JP2022020966A - Polyester woven knit and uniform using the same, as well as, manufacturing method of the polyester woven knit - Google Patents

Abstract

To provide a polyester woven knit that can express a rich color variation by using a spun-dyed, is less in lowering of friction fastness even by applying an alkali reduction process and can manufacture a uniform having a soft and excellent wearing feeling, and its manufacturing method.SOLUTION: A polyester woven knit obtained by knitting or weaving by using an original yarn made of a liquid coloration fiber or a polyester yarn obtained by combining the original yarn of one color or a plurality of colors in a part or an entirety, in which sublimation fastness in a state of the polyester yarn is evaluated as 4th to 5th grade or higher, an alkali reduction process is applied after knitting or weaving, and a value of brightness (L*) in a color system L*a*b* is an intermediate color or a deep color of 60 or smaller. Evaluations due to dry friction and wet friction due to a friction tester II type (Gakushin type) method are 4th grade or higher in both.SELECTED DRAWING: None

Description

The present invention relates to a polyester woven knit, a uniform using the same, and a method for manufacturing the polyester woven knit. In particular, the present invention relates to a polyester woven or knitted fabric having good contamination fastness in severe industrial washing and capable of forming a flexible and comfortable uniform.

Laundry of work clothes and uniforms is often handled by industrial laundry by a laundry company. In particular, in order to remove strong stains and special stains, washing under strict conditions is required.

Also, as a recent trend, many fashionable work clothes and uniforms are increasing. This tendency is spreading not only to office uniforms but also to medical uniforms and long-term care uniforms (hereinafter collectively referred to as "medical uniforms"). In particular, medical uniforms are not limited to conventional white goods, but uniforms with the same shape and abundant color variations in different colors, and uniforms that combine different colors in parts such as sleeves, collars, and torso are used in a wide variety of ways. There are many.

Polyester fiber woven and knitted fabrics are commonly used for fashionable and color-variable uniforms. Polyester fiber woven and knitted fabrics have excellent physical characteristics and can be dyed in bright colors, making them suitable for active and fashionable uniforms. However, even when a woven or knitted polyester fiber having excellent physical characteristics is used, a problem of color transfer due to washing may occur in severe industrial washing. In general, color transfer is likely to occur when dark uniforms and white or light uniforms are washed in the same bath.

Therefore, in industrial washing, it is a normal operation to sort by color, concentration, etc. before washing. However, in medical uniforms, it is necessary to consider special stains attached during treatment, surgery, long-term care, etc., or contamination by some pathogenic factor, and for hygienic reasons, it is suitable for sorting work at industrial laundry sites. Is said to be risky.

Therefore, in the industrial washing of medical uniforms, a specialized washing company often puts the medical uniforms delivered from a medical institution or a nursing care facility into an industrial washing machine for washing without sorting them. In that case, uniforms of various colors and uniforms having greatly different densities are mixed in the washing bath, and the problem of color transfer due to washing frequently occurs due to the severe conditions of industrial washing.

Generally, polyester fibers are dyed after being woven and knitted. In addition, in medical uniforms with abundant color variations and small production lots, dyeing may be performed after sewing to the uniforms. Disperse dyes are used for dyeing in woven and knitted products or dyeing in sewn products, but there is a certain limit to preparing dyes with excellent heat resistance and sublimation resistance in consideration of color transfer due to industrial washing. Yes, it is difficult to cover the abundant color variations of medical uniforms.

Therefore, as a polyester fiber having higher heat resistance and sublimation resistance than the dyed polyester fiber, there is a stock solution colored fiber (hereinafter, also referred to as “undiluted fiber”). In the case of polyester fiber, this original fiber is a fiber spun after coloring a molten polymer by adding a coloring material such as a pigment. As the pigment used, a pigment having excellent heat resistance and sublimation resistance is used, so that the dyeing fastness is excellent. If this uncoated fiber is used for medical uniforms, it is possible to prevent color transfer due to severe industrial washing.

Therefore, the present inventors have been able to express abundant color variations by using the uncoated fiber in the following Patent Document 1, and have excellent heat resistance and sublimation resistance, and there is little color transfer due to industrial washing. Provided are polyester yarns capable of producing uniforms, woven and knitted fabrics using the same, and uniforms using the same.

Utility Model Registration No. 3222833

Here, medical uniforms are required to be flexible and comfortable to wear as well as to cope with active work. Generally, polyester fibers having excellent physical properties are subjected to an alkali weight loss process in which the ester bonds on the fiber surface are hydrolyzed by an alkali. By this alkaline weight loss processing, the fibers of the polyester woven or knitted fabric can be made thinner to reduce the contact pressure between the intersecting yarns, the texture can be made softer, and the drapeability can be improved.

Therefore, when the polyester woven or knitted fabric according to Patent Document 1 is subjected to an alkali weight reduction process, the polyester woven or knitted fabric is originally made of a raw fiber having high fastness, so that the fastness is not lowered in most cases. However, for medium-colored or dark-colored woven and knitted fabrics, the friction fastness is reduced. It was found that this decrease in friction fastness was caused by the alkali weight reduction process, but there was a problem that it could not be improved even by performing a cleaning operation.

Therefore, the present invention is flexible because it can express abundant color variations by using the raw fiber in response to the above, and the friction fastness does not decrease even if the alkali weight reduction process is applied. It is an object of the present invention to provide a polyester woven knitted fabric capable of producing a comfortable uniform, a uniform using the polyester woven knitted fabric, and a method for producing the polyester woven knitted fabric.

In order to solve the above problems, the present inventors have studied the cause of the decrease in the friction fastness of the original fiber due to the alkali weight reduction processing, and examined the cleaning process after the alkali weight reduction processing to achieve the above purpose. We found that we could achieve this and reached the completion of the present invention.

That is, according to the description of claim 1, the polyester woven knitted fabric according to the present invention is described.
It is a woven or knitted fabric made by weaving or knitting a raw yarn made of undiluted colored fibers or a polyester yarn obtained by combining one color or a plurality of colors of raw cotton in part or in whole.
The sublimation fastness performance in the state of the polyester yarn was evaluated as 4-5 grade or higher in the judgment using JIS L 0805 (gray scale for contamination).
Alkaline weight loss processing is applied after weaving or knitting, and the whole or part of the woven or knitted product is a medium or dark color with a lightness (L ^* ) value of 60 or less in the L ^* a ^* b ^* color system. There,
The evaluation of dry friction and wet friction by the friction tester type II (Gakushin type) method specified in JIS L 0849 (Dyeing fastness test method for friction) is characterized by being grade 4 or higher.

