JP2005281891A - Moquette pile fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a moquette pile fabric having excellent strength and abrasion resistance without requiring exceptional after finish on the surface by a polymer, and also having excellent resistance to degradation by moist heat by using a synthetic fiber while reducing dependence on fossil resources. <P>SOLUTION: The moquette pile fabric is obtained by using a polyester-based conjugate fiber as a part or the whole. The polyester-based conjugate fiber is composed of an aromatic polyester-based polymer and a polylactic acid-based polymer regulated so that the outer periphery may be covered with the aromatic polyester-based polymer in the cross section of the fiber, and has 1.1-7.7 dtex single fiber size. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a moquette pile fabric, and in particular, a moquette that can be suitably used for a vehicle seat, which uses a polyester-based composite fiber that has a low environmental load and is excellent in strength, wear resistance, and wet thermal decomposition resistance. The present invention relates to a pile fabric.

  2. Description of the Related Art Conventionally, various fabrics made of synthetic fibers have been used for vehicle seats such as automobiles and trains in addition to natural leather and artificial leather. Synthetic fiber fabrics used as vehicle seats have been particularly upgraded in recent years. In this respect, pile fabrics are widely accepted because they have napped surfaces and give a high-class feeling.

  Pile fabrics used for vehicle seats include tricot brushed, pile knitted fabrics, double raschel knitted fabrics, and moquette fabrics. Among these fabrics, moquette fabric fabrics, The pile density is large and a multicolor pattern can be easily obtained, and it is positioned as the most luxurious.

  Synthetic fibers such as nylon and polyester are used as the fiber material of the moquette pile fabric. In particular, polyester fibers have been widely used in view of their excellent dimensional stability, weather resistance, mechanical properties, durability, and recyclability.

  However, most of the conventional synthetic fibers, including polyester, are made from valuable fossil resources such as petroleum. Also, they are hardly decomposed in the natural environment, and disposal is a problem. Since petroleum-based synthetic fibers that have been frequently used in the past have such global environmental problems, development of synthetic fibers made of biodegradable polymers that can replace them has been actively conducted in recent years. Among them, fibers made of polylactic acid polymers (hereinafter sometimes referred to as polylactic acid fibers) depend on fossil resources in that the polylactic acid used to form the fibers is derived from plant resources such as corn. In addition, after being processed into various products and used, polylactic acid is eventually decomposed into harmless carbon dioxide and water in natural environments such as soil or in compost. Is particularly promising. Polylactic acid fiber has such very good biodegradability, but even if it is incinerated, the heat of combustion is smaller than that of petroleum synthetic fiber, so that the environmental impact is also small. is there.

  However, polylactic acid fibers have a problem that strength and abrasion resistance are inferior to conventional synthetic fibers such as nylon and polyester. Moreover, there is a problem that the heat resistance, particularly heat and moisture resistance is inferior, the degree of polymerization is greatly reduced by wet heat treatment such as dyeing, and this also causes a decrease in strength. For this reason, the use of the conventional polylactic acid fiber material is limited, and the present situation is that it has not yet been put into practical use in a wide range of fields such as automobile materials.

In response to the above-described problems, applications requiring strength are dealt with by increasing the fineness and the amount of use to cover the lack of strength, but this is problematic in terms of lightness and cost. In terms of improving heat resistance, a technique of post-processing using a silicone resin or the like on the surface of a polylactic acid fiber has been proposed (for example, see Patent Document 1). With this technique, it seems that the surface is provided with slipperiness and can cover the lack of wear resistance. However, as described above, post-processing is required.
JP 2002-38378 A

  The present invention uses a synthetic fiber that has excellent strength and wear resistance, and also has excellent resistance to moisture and pyrolysis without reducing the dependence on fossil resources and requiring special post-processing with a polymer on the surface. Is intended to provide a moquette pile.

The inventors of the present invention have reached the present invention as a result of intensive studies in order to solve the above problems. That is, the gist of the present invention is as follows.
1. It is a moquette pile fabric using polyester composite fiber partly or entirely, and the polyester composite fiber fineness is composed of an aromatic polyester polymer and a polylactic acid polymer, A moquette pile fabric characterized in that it is a polyester-based composite fiber having an outer periphery covered with an aromatic polyester-based polymer and a single yarn fineness of 1.1 to 7.7 dtex.
2. In the moquette pile fabric according to 1 above, the polylactic acid polymer is a polylactic acid polymer composed of L-lactic acid and / or D-lactic acid having a melting point of 120 ° C. or higher and a heat of fusion of 10 J / g or higher.
3. In the 1 or 2 moquette pile fabric, the aromatic polyester polymer is a copolymer polyester obtained by copolymerizing isophthale mainly composed of polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, Those selected from the group consisting of copolymers of polytrimethylene terephthalate and polybutylene terephthalate.

