16 to 0.7 times the fineness (thickness) of any insoluble multifilament constituting the texture of the raw fabric. The method for producing a breathable fabric according to any one of claims 1 to 9.   The mass (weight per unit area) of the soluble multifilament yarn that occupies the unit area of the original fabric fabric of the soluble multifilament yarn woven into the original fabric is determined based on the mass of the insoluble polyfilament yarn constituting the fabric of the original fabric. The method for producing a breathable woven fabric according to any one of claims 1 to 10, wherein the mass (weight per unit area) of the insoluble multifilament occupying a unit area of the anti-woven fabric is 0.1 to 2.0 times. .

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