Further, the present invention is the polyester woven or knitted fabric according to claim 1, according to claim 2.
For the sublimation fastness performance, a sweat tester specified in JIS L 0854 (Dyeing fastness test method for sublimation) was used, and a polyester white cloth was attached to the raw yarn or raw cotton and a pressure of about 12.5 kPa was applied. It is characterized by performing a sublimation test for 10 minutes in a dry heat of 180 ° C. ± 2 ° C. in this state.

Further, the present invention is the polyester woven or knitted fabric according to claim 1 or 2, according to claim 3.
The single yarn fineness of the raw yarn or raw cotton is 4.444 dtex or less.

Further, according to the description of claim 4, the present invention is the polyester woven or knitted fabric according to any one of claims 1 to 3.
The weight loss rate in the alkaline weight loss processing is 5% by weight or more.

Further, the uniform according to the present invention is according to the description of claim 5.
It is characterized in that the polyester woven or knitted fabric according to any one of claims 1 to 4 is sewn by using a part or the whole.

Further, according to the description of claim 6, the method for producing a polyester woven knit according to the present invention is described.
The method for producing a polyester woven knit according to any one of claims 1 to 4.
After the polyester woven or knitted fabric after weaving or knitting is subjected to the alkali weight loss processing, the first washing step of washing the polyester woven or knitted fabric in a rope state and the second washing of washing the polyester woven or knitted fabric in a spread state. It is characterized by having a process.

Further, according to claim 7, the present invention is the method for manufacturing a polyester woven knit according to claim 6.
In the first cleaning step,
By spraying the cleaning liquid from the jet nozzle, the polyester woven and knitted fabric in a rope state is circulated, and the polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid.
In the second cleaning step,
The polyester woven or knitted fabric after the first washing step is spread and washed in a washing liquid.

Further, according to claim 8, the present invention is the method for manufacturing a polyester woven knit according to claim 6.
In the first cleaning step,
By spraying the cleaning liquid from the jet nozzle under high temperature and high pressure, the polyester woven and knitted fabric in a rope state is circulated, and the polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid under high temperature and high pressure.
In the second cleaning step,
The polyester woven or knitted fabric after the first cleaning step is spread and a cleaning agent is applied, the polyester woven or knitted fabric after the cleaning agent is applied is steamed in a spread state, and the polyester woven or knitted fabric after the steam treatment is spread. It is characterized in that it is washed in a washing liquid.

According to the above configuration, the polyester woven or knitted fabric according to the present invention is woven or knitted by using a polyester yarn made of undiluted colored fibers or a polyester yarn in which one color or a plurality of colors of raw cotton are combined in part or in whole. The sublimation fastness performance in the state of this polyester yarn is evaluated as 4-5 grade or higher in the judgment using JIS L 0805 (gray scale for contamination).

Further, this polyester woven knitted fabric is subjected to an alkali weight loss process after weaving or after knitting. Further, in this polyester woven or knitted fabric, the whole or a part of the woven or knitted fabric is a medium color or a dark color having a lightness (L ^* ) value of 60 or less in the L ^* a ^* b ^* color system. Further, this polyester woven knit has a grade 4 or higher evaluation of dry friction and wet friction by the friction tester type II (Gakushin type) method specified in JIS L 0849 (Dyeing fastness test method for friction). ..

As a result, polyester that can express abundant color variations using raw fibers and can produce a flexible and comfortable uniform without a decrease in friction fastness even if alkali weight reduction processing is applied. Weaving and knitting can be provided.

Further, according to the above configuration, the sublimation fastness performance is about 12. Using a sweat tester specified in JIS L 0854 (Dyeing fastness test method for sublimation), a polyester white cloth is attached to the raw yarn or raw cotton. Confirm by performing a sublimation test for 10 minutes in a dry heat of 180 ° C. ± 2 ° C. with a pressure of 5 kPa applied. This makes it possible to exert the above effect more concretely.

Further, according to the above configuration, the single yarn fineness of the raw yarn or the raw cotton may be 4.444 dtex or less. As a result, it is possible to express abundant color variations using the uncoated fiber, and to provide a uniform having excellent heat resistance and sublimation resistance and less color transfer due to industrial washing, and the above effect is more concrete. Can be demonstrated effectively.

Further, according to the above configuration, the weight loss rate in the alkaline weight loss processing of the polyester woven knit may be 5% by weight or more. This not only makes it possible to handle active work such as medical uniforms, but also improves flexibility and comfort, and makes it possible to exert the above effects more concretely.

Further, according to the above configuration, the uniform according to the present invention is sewn using the polyester woven or knitted fabric according to any one of claims 1 to 4 in part or in whole. As a result, abundant color variations can be expressed, and even if alkali weight reduction processing is applied, the friction fastness does not decrease, and it is possible to provide a uniform that is flexible and comfortable to wear. Further, in the medical uniform, the sorting work at the time of industrial washing becomes unnecessary, the washing work is reduced, and the risk of infection to the worker is reduced.

Further, according to the above configuration, the method for producing a polyester woven knit according to the present invention is the method for producing a polyester woven knit according to any one of claims 1 to 4. In this method, the polyester woven or knitted fabric after weaving or knitting is subjected to an alkali weight loss process, and then has a two-step cleaning step of a first cleaning step and a second cleaning step. In the first washing step, the polyester woven and knitted fabric is washed in a rope state. Next, in the second washing step, the polyester woven and knitted fabric is washed in a spread state.

As a result, the friction fastness does not decrease even if the alkali weight reduction process is applied, abundant color variations can be expressed, and the friction fastness does not decrease even if the alkali weight reduction process is applied, and it is flexible and comfortable to wear. It is possible to provide a method for producing a polyester woven or knitted fabric that can form a good uniform.

Further, according to the above configuration, in the first cleaning step, the polyester woven or knitted fabric in a rope state may be circulated by spraying the cleaning liquid from the jet nozzle. As a result, the circulating polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid. Further, in the second washing step, the polyester woven or knitted fabric after the first washing step may be spread and washed in the washing liquid. By these things, the above-mentioned effect can be exerted more concretely.