  According to the present invention, it is composed of a polylactic acid polymer that has a low dependence on fossil resources and has a low environmental impact during disposal, but it has high strength, wear resistance, and resistance to heat and moisture decomposition. It is possible to provide a moquette pile fabric which is excellent and excellent in texture. Therefore, the moquette pile fabric of the present invention can be suitably used for vehicle seats and the like as being friendly to the global environment.

  Hereinafter, the present invention will be described in detail.

  The moquette pile fabric of the present invention is formed using a polyester composite fiber, and the polyester composite fiber is a composite fiber composed of an aromatic polyester polymer and a polylactic acid polymer.

  Polylactic acid polymers include poly-L-lactic acid, poly-D-lactic acid, stereocomplex of poly-L-lactic acid and poly-D-lactic acid, and a copolymer of L-lactic acid and D-lactic acid (poly-L / D lactic acid) , A copolymer of L-lactic acid and hydroxycarboxylic acid, a copolymer of D-lactic acid and hydroxycarboxylic acid, a copolymer of L-lactic acid or D-lactic acid, aliphatic dicarboxylic acid and aliphatic diol, or Those blends can be used.

  Among them, a polylactic acid polymer in which L-lactic acid and D-lactic acid are used alone or in combination, and those having a melting point of 120 ° C. or higher and a heat of fusion of 10 J / g or higher are preferable.

  Poly L-lactic acid and poly D-lactic acid, which are homopolymers of polylactic acid polymers, have a melting point of about 180 ° C, but in the case of a copolymer of L-lactic acid and D-lactic acid (poly L / D lactic acid) If the proportion of any of the components is about 10 mol%, the melting point is about 130 ° C. Furthermore, when the proportion of any component is 18 mol% or more and less than 82 mol%, the melting point is less than 120 ° C. or does not show a clear melting point, the heat of fusion is less than 10 J / g, Since it shows strongly, even if it is made into a fiber, it is difficult to heat stretch and it becomes difficult to obtain a high-strength fiber, and heat resistance and wear resistance are lowered, which is not preferable.

  Accordingly, the polylactic acid-based polymer preferably has D-lactic acid and L-lactic acid as constituent components, and an optical purity indicating the ratio of one of the components is 82% or more, preferably 90% or more. Is more preferable. This optical purity can be controlled by, for example, the charging ratio of D-lactic acid or L-lactic acid when polymerizing polylactic acid using lactide as a raw material.

  In addition, a stereocomplex of poly (L-lactic acid) and poly (D-lactic acid) is particularly preferable because it has a high melting point of 200 to 230 ° C. and enables high-temperature dyeing and ironing after forming into a fabric. Specific examples of the hydroxycarboxylic acid used in the lactic acid polymer include glycolic acid, hydroxybutyric acid, hydroxyvaleric acid, hydroxycaproic acid, hydroxypentanoic acid, hydroxyheptanoic acid, hydroxyoctanoic acid and the like. Among these, hydroxycaproic acid or glycolic acid is advantageous from the viewpoint of cost and is preferably used.

  Specific examples of the aliphatic dicarboxylic acid and the aliphatic diol include sebacic acid, adipic acid, dodecanedioic acid, trimethylene glycol, 1,4-butanediol, 1,6-hexanediol, and the like.

  In the polylactic acid-based polymer, when other components are copolymerized with polylactic acid, the proportion of polylactic acid is preferably 80 mol% or more. When the proportion of polylactic acid is less than 80 mol%, the melting point of the polylactic acid polymer is lowered, and the above-mentioned preferable range of the melting point of 120 ° C. or higher may not be satisfied.

The molecular weight of the polylactic acid-based polymer is preferably 1 to 100 g / 10 min in melt flow rate measured at a temperature of 210 ° C. and a load of 2160 g according to the ASTM D-1238 method used as an index of molecular weight. 5 to 50 g / 10 min is more preferable. The melt flow rate With this range, it is possible to improve the strength, abrasion resistance and wet heat.

