JP2008238461A - Coating fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fabric having both design and air permeability and waterproof and water-repellent properties, and suitable for clothing applications. <P>SOLUTION: A coating fabric is characterized in that a highly foamed layer is provided in a pattern-like shape on one face of the fabric, and in addition, a protective layer is laminated and stuck on the surface of the highly foamed layer. In the present invention, they are preferable embodiments that the fabric is a waterproof and water-repellent woven fabric, the waterproof and water-repellent fabric is prepared from a polyester filament yarn, and a cover factor is preferably 1,500-2,500. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coating fabric suitable for casual use, sports use, outdoor use and the like.

  Conventionally, a sheet or fabric having decorativeness or design has been proposed by forming a resin layer having a three-dimensional effect in a pattern.

  As a means for imparting such characteristics, thermally expandable microcapsules are used. Thermally expandable microcapsules are excellent in terms of processing stability and safety.

  For example, in Patent Document 1, a printed sheet is adhered on a backing material with a thermoplastic resin foam layer sandwiched, and the printed sheet forms a raised printed layer of cured resin ink on the lower surface of a plastic base sheet. The foamed resin layer is synchronized with the raised printing, the part with the raised printed layer is the part where foaming is suppressed, the part without the foamed part is highly foamed, and the surface is uneven due to the strength of foaming. A decorative sheet for interior building materials is disclosed.

Patent Document 2 discloses a decorative sheet composed of an expanded layer including a thermoplastic resin and thermally expandable microcapsules, a metal layer, and a primer layer. In this sheet, the thermally expandable microcapsules are distributed in a pattern to make the expanded layer rich in unevenness. That is, by heating and foaming the heat-expandable microcapsules, a feeling of unevenness appears between the region having the microcapsules and the region not having the microcapsules, and a sheet having a metallic three-dimensional effect can be obtained.
Japanese Patent Laid-Open No. 5-200927 JP 2000-33660 A

  However, none of the above techniques can be applied to apparel applications, and furthermore, characteristics relating to wearing comfort such as breathability and waterproofness cannot be realized.

  This invention is made | formed in view of such the present condition, and makes it a subject to provide the cloth suitable for the clothing use which has air permeability, water repellency, etc. while having designability.

  As a result of diligent research to solve the above problems, the present inventor is rich in unevenness if a high foam layer is provided in a pattern on a fabric and a protective layer is laminated so as to cover the high foam layer. It has been found that a coating fabric suitable for apparel use, which has design properties and at the same time has air permeability, etc., has reached the present invention.

  That is, the gist of the present invention is a coated fabric in which a highly foamed layer is provided in a pattern on one side of the fabric, and a protective layer is laminated and bonded to the surface of the highly foamed layer. . In the present invention, it is preferable that the cloth is a water-repellent woven fabric, and that the water-repellent woven fabric is made of a polyester filament yarn and has a cover factor of 1500 to 2500.

  The coated fabric of the present invention is excellent in design because the highly foamed layer is provided in a pattern. And since the protective layer is laminated | stacked in the form which covers the highly foamed layer, the damage of the highly foamed layer by repeated use can be suppressed. Moreover, since the coating fabric of this invention coats only a part of fabric surface, it is excellent in air permeability.

  In the present invention, it is preferable that the fabric used as the coating base fabric is a water-repellent woven fabric. Furthermore, if a specific fabric is employed as the water-repellent fabric, the waterproofness of the coated fabric can be further improved.

  Hereinafter, the present invention will be described in detail.

  As the fabric in the present invention, generally usable fabrics such as woven fabric, knitted fabric and non-woven fabric can be adopted. As the fibers constituting the fabric, any fiber can be used, for example, polyamide-based synthetic fibers such as nylon 6 and nylon 66, polyester-based synthetic fibers such as polyethylene terephthalate, polyacrylonitrile-based synthetic fibers, and polyvinyl alcohol-based fibers. In addition to synthetic fibers, semi-synthetic fibers such as triacetate and mixed fibers such as nylon 6 / cotton and polyethylene terephthalate / cotton can be used.