Further, according to the above configuration, in the first cleaning step, the polyester woven or knitted fabric which has been made into a rope state by spraying the cleaning liquid from the jet nozzle under high temperature and high pressure may be circulated. As a result, the circulating polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid under high temperature and high pressure. Further, in the second cleaning step, the polyester woven or knitted fabric after the first cleaning step is spread and a cleaning agent is applied. Next, the polyester woven or knitted fabric after the cleaning agent is applied is steam-treated in a spread state. Next, the polyester woven or knitted fabric after the steam treatment may be spread and washed in a washing liquid. By these things, the above-mentioned effect can be exerted more concretely and effectively.

Hereinafter, the polyester woven and knitted fabric according to the present invention, the uniform using the same, and the method for producing the polyester woven and knitted fabric will be described by embodiment. The present embodiment will be described by taking a medical uniform as an example, but the present invention is not limited to the following embodiments.

≪Polyester thread≫
The polyester woven knitted fabric according to the present embodiment is a woven or knitted polyester yarn, and the polyester fibers constituting the polyester yarn may be long fibers or short fibers. When the polyester fiber is a long fiber, it constitutes a multifilament yarn. When the polyester fiber is a staple fiber, it constitutes a spun yarn. The type of polymer (polyester resin) used for the polyester fiber is not particularly limited, and may be polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, or other resin.

The polyester yarn used in this embodiment is made of a dyed fiber. As described above, the original fiber is a fiber spun after coloring a molten polymer by adding a coloring material such as a pigment. That is, the polyester fiber used in the present embodiment is not dyed at any stage of the state of the raw yarn or the raw cotton after spinning, after weaving or knitting, or after sewing. Therefore, since the pigment is contained at the spinning stage, it is difficult to produce extremely fine fibers.

Further, as the pigment used for the original fiber, a pigment having excellent heat resistance and sublimation resistance is used as ultrafine particles. The present inventors have examined various pigments such as the particle size of the pigment and the amount added to the polymer while considering the fineness of the single yarn and the physical characteristics, and selected colored polyester fibers that can be used in the present embodiment. ..

On the other hand, the single yarn fineness of the raw yarn (in the case of long fibers) or raw cotton (in the case of short fibers) constituting the polyester yarn used in the present embodiment is not particularly limited, but is an active and fashionable design. In order to form the medical uniform of the above, fine fibers to some extent are preferable. For example, it is preferable that the single yarn fineness is 4.444 dtex (decitex) or less in consideration of performing an alkali weight loss process after weaving or knitting.

In the case of not coloring at the stage of raw yarn or raw cotton and then dyeing with a dye (single molecule), it is also possible to produce a yarn having a single yarn fineness finer than 4.444 dtex. However, in the present embodiment, since the uncoated fiber (using a pigment) having high fastness is used, there is a limit to the single yarn fineness for producing a raw yarn or raw cotton of stable quality. In particular, in the case of raw yarn (long fiber), it is preferable that the single yarn fineness is 4.444 dtex or less. On the other hand, in the case of raw cotton (staple fiber) whose quality is easy to stabilize, a single yarn fineness of 2.222 dtex (decitex) or less may be used. Further, the single yarn fineness may be 1.666 dtex or less.

The selection of the original fiber used in this embodiment was evaluated by the sublimation fastness performance in the state of the polyester yarn. The present inventors have found in Patent Document 1 a unique sublimation fastness test method as a condition for polyester yarns that do not cause color transfer during industrial washing of medical uniforms (details will be described later).

Further, in order to manufacture a medical uniform having abundant color variations, abundant color variations are required for the polyester yarn constituting the polyester woven knitted fabric. In the present embodiment, a polyester yarn in which one color or a plurality of colors of the original fibers are combined is used, and the polyester yarn is woven or knitted to obtain a polyester woven knitted fabric. In the case of polyester yarn using one color of uncoated fiber, a pigment blended in a specific color is mixed from the molten polymer stage to spin a raw yarn or raw cotton having a predetermined hue, saturation and lightness. In this case, since a single color raw yarn or raw cotton is used, a polyester yarn having the same hue, saturation and lightness as the raw yarn or raw cotton regardless of whether it is a long fiber or a short fiber. Is obtained.

Further, in the case of a polyester yarn in which a plurality of colors of raw fibers are combined, raw yarns or raw cottons of different colors are prepared and mixed to obtain a polyester yarn having a predetermined hue, saturation and lightness. When the polyester fiber is a long fiber, the selected raw yarns of a plurality of colors are combined by twisting to obtain a polyester long fiber yarn having a predetermined hue, saturation and lightness. Although it is a special method, there is also a method called spinning mixed fiber in which long fibers of different colors are mixed at the spinning stage. On the other hand, when the polyester fibers are short fibers, the selected raw cottons of a plurality of colors are combined by mixed spinning (hereinafter referred to as "blended spinning") to obtain polyester short fiber yarns having a predetermined hue, saturation and lightness. The polyester yarn obtained by twisting the yarns of a plurality of colors or blending the raw cottons in this way can be recognized as a uniform color like the yarn dyed in one color.

The method of combined twisting and blending is not particularly limited, and the method usually used for polyester fibers may be used. The thickness (fineness or count) of the polyester yarn produced by combining the raw yarn or the raw cotton is not particularly limited, and may be configured according to the plan of the medical uniform which is the final product. Further, when producing a polyester yarn, a stretch yarn such as a polyurethane yarn may be combined to form a stretch yarn.

≪Polyester woven knitted fabric≫
Next, the polyester yarn thus produced is woven or knitted to produce the polyester woven knitted fabric according to the present embodiment. The weaving structure of the woven fabric to be woven or the knitting structure of the knitted fabric to be knitted is not particularly limited, and may be configured according to the plan of the medical uniform which is the final product. The woven or knitted polyester woven or knitted fabric is completed as a normal woven or knitted fabric through preparatory steps such as degluing, scouring, and heat setting according to a normal process. In this embodiment, the fibers are uncoated fibers and are not dyed. Further, in the present embodiment, an alkali weight loss process is subsequently performed (described later).