  In the polylactic acid-based polymer, various additives as necessary, for example, heat stabilizers, crystal nucleating agents, matting agents, pigments, light proofing agents, weathering agents, lubricants, antioxidants, antibacterial agents, fragrances Further, plasticizers, dyes, surfactants, flame retardants, surface modifiers, various inorganic and organic electrolytes, and other various additives can be contained within a range that does not impair the object of the present invention.

  Furthermore, the end group of the polylactic acid polymer is terminated with a carbodiimide compound, an epoxy compound, an oxazoline compound, an oxazine compound, an aziridine compound, etc. for the purpose of suppressing the hydrolysis of the polylactic acid polymer and improving the heat and heat resistance. It is also preferable to use it after blocking with a blocking agent.

  On the other hand, the aromatic polyester polymer may be any fiber-forming polyester polymer having an aromatic group in the polyester skeleton. Examples thereof include polyethylene terephthalate, copolymerized polyesters mainly composed of polyethylene terephthalate, and polybutylene. Copolymer polyesters mainly composed of terephthalate and polybutylene terephthalate, polybutylene terephthalates, and copolymer polyesters mainly composed of polybutylene terephthalate can be used. Examples of the copolymer component in the copolymer polyester mainly composed of polyethylene terephthalate include isophthalic acid, 5-sulfoisophthalic acid, 1,4-butanediol, and diethylene glycol. Examples of the copolymer component in the copolyester mainly composed of polytrimethylene terephthalate include isophthalic acid, 5-sulfoisophthalic acid, ethylene glycol, 1,4-butanediol, and diethylene glycol. Examples of the copolymer component in the copolyester mainly composed of polybutylene terephthalate include isophthalic acid, 5-sulfoisophthalic acid, ethylene glycol, and diethylene glycol.

  The melting point of the aromatic polyester polymer is preferably higher than the melting point of the polylactic acid polymer, and the difference is preferably in the range of 0 to 60 ° C. The specific melting point is 200 to 240 ° C. Is preferred. This is because if the difference between the melting points of the two is too large, spinning operability may be hindered during composite spinning, and thermal decomposition of the polylactic acid polymer may be caused. Preferred aromatic polyester polymers having a melting point of 200 to 240 ° C. include copolymerized polyesters obtained by copolymerizing isophthalic acid mainly composed of polyethylene terephthalate, polytrimethylene terephthalate (homopolyester), polybutylene terephthalate ( Homopolyester), and a copolymer of polyethylene terephthalate and polybutylene terephthalate. Among these, it is preferable to use one or two or more in combination.

  In addition, in the aromatic polyester polymer, as in the case of the polylactic acid polymer, various additives can be included as needed within a range not impairing the object of the present invention.

  The polyester composite fiber used in the present invention has an outer periphery covered with an aromatic polyester in the fiber cross section. That is, it has a cross-sectional shape arranged so that the aromatic polyester polymer surrounds the polylactic acid polymer as described above, and the outer peripheral surface of the composite fiber is covered with the aromatic polyester. become. Examples of such a fiber cross section include concentric or eccentric core-sheath type and sea-island type. In the case of core-sheath type, a polylactic acid polymer is provided on the island part in the case of sea-island type.

  In this way, by making a composite form having a cross-sectional shape whose outer periphery is covered with an aromatic polyester, the lack of strength and wear resistance, which is a problem of the polylactic acid polymer, is reduced. The composite fiber as a whole is excellent in strength and wear resistance. Similarly, the heat and moisture resistance is improved.

  The volume ratio of the polylactic acid polymer to the aromatic polyester polymer in the polyester composite fiber is such that the ratio of polylactic acid polymer / aromatic polyester polymer is in the range of 20/80 to 80/20. It is preferable to do so. When the volume ratio is within this range, the outer periphery can be covered with the aromatic polyester polymer in the fiber cross section, and the spinning operability can be kept good.

  The outer shape of the fiber cross section is not particularly limited, and may be not only a circular shape but also a polygonal shape such as an ellipse, a rhombus, a T shape, a well shape, and a triangle. Further, it may be a solid cross section or a hollow cross section.

  In the present invention, the polyester composite fiber may be used as either a long fiber or a short fiber, and is not particularly limited. The fineness of the polyester composite fiber is not particularly limited, but the single yarn fineness of the polyester composite fiber used for the pile portion of the moquette pile fabric is preferably 1.1 to 7.7 dtex. The smaller the single yarn fineness, the softer the texture is, but if it is less than 1.1 dtex, the pile is liable to fall down and tends not to be practically used. On the other hand, if the single yarn fineness exceeds 7.7 dtex, the texture becomes hard and the sense of quality tends to be impaired.