  In the coated fabric of the present invention, a highly foamed layer is provided in a pattern on one side of the fabric. The highly foamed layer is basically formed of synthetic resin and thermally expandable microcapsules. The synthetic resin is not particularly limited as long as it can realize a texture suitable for apparel use. However, a resin having a resin film forming ability of 100 to 100% modulus of 0.5 to 20 MPa, preferably 1 to 10 MPa is adopted. Is preferred. Specifically, polyurethane, polyester, acrylic, polyamide, polyethylene-vinyl acetate, polyethylene, polypropylene, or the like may be used alone or in combination. Among these, it is particularly preferable to use polyurethane alone.

  On the other hand, any conventionally known heat-expandable microcapsules can be used. Specifically, the particle diameter is about 5 to 50 μm, and the outer shell is formed of a thermoplastic resin made of a polymer such as vinylidene chloride and acrylonitrile, and isobutane, isopentane, n-pentane is formed inside the outer shell. Thermally expandable microcapsules in which low boiling point hydrocarbons such as are encapsulated can be used. Such thermally expandable microcapsules expand about 20 to 70 times in volume under heating at about 80 to 200 ° C.

  And as a content rate of the thermally expansible microcapsule in a highly foamed layer, 1-40 mass% is preferable, and 3-20 mass% is especially preferable. When the content ratio of the heat-expandable microcapsule is less than 1% by mass, the three-dimensional effect of the highly foamed layer tends to be poor. On the other hand, when the content exceeds 40% by mass, it becomes difficult to hold the heat-expandable microcapsule by the synthetic resin. In addition, the highly foamed layer tends to be brittle and durability tends to decrease, which is not preferable.

  In addition, from the viewpoint of improving the design properties of the highly foamed layer, cosmetics such as fillers, pigments, and pearl pigments are used in the highly foamed layer, respectively, and isocyanate resins, epoxy resins, and the like from the viewpoint of improving the strength of the highly foamed layer. From the viewpoint of improving the functionality of the highly foamed layer, the crosslinking agent may contain additives such as a deodorant, an antibacterial agent and a flameproofing agent.

  In the present invention, a highly foamed layer is provided in a pattern on one side of the fabric. This “provided in a pattern” means that the highly foamed layer is laminated so as to exhibit a certain pattern as a whole. The pattern may be arbitrary. Specifically, uniform patterns such as dots, grids, lines, diagonal lines, checkered patterns, pyramids, turtle shell patterns, specific trademark patterns, or random patterns. Can be adopted.

  The area ratio of the highly foamed layer in the fabric surface is preferably in the range of 2 to 70%, more preferably in the range of 5 to 50%. When the area ratio is less than 2%, the coated fabric tends to hardly exhibit the design characteristics even when a fine line pattern is adopted as the pattern. On the other hand, when the area ratio exceeds 70%, the breathability of the coated fabric is lowered and the texture Tends to harden, which is not preferable.

  The thickness of the highly foamed layer is preferably in the range of 5 to 100 μm, more preferably in the range of 10 to 80 μm, and particularly preferably in the range of 20 to 50 μm. When the thickness is less than 5 μm, the unevenness of the coated fabric is reduced and the design property tends to be poor. On the other hand, when the thickness exceeds 100 μm, not only the mass of the coated fabric tends to increase, but also the texture is cured. The high foam layer tends to easily fall off due to wear or washing, which is not preferable.

  In the coated fabric of the present invention, a protective layer is laminated and bonded to the surface of the highly foamed layer. However, the protective layer is not provided on the entire surface of the fabric, but only on the pattern-like highly foamed layer. That is, the protective layer is formed in synchronization with the pattern of the highly foamed layer. The protective layer protects the high foam layer from external force by covering the high foam layer, so the pattern of the protective layer is the same as the high foam layer and the size is the same or slightly larger than the high foam layer. .

  Moreover, as a protective layer, it is preferable to form a layer by adopting the same synthetic resin as that basically constituting the highly foamed layer. Therefore, it is preferable to use polyurethane alone in the protective layer. In the protective layer, if necessary, cosmetic agents such as fillers, pigments and pearl pigments, crosslinking agents such as isocyanate resins and epoxy resins, or lubricants, antiwear agents, deodorant / antibacterial agents, flameproofing agents. Additives such as these may be included as appropriate.

  As thickness of a protective layer, the range of 1-50 micrometers is preferable, The range of 3-30 micrometers is more preferable, The range of 5-20 micrometers is especially preferable. If the thickness is less than 1 μm, it tends to be difficult to protect the highly foamed layer as the protective layer, while if it exceeds 50 μm, the texture of the coated fabric tends to be hard, which is not preferable.