The polyester woven or knitted fabric at this stage and after the alkali weight reduction process described later is a medium-colored or dark-colored woven or knitted fabric having a lightness (L ^* ) value of 60 or less in the L ^* a ^* b ^* color system. In particular, it has a feature that a good effect is exhibited even in a dark color having a lightness (L ^* ) value of 30 or less. It should be noted that not only the entire polyester woven or knitted fabric is medium-colored or dark-colored, but also a part such as a border pattern or a checkered pattern may be medium-colored or dark-colored and includes a white or light-colored portion. .. As described above, it is an object of the present embodiment to prevent color transfer due to industrial washing from occurring due to the whole or part of the polyester woven or knitted fabric having a medium color or a dark color.

In addition, various fastness of polyester woven and knitted fabric at this stage is very good as 4th grade or higher, light fastness (JIS L 0842), washing fastness (JIS L 0844), sweat fastness (JIS L 0848). ), Friction fastness (JIS L 0849; type II), as well as industrial washing (described later). The friction fastness at this stage is very good because it has not been subjected to the alkali weight reduction process.

≪Alkaline weight loss processing≫
In the present embodiment, the polyester woven or knitted fabric after the above-mentioned preparation step is subjected to an alkali weight loss process. Alkaline weight loss processing is to hydrolyze the surface of polyester fiber with an alkaline concentrated solution to eliminate the original rigidity of the fiber, and further reduce the contact pressure between the intersecting threads due to the thread thinning accompanying the weight reduction to make the texture flexible. It is a process that improves drapeability. Although it is a processing method generally used for ordinary polyester woven and knitted fabrics, it is also adopted in this embodiment in order to provide a flexible and comfortable medical uniform.

The formulation and apparatus for the alkali weight loss processing in the present embodiment are not particularly limited, and the method adopted for ordinary polyester woven and knitted fabrics may be adopted. In general, sodium hydroxide is used as an alkali in the weight loss processing of a polyester woven knit, and the amount of sodium hydroxide used can be quantitatively determined according to the desired weight loss rate. Further, as for the apparatus, a continuous weight loss processing machine such as a pad steam method or a liquid flow weight reduction processing machine using a liquid flow dyeing machine may be used.

Further, the weight loss rate of the alkali weight loss processing in the present embodiment may be appropriately selected depending on the single yarn fineness of the raw yarn or the raw cotton, the yarn standard, the woven fabric standard, the required flexibility and the like. In general, in order to obtain a polyester woven or knitted fabric that is flexible and has excellent drapeability, a weight loss rate of 5% by weight or more is preferable, and a weight loss rate of 10% by weight or more is more preferable. The upper limit of the weight loss rate is generally about 30% by weight. The polyester woven or knitted fabric after the alkali weight reduction process is a medium-colored or dark-colored woven or knitted fabric having a lightness (L ^* ) value of 60 or less in the L ^* a ^* b ^* color system.

When the polyester woven or knitted fabric after the preparatory process is subjected to an alkali weight reduction process, most of the fastness does not decrease because it is originally made of a raw fiber having high fastness. However, in the present embodiment, since one of the purposes is to prevent color transfer, it is a medium-colored or dark-colored polyester woven or knitted fabric. It was found that the friction fastness of these medium-colored or dark-colored polyester woven and knitted fabrics was reduced. Alkaline weight loss processed polyester woven and knitted fabrics are usually washed. However, the decrease in friction fastness due to the alkali weight reduction process could not be improved even by performing normal cleaning operations.

The present inventors considered the cause of the decrease in the frictional fastness of the original fiber due to the alkali weight reduction process as follows. The surface of the polyester fiber was hydrolyzed and threaded by the alkali weight reduction process, so that the pigment originally embedded in the original fiber was partially exposed on the fiber surface. Unlike dyes, pigments are aggregated or crystallized colorant molecules and do not dissolve in water or organic solvents. Therefore, even if a part of the pigment is exposed on the fiber surface, the color does not transfer and the fastness is good. be.

However, it is considered that when the pigment exposed on the surface is worn with the test cloth as in the friction fastness test, a part of the pigment falls off and contaminates the test cloth. However, in the cleaning operation after the alkali weight reduction process, although cleaning was performed with an open soap using a detergent, the decrease in friction fastness did not improve.

≪Washing process≫
Therefore, the present inventors decided to reexamine the cleaning operation after the alkali weight reduction process. As described above, the present inventors considered that a part of the pigment exposed on the fiber surface by the alkali weight reduction process was worn by the test cloth in the friction test and fell off, contaminating the test cloth. In that case, it was considered that the friction fastness after the cleaning operation would be improved if the pigment exposed on the fiber surface was scraped off in advance by the cleaning operation.

Therefore, as an industrial fiber processing operation, it was decided to wash the polyester woven or knitted fabric after the alkali weight loss processing in a rope state. If the polyester woven or knitted fabric in a wet state in the cleaning liquid is washed in a rope state, the polyester woven or knitted fabrics can be rubbed against each other in the cleaning liquid to scrape off the pigment exposed on the fiber surface. Specifically, a high-temperature and high-pressure cleaning operation was performed with a high-pressure liquid flow dyeing machine using a cleaning agent. However, even so, the decrease in friction fastness did not improve.

The present inventors further considered the cause. Normally, if the woven or knitted fabric is dyed with a dye, the dye adhering to the woven or knitted fabric can be removed without dyeing the fibers even if the rope is washed in the cleaning liquid. Further, the dye that has not been dyed can be decolorized and removed by reduction cleaning. However, in this embodiment, it is the pigment that is worn and adheres to the woven or knitted fabric. Unlike dyes (single molecules), pigments are aggregated or crystallized colorant molecules even if they are scraped off. These pigments cannot be decolorized by reduction cleaning, are not only insoluble in water, and are difficult to disperse even when a detergent (surfactant) is used. Therefore, even if the rope is washed in the washing liquid, the pigment that has fallen off cannot be removed.

Therefore, the present inventors consider that the pigment exposed on the fiber surface is removed by washing the rope state. Therefore, a method for cleaning the pigment that has fallen off from the fiber surface and adhered to the woven or knitted fabric has been investigated. As a result, it was possible to improve the decrease in friction fastness by adopting the following two-stage cleaning process. First, in the first washing step, the polyester woven or knitted fabric that has been subjected to the alkali weight reduction process is washed in a rope state. Next, in the second washing step, the polyester woven or knitted fabric after the first washing step is washed in a spread state. These cleaning steps will be described below.