  The moquette pile fabric of the present invention is obtained by weaving with an ordinary moquette loom using the polyester-based composite fibers described above. When obtaining the moquette pile fabric of the present invention, only the above-mentioned polyester-based composite fibers may be used alone, or may be used by mixing with other fibers. You may use it by carrying out a spinning twist, a knit, and a knit. At this time, other fibers to be mixed include ordinary polylactic acid fibers, synthetic fibers such as polyester, nylon, acrylic and aramid, rayon fibers such as viscose, cupra and polynosic, and solvent-spun cellulose such as lyocell. Examples include fiber, silk, cotton, hemp, wool, and other animal hair fibers. Therefore, the moquette pile fabric of the present invention is constituted by using the above-mentioned polyester-based composite fiber as a part thereof, but in view of the object of the present invention, it occupies the entire fibers constituting the moquette pile fabric. As a ratio of the said polyester type composite fiber, 50 mass% or more is preferable, 80% or more is more preferable, and 100% is especially preferable.

  The pile height, pile density, and the like in the moquette pile fabric of the present invention are not particularly limited, and may be in a range commonly used in conventional moquette pile fabrics.

Hereinafter, the present invention will be described in detail by way of examples. In addition, the measuring method and evaluation method of various characteristics described in the Examples are as follows.
1) Melt flow rate value of polylactic acid polymer (g / 10 min):
The measurement was performed according to the method described in ASTM D-1238. The measurement conditions were a temperature of 210 ° C. and a load of 2160 g.
2) Relative viscosity of aromatic polyester polymer:
The measurement was performed under the conditions of a sample concentration of 0.5 g / 100 ml and a temperature of 20 ° C. using an equal mass mixture of phenol and ethane tetrachloride as a solvent.
3) Melting point (℃), heat of fusion (J / g)]
A differential scanning calorimeter DSC-2 manufactured by Perkin Elmer was used, and the measurement was performed under the condition of a heating rate of 20 ° C./min.
4) Strength of fiber (short fiber):
The tensile strength was measured by a standard test of tensile strength described in JIS L1015 8.7.1 (JIS 1999 version).
5) Moisture and thermal decomposition resistance:
The fiber is subjected to a wet heat treatment in which the fiber is held for 1000 hours under a moist heat condition of a temperature of 50 ° C. and a relative humidity of 95%, and the strength of the fiber before and after the wet heat treatment is measured. Was used as an index of resistance to moist heat decomposition. The fiber strength was measured according to the above 4).

Strength retention (%) = (strength after treatment / strength before treatment) × 100
6) Abrasion resistance:
Using the short fibers obtained in the examples, a ring spinning machine was used to obtain a 10th (cotton count) spun yarn (single yarn). It was measured by the wear strength A method described in JIS L1018 8.18.1 (JIS 1999 version).
7) Texture:
For the moquette pile fabrics obtained in the examples, the texture of the pile surface was evaluated in five stages by sensory evaluation. The most preferred texture was soft and the fifth grade was rated, and the unfavorable texture was classified as first grade. Grade 3 or higher was accepted.
8) Hair fallability:
Place a 10cm square moquette pile fabric in the center of an iron cylinder load with a diameter of 4cm and a weight of 500g, leave it in a hot air dryer at 80 ° C for 2 hours, remove it from the dryer, remove the load, Leave for 30 minutes and then observe the raised state of the part where the load is applied and the part where the load is not applied. The ones that have been classified as 1st grade.

Example 1
The polylactic acid polymer is a poly L / D lactic acid having a melting point of 170 ° C., a heat of fusion of 38 J / g, an optical purity of 98.5% L, and a melt flow rate value (hereinafter referred to as MFR) of 23 g / 10 min. A chip (manufactured by Cargill Dow) was prepared. As an aromatic polyester polymer, a copolymer polyester chip having a relative viscosity of 1.37 and a melting point of 217 ° C. prepared by copolymerizing polyethylene terephthalate with 15 mol% of isophthalic acid was prepared. After drying both chips under reduced pressure by a conventional method, using a melt spinning apparatus for obtaining a normal round cross-section, concentric core-sheath composite fiber, the polylactic acid polymer is the core and the aromatic polyester polymer is the sheath And the core / sheath volume ratio was 50/50, and spinning was performed at a spinning temperature of 240 ° C. After the spun yarn was cooled, it was drawn at a take-up speed of 1000 m / min to obtain an undrawn yarn (polyester composite fiber). The resulting unstretched yarn is converged into a 330,000 dtex tow, stretched at a stretch ratio of 3.2 times, heat treated with a 140 ° C heat drum, and then crimped using an indentation type crimper. After that, it was cut into a length of 74 mm to obtain a short fiber having a fineness of 4.4 dtex. This short fiber was spun by a 3 吋 spinning device, and twisted in the Z direction with a number of twists of 14.3 times / 2.54 cm to obtain a 20th (cotton count) spun yarn. Next, two spun yarn yarn-dyed cheese dyes were used to obtain twin yarns twisted in the S direction at 11.5 times / inch. Then, using this yarn for pile yarn and ground texture, weaving with a moquette loom according to the moquette standard with a cocoon density of 23 wings / 2.54 cm, 48 wefts driven / 2.54 cm, and a pile height of 2.5 mm. The moquette pile fabric of the present invention was obtained through the shirring and backing processes.