  Since the highly foamed layer is provided in a pattern shape as described above, the coated fabric of the present invention is excellent in design. Therefore, the design property is not exhibited only by providing a simple synthetic resin layer that is not a highly foamed layer in a pattern, and the design property is not exhibited even if the highly foamed layer is provided on one entire surface of the fabric. And since the protective layer is laminated | stacked in the form which covers the highly foamed layer, the damage of the highly foamed layer by repeated use can be suppressed. Moreover, since the coating fabric of this invention coats only a part of fabric surface, it is excellent in air permeability.

  The coated fabric of the present invention is suitable for casual uses such as blousons and coats, sports uses such as ski wear and snowboard wear, and outdoor uses such as mountaineering clothing and cycling clothing. It is preferable to have a function (water repellency) to prevent rainwater from entering.

  Accordingly, in the present invention, it is preferable to employ a water-repellent woven fabric as the fabric used as the coating base fabric. The water-repellent fabric refers to a fabric having waterproofness and water repellency. Specifically, the waterproof property is a water resistance of 2 kpa or more according to JIS L1092 (low water pressure method) as a waterproof property, and JIS L1092 ( This refers to a woven fabric having a water repellency of 4th grade or higher by a spray method.

  Further, when it is desired to further improve waterproofness, for example, a polyester filament yarn is used as a fabric used as a coating base fabric, and the cover factor is preferably 1500 to 2500, and more preferably 1800 to 2300. A woven fabric may be employed.

  Here, the cover factor is a coefficient representing the density of the fabric structure determined by the thickness of the yarn constituting the fabric and the fabric density. If the cover factor is less than 1500, the gap between the yarns tends to increase, and even if the crushing process described later is performed, it tends to be difficult to realize good waterproof properties. No matter how the structure and the fabric structure are devised, the texture of the coated fabric tends to become hard and the air permeability tends to decrease, which is not preferable.

Next, a method for producing the coated fabric of the present invention will be described.
First, a fabric used as a coating base fabric is prepared. Although it does not specifically limit as a fabric, A woven / knitted fabric is preferable. Moreover, as a thread | yarn which comprises a fabric, the filament thread | yarn which consists of a polyamide-type or a polyester-type synthetic fiber is preferable. In this case, the single yarn fineness is preferably in the range of 0.1 to 3.0 dtex, and the total fineness is preferably in the range of 30 to 170 dtex. When the single yarn fineness is less than 0.1 dtex or the total fineness is less than 30 dtex, the strength and fastness of the coated fabric tend to decrease. On the other hand, when the single yarn fineness exceeds 3.0 dtex or the total fineness exceeds 170 dtex. It is difficult to obtain a dense structure, and as a result, the water repellency tends to decrease, which is not preferable.

  When a woven fabric is employed as the fabric, it is preferable to employ a water-repellent fabric as described above, but this water-repellent fabric can be obtained by subjecting the fabric to a water-repellent treatment. As the water repellent used in the water repellent processing, known ones such as paraffin water repellent, polysiloxane water repellent, fluorine water repellent can be used. As a treatment method, a general padding method, spray method, or the like can be adopted. When particularly good waterproof properties are required, a fluorine-based water repellent is used, for example, padding (squeezing) with an aqueous dispersion containing 8% AG-7000 (Asahi Glass Co., Ltd., fluorine-based water repellent emulsion). And then heat treatment at 130 to 180 ° C. for 30 to 300 seconds. Moreover, when durability is also required, it is preferable to use together crosslinking agents, such as a melamine resin, an isocyanate resin, and a glyoxal resin.

  Moreover, when employ | adopting a knitted fabric as a fabric, dense structure knitted fabrics, such as a high gauge tricot and a high gauge tricot satin, are preferable.

  The fabric used as the coating base fabric preferably has a dense structure as described above. However, in order to further promote the dense structure of the fabric, the fabric may be crushed. The crushing process is usually performed using a calendar processing machine or the like, and the processing conditions depend on the form of the fabric, but the temperature is preferably 130 to 190 ° C. and the pressure is preferably 0.1 to 10 Mpa.