(1) First cleaning step In the first cleaning step, the polyester woven or knitted fabric that has been subjected to the alkali weight reduction process is washed in a rope state. The purpose of this step is to wash the polyester woven or knitted fabric wet in the cleaning liquid in a rope state so that the polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid and the pigment exposed on the fiber surface is scraped off. do.

In industrial fiber processing operations, there are various devices for cleaning woven and knitted fabrics in a rope state. In the present embodiment, the cleaning device used in the first cleaning step is not particularly limited, but for example, a wins dyeing machine, a liquid flow dyeing machine, or the like can be used. In particular, a liquid flow dyeing machine that circulates a woven or knitted fabric in a rope state by spraying a cleaning liquid from a jet nozzle is effective for rubbing polyester woven or knitted fabrics with each other in the cleaning liquid. Further, a high-pressure liquid flow dyeing machine capable of raising the temperature of the cleaning liquid to 100 ° C. or higher can also be used.

In the first cleaning step, a cleaning agent (surfactant) is used in the cleaning liquid, but the type of cleaning agent is not particularly limited, and the one generally used for cleaning operations of polyester woven and knitted fabrics is adjusted to the cleaning temperature. It may be selected as appropriate. The cleaning temperature in the first cleaning step is not particularly limited, but may be about the same as the cleaning temperature of a general polyester woven or knitted fabric.

In this embodiment, it is preferable that the temperature is equal to or higher than the glass transition temperature of the polyester fiber for the purpose of removing the pigment exposed on the fiber surface. A general polyester fiber is made of polyethylene terephthalate (PET) and has a glass transition temperature of 69 ° C. Therefore, it is preferable to wash at a temperature of 70 ° C. or higher. Further, when cleaning under high temperature and high pressure using a high pressure liquid flow dyeing machine, it is preferable to perform cleaning in a temperature range of 105 to 130 ° C. The cleaning time is not particularly limited, but may be, for example, about 30 to 120 minutes.

After washing in a rope state, the same device is used to wash in a rope state to remove the pigment scraped off from the polyester woven or knitted fabric. When a high-pressure liquid flow dyeing machine is used, the polyester woven or knitted fabric in a rope state is circulated and washed with water by spraying water washing water from a jet nozzle. However, the pigment adhering to the polyester woven or knitted fabric cannot be sufficiently removed by the washing operation and the washing operation in the first washing step.

(2) Second cleaning step In the second cleaning step, the polyester woven or knitted fabric after the first cleaning step is washed in a spread state. The purpose of this step is to wash and remove the pigment that has been scraped off in the first washing step and adheres to the polyester woven or knitted fabric.

In industrial fiber processing operations, there are various devices for cleaning woven and knitted fabrics in a spread state. In the present embodiment, the cleaning device used in the second cleaning step is not particularly limited, but for example, an open soaper or the like can be used. This open soaper is a device for continuously cleaning woven and knitted fabrics in a spread state, and consists of several to a dozen cleaning tanks with rolls for feeding the woven and knitted fabrics and the same number of mangles. Each washing tank is individually separated, and in the second washing step, each tank in the first half can be used as a washing tank, and each tank in the latter half can be used as a water washing tank. When moving from a washing tank to the next washing tank or a water washing tank, the woven or knitted fabric is squeezed with a mangle, so that the cleaning efficiency of the pigment adhering to the polyester woven or knitted fabric is improved.

In addition, in front of each washing tank, apply chemicals to the spread woven or knitted fabric, and use an open soaper equipped with a pad steamer (combination of padder and steam box) that steams (steams) the spread state. You may. In this case, a cleaning agent (surfactant) is applied to the expanded polyester woven or knitted fabric with a padder, and the expanded polyester woven or knitted fabric is steamed with a steam box. The steam box is often steamed at 100 ° C. at normal pressure. Next, washing and washing with water are performed in a continuous washing tank. By steaming the polyester woven or knitted fabric to which the cleaning agent is applied, the cleaning efficiency of the pigment adhering to the polyester woven or knitted fabric is improved, and then the polyester woven or knitted fabric is washed and washed with water in each washing tank to improve the cleaning efficiency of the pigment. Is further improved. Further, it is considered that the pigment removal efficiency is improved by squeezing with the mangle of each washing tank.

The type of the cleaning agent used in the second cleaning step is not particularly limited, and generally, the one used for the cleaning operation of the polyester woven or knitted fabric may be appropriately selected according to the cleaning temperature and the steaming temperature. The cleaning temperature of each cleaning tank in the second cleaning step is not particularly limited, but is preferably around 90 ° C., for example. The steaming time and washing time are not particularly limited, but for example, it is preferable to steam at 100 ° C. for about 10 to 30 minutes.

≪Friction fastness≫
As described above, by performing the second cleaning step after the first cleaning step, the pigment adhering to the polyester woven or knitted fabric that could not be sufficiently removed in the first cleaning step can be efficiently removed. As a result, the medium-colored or dark-colored polyester woven or knitted fabric according to the present embodiment has dry friction and wetness according to the friction tester type II (Gakushin type) method specified in JIS L 0849 (Dyeing fastness test method for friction). The evaluation of friction is grade 4 or higher, and together with other fastness, it has good physical properties as a medical uniform.

≪Medical uniform≫
Next, the woven and knitted fabric thus produced is sewn to produce a medical uniform. The design and sewing method of the uniform to be manufactured are not particularly limited.

Next, the method for producing the polyester woven knitted fabric according to the present embodiment, particularly the washing step, will be described with reference to each embodiment. The present invention is not limited to the following examples.

In the first embodiment, the production (particularly cleaning step) and evaluation (particularly friction fastness) of the polyester long fiber woven fabric will be described using the raw yarn of the long polyester raw fiber.

≪Polyester long fiber yarn≫
In the first embodiment, a masterbatch for spinning in which pigments are blended according to the three target colors (royal blue, turquoise blue, dark navy) of the final fabric is used, and 167 dtex / 48 fiber (single yarn fineness 3.48 dtex) is used. ), A polyester long fiber yarn composed of three types of original fibers was spun.