Examples 2-3
A moquette pile fabric of the present invention was obtained in the same manner as in Example 1 except that the volume ratio of the core / sheath was changed as shown in Table 1 below.

Example 4
The moquette pile fabric of the present invention is the same as in Example 1 except that polytrimethylene terephthalate (relative viscosity 1.44, melting point 215 ° C.) is used as the aromatic polyester polymer instead of the copolymer polyester. Got.

Example 5
The moquette pile fabric of the present invention was obtained in the same manner as in Example 1 except that polybutylene terephthalate (relative viscosity 1.46, melting point 218 ° C.) was used as the aromatic polyester polymer in place of the copolyester. Obtained.

Comparative Example 1
A comparative moquette pile fabric was obtained in the same manner as in Example 1 except that not a polyester-based composite fiber but a fiber composed only of a polylactic acid-based polymer was spun.

Comparative Example 2
A comparative moquette pile fabric was obtained in the same manner as in Example 1 except that the fineness of the short fibers was adjusted to 0.7 dtex by adjusting the amount of polymer discharged during spinning.

Comparative Example 3
A comparative moquette pile fabric was obtained in the same manner as in Example 1 except that the fineness of the short fibers was adjusted to 11 dtex by adjusting the discharge amount of the polymer during spinning.

Reference Example A moquette pile fabric was obtained in the same manner as in Example 1 except that not a polyester-based composite fiber but a fiber composed only of an aromatic polyester-based polymer was spun.

  The results of measuring and evaluating the properties of the fibers and moquette pile fabrics obtained in Examples 1 to 5, Comparative Examples 1 to 3 and Reference Example are shown in Table 1 below.

  As is apparent from the results in Table 1, the moquette pile fabrics of Examples 1 to 5 have a low dependence on petroleum-based raw materials, and are composed of polyester-based composite fibers that are excellent in strength, moist heat resistance, and abrasion resistance. In terms of texture and hair fall, it was inferior to that of only a polyester fiber derived from petroleum-based raw materials (reference example). On the other hand, the thing of the comparative example 1 is comprised with the fiber which consists only of a polylactic acid-type polymer, and the intensity | strength and abrasion resistance of a fiber are low, and after wet heat processing, the fiber becomes tattered and the measurement of strength is possible. It was not possible, and it was extremely inferior in heat-and-moisture resistance. Moreover, the thing of the comparative example 2 becomes a thing which is easy to fall down because the fineness of a pile is too small, and the thing of the comparative example 3 becomes a bad thing because the fineness of a pile is too small, and all are lacking in practical value. It was a thing.

Claims (3)

It is a moquette pile fabric using polyester composite fiber partly or entirely, and the polyester composite fiber fineness is composed of an aromatic polyester polymer and a polylactic acid polymer, A moquette pile fabric characterized in that it is a polyester-based composite fiber having an outer periphery covered with an aromatic polyester-based polymer and a single yarn fineness of 1.1 to 7.7 dtex. 2. The moquette pile according to claim 1, wherein the polylactic acid polymer is a polylactic acid polymer comprising L-lactic acid and / or D-lactic acid having a melting point of 120 ° C. or higher and a heat of fusion of 10 J / g or higher. Fabric. The aromatic polyester-based polymer is a copolymer polyester obtained by copolymerizing polyethylene terephthalate as a main component with isophthalate, polytrimethylene terephthalate, polybutylene terephthalate, and a copolymer of polytrimethylene terephthalate and polybutylene terephthalate. The moquette pile fabric according to claim 1 or 2, wherein the fabric is selected from.