  After preparing the fabric, a synthetic resin layer capable of forming a highly foamed layer and a protective layer is sequentially provided in a pattern on the fabric. As an example, the synthetic resin layer concerning each layer can be sequentially formed by drying after the coating means using a gravure roll or a screen mesh. At this time, it is preferable to appropriately adjust the viscosity of the synthetic resin solution applied to both layers from the viewpoint of increasing the accuracy of the pattern formed by the highly foamed layer and the degree of synchronization formed by both layers. That is, the synthetic resin solution applied to the highly foamed layer can reflect a highly accurate pattern on the fabric by setting it to a relatively high viscosity, while the synthetic resin solution applied to the protective layer is set to a relatively low viscosity. Thereby, the synthetic resin layer concerning a highly foamed layer can be fully coat | covered. Moreover, although the reason is not certain, when the coating applied to both layers is performed quickly and continuously, the accuracy of the pattern formed by the highly foamed layer tends to increase.

  After forming each synthetic resin layer, it heats at 80-200 degreeC for 10 to 300 seconds using a dryer or a heat setter machine. Thereby, while being able to foam the thermally expansible microcapsule contained in the synthetic resin layer concerning a highly foamed layer, the synthetic resin layer concerning a protective layer can also be bridge | crosslinked. The coated fabric of the present invention can be obtained as described above.

EXAMPLES Hereinafter, although an Example demonstrates this invention further more concretely, the measurement and evaluation of the performance of the coating fabric in an Example, a comparative example, and a reference example were performed with the following method.
(1) Water pressure resistance The water pressure was evaluated by the low water pressure method described in JIS L1092.
(2) Water repellency evaluated by the spray method described in JIS L1092.
(3) Designability;
The three-dimensional effect and visibility were visually evaluated in the following four stages.
◎ ・ ・ ・ Quality and solidness / visibility are good ○ ・ ・ ・ Quality and stereoscopic effect / visibility are almost good △ ・ ・ ・ Quality and stereoscopic effect / visibility are slightly poor × ・ ・ ・ Quality and stereoscopic effect / visibility Visibility is poor (4) Washing durability The above-mentioned (1) to (3) were evaluated for the coated fabric after 20 washings (JIS L0217 103 method).
(5) Air permeability It evaluated by the fragile method of JIS L-1096 description.
(6) Texture In the handling (hand), the following four levels were evaluated.
◎ ・ ・ ・ Very soft ○ ・ ・ ・ Slightly soft △ ・ ・ ・ Slightly hard × ・ ・ ・ Hard

Example 1
Using a single yarn of nylon multifilament 78dtex68f as a warp and a double yarn as a weft, weaving a 2/2 twill fabric with a warp density of 150 / 2.54 cm and a weft density of 70 / 2.54 cm, scouring and dyeing (Nippon Kayaku Co., Ltd., “Kayanol Cyanine Green G (trade name)” was used at 1% omf) to obtain a fabric as a coating base fabric.

  Then, using a screen mesh made of polyester 17 dtex monofilament designed so that a 5 mm square checkered pattern can be applied to the surface of the fabric, a polyurethane resin solution (solid content concentration 33%, The viscosity was 6000 mPa · s / 25 ° C.). Thereafter, it was dried at 100 ° C. for 2 minutes to form a synthetic resin layer having a checkered pattern having a thickness of about 30 μm and a size of 5 mm square. In the synthetic resin layer, the thermally expandable microcapsules were not yet expanded.

<Prescription 1>
80 parts by mass of Superflex E-4000 (Daiichi Kogyo Seiyaku Co., Ltd., non-reactive water-soluble polyurethane resin having a resin solid content of 40%)
Microsphere H750 2 parts by mass (manufactured by Dainichi Seika Kogyo Co., Ltd., thermally expandable microcapsules having a particle diameter of about 25 μm and an appropriate foaming temperature range of 150 to 170 ° C.)
4 parts by mass of M2005A (Daiichi Kogyo Seiyaku Co., Ltd., thickener)
10 parts by weight of water 10 parts by weight of isopropyl alcohol

  Next, using the screen mesh, the synthetic resin layer having a checkerboard pattern is completely covered with a polyurethane resin solution (solid content concentration 14%, viscosity 2000 mPa · s / 25 ° C.) having the composition shown in Formula 2 below. Coated. Then, it is dried at 100 ° C. for 2 minutes, and a synthetic resin layer (synthetic resin layer for the protective layer) having a checkered pattern having a thickness of about 10 μm and a slight variation, but a size of 5.0 to 5.5 mm square. Formed.