Next, the sublimation fastness performance of the obtained three types of polyester long fiber yarns was evaluated. In Patent Document 1, the present inventors have found the following sublimation fastness test method as a condition of a polyester yarn that does not cause color transfer during industrial washing of medical uniforms.

First, a sublimation fastness test is performed in the state of polyester yarn. In Example 1, three types of polyester filament yarns were evaluated as test subjects. For the sublimation fastness test, a sweat tester specified in JIS L 0854 (Dyeing fastness test method for sublimation) is used. A composite test piece in which a polyester white cloth is attached to a predetermined amount of polyester yarn is sandwiched between stainless steel plates and fixed in this testing machine under a pressure of about 12.5 kPa. The tester in this state is placed in a dryer at 180 ° C. ± 2 ° C. with the composite test piece held in the vertical direction, and is subjected to dry heat treatment for 10 minutes. Immediately after the drying treatment, the composite test piece is taken out, the polyester yarn and the polyester white cloth are spread separately, and allowed to cool.

The evaluation of the sublimation test is based on the degree of contamination of the polyester white cloth attached to the polyester yarn. Specifically, the degree of pollution is determined using JIS L 0805 (gray scale for pollution). In this embodiment, those having a pollution degree of 4-5 grade or higher are used. The degree of discoloration and fading in the sublimation test of the polyester yarn may be evaluated. The present inventors have found that this sublimation test method and evaluation criteria have a good correlation with the color transfer of actual medical uniforms due to industrial washing. Table 1 shows the sublimation fastness performance of the three types of polyester long fiber yarns measured.

≪Polyester long fiber woven fabric≫
Next, weaving was performed using each of the three types of polyester long fiber yarns, and three types of polyester long fiber woven fabrics were produced. The weaving structure of each woven fabric was a four-twill (2/2 right-handed) twill weave, and the weaving density was 121 warps / inch and 107 wefts / inch.

These three types of polyester long fiber woven fabrics were refined and relaxed by a usual method, and a hydrophilic softener was applied to obtain each polyester long fiber woven fabric of Example 1 (before alkali weight loss processing). The hue, saturation, and lightness of each of the obtained polyester long fiber fabrics are shown in Table 1 with the respective values of lightness (L ^* ) and chromaticity (a ^* , b ^* ) in the L ^* a ^* b ^* color system.

In Table 1, the L ^* values of the three types of polyester long fiber woven fabrics were all 60 or less. The L ^* value of No. 1 (royal blue) was 22.6, which was a dark woven fabric. The L ^* value of No. 2 (turquoise blue) was 40.6, which was a medium-colored woven fabric. The L ^* value of No. 3 (dark navy) was 20.3. It was a dark woven fabric. In addition, the sublimation fastness performance of the three types of polyester long fiber yarns used in these polyester long fiber woven fabrics was as good as 4-5 grade or higher.

Next, a typical industrial washing test performed on medical uniforms was performed on three types of polyester long fiber woven fabrics. First, a sample of 10 cm × 20 cm was taken from each woven fabric, and a polyester white cloth of the same size and short sides were sewn together to form a composite test piece. A small rotary pod type dyeing tester (mini color; manufactured by Texam Giken Co., Ltd.) was used as the washing tester, and the washing process was performed at a bath ratio of 1: 8, a rotation speed of 45 times / minute, and 80 ° C. for 40 minutes.

After the composite test piece after the washing treatment was thoroughly washed with water, dehydrated and air-dried, the discoloration and fading of the sample and the contamination of the polyester white cloth were evaluated in the same manner as in the sublimation test. Two typical types of industrial laundry prescriptions were used. The industrial washing test I was a washing method in which a bleaching agent was not used in combination, and the industrial washing test II was a washing method in which a bleaching agent (sodium hypochlorite) was used in combination. Table 2 shows the washing bath prescription for each washing method.

Table 3 shows the evaluation results of the two types of industrial washing tests for the three types of polyester long fiber woven fabrics. In addition, general dyeing fastness was measured for each polyester long fiber woven fabric at this stage (before alkali weight reduction processing). The measured dyeing fastness was light fastness (JIS L 0842), washing fastness (JIS L 0844), sweat fastness (JIS L 0848), and friction fastness (JIS L 0849; type II). Table 3 shows the evaluation results of the dyeing fastness of each of the three types of polyester long fiber woven fabrics.

In Table 3, various fastnesses of each polyester long fiber woven fabric at this stage (before alkali weight reduction processing) were 4th grade or higher, which was very good. In addition, in Table 3, the results of the two types of industrial washing tests were also good. The friction fastness at this stage was very good because the alkali weight reduction process was not applied.

≪Alkaline weight loss processing≫
Next, three types of polyester long fiber woven fabrics were subjected to alkali weight loss processing. In Example 1, an alkali weight loss process was performed using a high-pressure liquid flow dyeing machine under the conditions shown in Table 4. Each polyester long fiber woven fabric after the alkali weight reduction process was washed with hot water at 60 ° C., neutralized with acid, washed with water and dried. Then, a hydrophilic softener was applied to obtain each polyester long fiber woven fabric (after alkali weight loss processing) of Example 1. Table 4 shows the weight loss rate of each polyester long fiber woven fabric.

In Table 4, the weight loss rate of each polyester long fiber woven fabric after the alkali weight loss processing was about 10 to 11% by weight, and the texture became flexible and the drape property was improved.

Next, two types of industrial washing tests and general dyeing fastness were evaluated for three types of polyester long fiber woven fabrics after alkali weight reduction processing, and the evaluation results are shown in Table 5.

In Table 5, the friction fastness of each polyester long fiber woven fabric was greatly reduced by performing the alkali weight reduction process. In addition, the results of various other fastness and industrial washing tests did not deteriorate, and were good even after the alkali weight reduction process.

≪Washing process≫
(1) First Cleaning Step In Example 1, each polyester long fiber woven fabric after alkali weight loss processing was washed in a rope state using a high-pressure liquid flow dyeing machine under the conditions shown in Table 6.

After washing, each polyester long fiber woven fabric was washed twice with water using the same high-pressure liquid flow dyeing machine and dried. Then, a hydrophilic softener was applied to obtain each polyester long fiber woven fabric after the first washing step.

Next, the friction fastness to the three types of polyester long fiber woven fabrics after the first cleaning step was evaluated, and the evaluation results are shown in Table 7.

In Table 7, the friction fastness after the first cleaning step was slightly improved in wet friction, but good results were not obtained. In the first washing step, it is considered that the effect of scraping off the pigment exposed on the fiber surface is recognized by washing the polyester long fiber woven fabric in a rope state under high temperature and high pressure using a high pressure liquid flow dyeing machine. However, the effect of removing the scraped-off pigment adhering to the woven or knitted material was not recognized.

(2) Second Cleaning Step In the first embodiment, each polyester long fiber woven fabric after the first cleaning step was washed in a spread state using an open soaper equipped with a pad steamer. First, a cleaning agent of 2 g / L was applied to the expanded polyester long fiber woven fabric with a padder, and the expanded polyester long fiber woven fabric was steamed at 100 ° C. for 20 minutes with a steam box. Next, in the interlocking 10-tank open soaper, running cleaning was performed at 90 ° C. at a speed of 40 m / min. Then, it was dried in an interlocking cylinder dryer, and a hydrophilic softener was applied to obtain each polyester long fiber woven fabric after the second washing step.

Next, the friction fastness to the three types of polyester long fiber woven fabrics after the second cleaning step was evaluated, and the evaluation results are shown in Table 8.

In Table 8, the friction fastness after the second cleaning step was greatly improved and good results were obtained. As described above, by performing the second cleaning step after the first cleaning step, the pigment adhering to the polyester long fiber woven fabric that could not be sufficiently removed in the first cleaning step can be satisfactorily removed. rice field. As a result, the medium-colored or dark-colored polyester long fiber woven fabric according to Example 1 was evaluated for dry friction and wet friction by the friction tester type II (Gakushin type) method specified in JIS L0849. It has become a grade or higher and has good physical properties as a medical uniform in combination with other fastness.

In the second embodiment, the production (particularly cleaning step) and evaluation (particularly friction fastness) of the polyester short fiber woven fabric will be described using the raw cotton of the short fiber polyester staple fiber.

≪Polyester staple fiber thread≫
In Example 2, a masterbatch for spinning in which pigments are mixed according to the three target colors (navy blue, turquoise blue, burgundy) of the final woven fabric is used, and three types of raw cotton having a single yarn fineness of 1.666 dtex are used. (Original short fiber) was spun. Three types of polyester staple yarns of 28 count single yarns were produced from this raw cotton by an air spinning method.

Next, the sublimation fastness performance of the obtained three types of polyester staple yarns was evaluated. The method for evaluating the sublimation fastness performance is the same as that in the first embodiment. In this embodiment, those having a pollution degree of 4-5 grade or higher are used. Table 9 shows the sublimation fastness performance of the three types of polyester staple yarns measured.

≪Polyester staple fiber woven fabric≫
Next, weaving was performed using each of the three types of polyester staple fiber yarns to produce three types of polyester staple fiber fabrics. The weaving structure of each woven fabric was a plain woven fabric (poplin), and the weaving density was 120 warps / inch and 64 wefts / inch.

These three types of polyester staple fiber woven fabrics were continuously deglued and refined by a usual method, and a hydrophilic softener was applied to obtain each polyester staple fiber woven fabric of Example 2 (before alkali weight loss processing). The hue, saturation, and lightness of each of the obtained polyester short fiber fabrics are shown in Table 9 with the respective values of lightness (L ^* ) and chromaticity (a ^* , b ^* ) in the L ^* a ^* b ^* color system.

In Table 9, the L ^* values of the three types of polyester staple fiber woven fabrics were all 60 or less. The L ^* value of No. 4 (navy blue) was 25.8, which was a dark woven fabric. The L ^* value of No. 5 (turquoise blue) was 42.4, which was a medium-colored woven fabric. The L ^* value of No. 6 (burgundy) was 24.4, which was a dark woven fabric. In addition, the sublimation fastness performance of the three types of polyester staple fiber yarns used in these polyester staple fiber fabrics was as good as 4-5 grade or higher.

Next, a typical industrial washing test performed on medical uniforms was performed on three types of polyester staple fabrics. The method and formulation of the industrial washing test are the same as those in Example 1 above. Table 10 shows the evaluation results of two types of industrial washing tests for the three types of polyester staple fiber fabrics.

In addition, general dyeing fastness was measured for each polyester staple fiber woven fabric at this stage (before alkali weight reduction processing). The measured dyeing fastness was light fastness (JISL 0842), washing fastness (JISL 0844), sweat fastness (JISL 0848), and friction fastness (JISL 0849; type II) as in Example 1. rice field. Table 10 shows the evaluation results of the dyeing fastness of each of the three types of polyester staple fiber woven fabrics.

In Table 10, the various fastnesses of each polyester staple fiber woven fabric at this stage (before the alkali weight reduction process) were 4th grade or higher, which were very good. In addition, in Table 10, the results of the two types of industrial washing tests were also good. The friction fastness at this stage was very good because the alkali weight reduction process was not applied.

≪Alkaline weight loss processing≫
Next, three types of polyester staple fiber woven fabrics were subjected to alkali weight loss processing. In Example 2, the alkali weight reduction process was performed under the conditions shown in Table 11 using a normal pressure steamer (pad steam → continuous soaper → cylinder drying). Each polyester staple fiber woven fabric after the alkali weight loss processing was provided with a hydrophilic softener to obtain each polyester staple fiber woven fabric of Example 2 (after the alkali weight loss processing). Table 11 shows the weight loss rate of each polyester staple fiber woven fabric.

In Table 11, the weight loss rate of each polyester staple fiber woven fabric after the alkali weight loss processing was about 11 to 12% by weight, and the texture became flexible and the drape property was improved.

Next, two types of industrial washing tests and general dyeing fastness were evaluated for three types of polyester staple fiber fabrics after alkali weight reduction processing, and the evaluation results are shown in Table 12.

In Table 12, the friction fastness of each polyester staple fiber woven fabric was greatly reduced by performing the alkali weight reduction process. In addition, the results of various other fastness and industrial washing tests did not deteriorate, and were good even after the alkali weight reduction process.