<Prescription 2>
50 parts by mass of ELASTRON TP-20 (Daiichi Kogyo Seiyaku Co., Ltd., heat-reactive water-soluble polyurethane resin with a resin solid content of 25%)
Elastron CAT? 21 5 parts by mass (Daiichi Kogyo Seiyaku Co., Ltd., elastron resin catalyst)
50 parts by weight of water And heated at 170 ° C. for 1 minute to expand the thermally expandable microcapsules in the synthetic resin layer applied to the highly foamed layer and to crosslink the synthetic resin layer applied to the protective layer. The coated fabric of the present invention was obtained as described above.

(Example 2)
Using a single yarn of nylon multifilament 78dtex68f as the warp, we first weave a plain fabric with a warp density of 120 / 2.54 cm and a weft density of 95 / 2.54 cm, and scouring and dyeing (Nippon Kayaku Co., Ltd.) “Kayanol Blue NR (trade name)” was used at 1% omf). Then, it was padded with an aqueous dispersion containing 8% Asahi Guard AG-7000 (manufactured by Asahi Glass Co., Ltd.) as an emulsion type fluorine-based water repellent, dried, and heat treated at 170 ° C. for 1 minute. Then, the cloth which is a coating base fabric was obtained by crushing the cloth under the conditions of a temperature of 150 ° C. and a pressure of 300 kpa using a calendering machine.

  Next, using this fabric, coating (however, coating on the crushing surface), drying and heating were performed in the same manner as in Example 1 to obtain the coated fabric of the present invention.

(Example 3)
Weaving a plain fabric (cover factor: 2133) with a warp density of 125 / 2.54cm and a weft density of 95 / 2.54cm using polyester ultra multifilament 94dtex170f for warp and weaving, dyeing (Mitsui BASF dye stock) “Miketon Polyester Navy Blue 3GS (trade name)” manufactured by company was used with 2% omf). Then, padding is performed with an aqueous dispersion containing 8% Asahi Guard AG-7000 (Asahi Glass Co., Ltd.) as an emulsion type fluorine-based water repellent, and after drying, heat treated at 170 ° C. for 1 minute. Thus, a fabric as a coating base fabric was obtained.

  Next, this fabric was used for coating, drying and heating in the same manner as in Example 1 to obtain a coated fabric of the present invention.

(Comparative Example 1)
A coated fabric was obtained in the same manner as in Example 1 except that the microsphere H750 in the formulation 1 was omitted.

(Comparative Example 2)
In the coating of the synthetic resin solution on the protective layer, instead of coating the resin solution in a checkered pattern using a screen mesh, the resin solution is coated on the entire surface of the fabric using a knife coater (coating amount 70 g / A coated fabric was obtained in the same manner as in Example 2 except for m ² ).

(Reference Example 1)
A coated fabric of the present invention was obtained in the same manner as in Example 3 except that the warp density was 75 / 2.54 cm and the weft density was 70 / 2.54 cm (cover factor: 1406).

(Reference Example 2)
A coated fabric of the present invention was obtained in the same manner as in Example 3 except that the warp density was 145 / 2.54 cm and the weft density was 125 / 2.54 cm (cover factor: 2618).

  With respect to the above coated fabric, performance was measured and evaluated. The results are shown in Table 1 below.

  As is clear from Table 1, the coated fabrics according to Examples 1 to 3 were excellent in design and breathability. On the other hand, since the coating fabric according to Comparative Example 1 could not form a highly foamed layer, the result was inferior in design. And since the protective layer was formed in the whole one side of the fabric, the coating fabric concerning the comparative example 2 was inferior in design property, and became a state by which air permeability is hardly recognized.

In addition, the coated fabric according to Reference Example 1 was inferior in waterproofness because the fabric used as the coating base fabric was not dense. And since the fabric used as a coating base fabric was too dense, the coating fabric concerning Reference Example 2 resulted in inferior air permeability and texture.

Claims (3)

  A coated fabric, wherein a highly foamed layer is provided in a pattern on one side of the fabric, and a protective layer is laminated and bonded to the surface of the highly foamed layer.   The coated fabric according to claim 1, wherein the fabric is a water-repellent woven fabric. The coated fabric according to claim 2, wherein the water-repellent fabric is made of polyester filament yarn and has a cover factor of 1500 to 2500.