≪Washing process≫
(1) First cleaning step In the second embodiment, each polyester staple fiber woven fabric after the alkali weight reduction process is roped under the same conditions as in the first embodiment (see Table 6) using a high-pressure liquid flow dyeing machine. Washed with. After washing, each polyester staple fiber fabric was washed twice with water using the same high-pressure liquid flow dyeing machine and dried. Then, a hydrophilic softener was applied to obtain each polyester staple fiber woven fabric after the first washing step.

Next, the friction fastness to the three types of polyester staple fiber woven fabrics after the first cleaning step was evaluated, and the evaluation results are shown in Table 13.

In Table 13, the friction fastness after the first cleaning step was slightly improved in wet friction, but good results were not obtained. In the first washing step, the effect of scraping off the pigment exposed on the fiber surface is considered to be recognized by washing the polyester staple fiber woven fabric in a rope state under high temperature and high pressure using a high pressure liquid flow dyeing machine. However, the effect of removing the scraped-off pigment adhering to the woven or knitted material was not recognized.

(2) Second Cleaning Step In the second embodiment, as in the first embodiment, each polyester staple fiber woven fabric after the first cleaning step is washed in a spread state by using an open soaper equipped with a pad steamer. did. The conditions of the second cleaning step are the same as those of the first embodiment. Then, it was dried in an interlocking cylinder dryer, and a hydrophilic softener was applied to obtain each polyester staple fiber woven fabric after the second washing step.

Next, the friction fastness to the three types of polyester staple fiber woven fabrics after the second cleaning step was evaluated, and the evaluation results are shown in Table 14.

In Table 14, the friction fastness after the second cleaning step was greatly improved and good results were obtained. As described above, by performing the second cleaning step after the first cleaning step, the pigment adhering to the polyester staple fiber woven fabric that could not be sufficiently removed in the first cleaning step can be satisfactorily removed. rice field. As a result, the medium-colored or dark-colored polyester staple fiber woven fabric according to Example 2 was evaluated for dry friction and wet friction by the friction tester type II (Gakushin type) method specified in JIS L 0849. As described above, it has good physical properties as a medical uniform in combination with other fastness.

As described above, according to the present invention, abundant color variations can be expressed by using the raw fiber, and even if the alkali weight reduction process is applied, the friction fastness does not decrease, and the fabric is flexible and comfortable to wear. It is possible to provide a polyester woven knit that can produce a good uniform, a uniform using the same, and a method for producing the polyester woven knit.

In carrying out the present invention, not only the above-described embodiment and each embodiment but also various modifications as follows can be mentioned.
(1) In each of the above examples, when spinning the raw yarn or the raw cotton of the original fiber, a masterbatch for spinning was used in which a pigment preliminarily toned according to the target color was blended. Therefore, the polyester yarn of the target color is not produced by blending or spinning the raw yarn or the raw cotton after spinning. However, the present invention is not limited to this, and a plurality of single color raw yarns or raw cottons may be mixed or blended to produce a polyester yarn of a desired color.
(2) In each of the above examples, a woven fabric using polyester yarn was manufactured. However, the present invention is not limited to this, and knitted fabrics using polyester yarn may be manufactured.
(3) In the above-described embodiment and each embodiment, medical uniforms have been described as applications for polyester woven and knitted fabrics. However, the use of the polyester woven knitted fabric according to the present invention is not limited to medical uniforms worn by medical personnel and long-term care personnel, and uniforms and sportswear for other purposes, or general clothing and materials. It may be used as.

Claims (8)

It is a woven or knitted fabric made by weaving or knitting a raw yarn made of undiluted colored fibers or a polyester yarn obtained by combining one color or a plurality of colors of raw cotton in part or in whole.
The sublimation fastness performance in the state of the polyester yarn was evaluated as 4-5 grade or higher in the judgment using JIS L 0805 (gray scale for contamination).
Alkaline weight loss processing is applied after weaving or knitting, and the whole or part of the woven or knitted product is a medium or dark color with a lightness (L ^* ) value of 60 or less in the L ^* a ^* b ^* color system. There,
A polyester woven knitted fabric characterized in that the evaluation of dry friction and wet friction by the friction tester type II (Gakushin type) method specified in JIS L 0849 (Dyeing fastness test method for friction) is grade 4 or higher. .. For the sublimation fastness performance, a sweat tester specified in JIS L 0854 (Dyeing fastness test method for sublimation) was used, and a polyester white cloth was attached to the raw yarn or raw cotton and a pressure of about 12.5 kPa was applied. The polyester woven or knitted fabric according to claim 1, wherein the sublimation test is performed for 10 minutes in a dry heat of 180 ° C. ± 2 ° C. in a state. The polyester woven knit according to claim 1 or 2, wherein the single yarn fineness of the raw yarn or raw cotton is 4.444 dtex or less. The polyester woven or knitted fabric according to any one of claims 1 to 3, wherein the weight loss rate in the alkaline weight loss processing is 5% by weight or more. A uniform characterized by being sewn using the polyester woven or knitted fabric according to any one of claims 1 to 4 in part or in whole. The method for producing a polyester woven knit according to any one of claims 1 to 4.
After the polyester woven or knitted fabric after weaving or knitting is subjected to the alkali weight reduction process, the first washing step of washing the polyester woven or knitted fabric in a rope state and the second washing of washing the polyester woven or knitted fabric in a spread state. A method for producing a polyester woven knit, which comprises a process. In the first cleaning step,
By spraying the cleaning liquid from the jet nozzle, the polyester woven and knitted fabric in a rope state is circulated, and the polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid.
In the second cleaning step,
The method for producing a polyester woven or knitted product according to claim 6, wherein the polyester woven or knitted fabric after the first cleaning step is spread and washed in a cleaning liquid. In the first cleaning step,
By spraying the cleaning liquid from the jet nozzle under high temperature and high pressure, the polyester woven and knitted fabric in a rope state is circulated, and the polyester woven and knitted fabrics are rubbed against each other in the cleaning liquid under high temperature and high pressure.
In the second cleaning step,
The polyester woven or knitted fabric after the first cleaning step is spread and a cleaning agent is applied, the polyester woven or knitted fabric after the cleaning agent is applied is steamed in a spread state, and the polyester woven or knitted fabric after the steam treatment is spread. The method for producing a polyester woven or knitted fabric according to claim 6, wherein the polyester woven or knitted fabric is washed in a washing liquid.