JP3897154B2 - Method for producing dust-free garment using recovered polyester with excellent wearing comfort - Google Patents

Description

【０００９】
【発明の実施の形態】
本発明により得られるポリエステル無塵衣は、２０℃、６５％RH環境における吸湿率が１.５％以上、より好ましくは２％以上、更に好ましくは２.５％以上である。吸湿性が１.５％未満であれば、クリーンルーム内で該無塵衣を着用して作業しても高吸湿性を実感できるものにはならない。また吸湿率の上限値については特に規定するものではないが、あまり吸湿性が高くなり過ぎると乾燥し難しくなり、黴の発生や着用時の重量感、まとわりつきを感じるものになってしまい好ましいとは言えない。吸湿率は１０%程度までに留めておくことが好ましい。
【００１０】
また２０℃、６５%RH環境と３０℃、９５%RH環境における吸放湿度差は３%以上、より好ましくは５%以上であることが望まれる。ここで２０℃、６５%RH環境は外気の標準環境を示し、３０℃、９５%RH環境は無塵衣と肌の間に存在する空気の環境（衣服内環境）を示すものである。該吸放湿度差が３%未満では実着用時に「水分（汗）を吸って、放出する」という体感を得ることが出来ず、肌面のさらさら感が感じられるものにはならないのである。
【００１１】
また、本発明により得られる回収ポリエステルを用いたポリエステル無塵衣の吸水速度はウィッキング法で１秒以下であることが好ましい。吸水速度は如何に水滴が布帛表面及び内部に拡散していくかを示す尺度であり遅くなる程、水滴が床面やその他作業環境に飛散し易く思わぬ大事故を引き起こす可能性もある。また吸水速度が遅く留まるほど、肌面の濡れ感が持続し、着用快適な作業衣（無塵衣）にはならない。吸水速度を早くするには繊維の毛細管現象や繊維表面濡れ性を向上させることによって達成し得る。
【００１２】
また、速乾性については２０℃、６５％ＲＨ環境下で３０分間の風乾にて乾燥率７０%以上、より好ましくは８０%以上である。実着用の場合は環境温湿度の他、空気の移動状態、肌面からの熱移動等の要因によって乾燥度合が異なるが、２０℃、６５％RH環境下で３０分間の風乾にて乾燥率が７０%未満となると吸水・吸汗した水分の保持能力が高すぎ、いつまでも湿潤したものになってしまい、肌への張り付きやそれに伴う運動性能の悪化を引き起こし、作業効率や着用感を著しく損ねてしまう。上限値については特に限定するものではないが、乾燥率が１００%に近くなるほど速乾性が向上するため、いつまでもサラサラとした触感を得ることが出来る。
【００１３】
制電特性については摩擦帯電圧測定で１KV以下の性能、より好ましくは０.７KV以下、更に好ましくは０.５KV以下の性能を保持することが無塵衣の特性上、好ましい。摩擦帯電圧が１KVを超過する範囲となれば、空気中の塵埃を吸着させ易くなる他、揮発性有機溶媒等を使用する職場に当っては静電気による引火の原因となり、作業上好ましくない。更には着用感も好ましいものではないため、精神的苦痛を伴うものになる。
【００１４】
発塵量については１００〜５００個／ft³・100ｃｍ²の範囲、より好ましくは１００〜３５０個／ft³・100ｃｍ²の範囲である。食品・薬品分野や精密機械製造分野、その他機械、化学分野等において発塵量は少ないのに越したことはないが、１００個／ft³・100ｃｍ²未満の超クリーン分野では工程機械化が進み、人間が直接作業する分野で無くなっている。無塵衣の生産コスト、洗浄コストから見ても割高となり、過度の性能を得る代償は大きなものとなる。
また、５００個／ft³・100ｃｍ²を超過する領域では塵埃の発生量が多すぎ、生産品の歩留まりの悪化や異物混入の問題が生じやすい。
【００１５】
本発明において、ポリエステル無塵衣に供する布帛の引裂強度は９.８N以上、より好ましくは１５.０N以上である。引裂強度が９.８N未満となると無塵衣、作業着として着用した場合、特に肘や膝など屈曲する部分などは大きな生地変形を伴うために、どうしても裂け易く実用に供することが出来ない。引裂強度については大きな値を有するほど望ましいが、布帛を構成する繊維の繊維軸方向への配向度を向上させて高強力糸とする必要があり、これに伴う染色性の低下やぬめり感のある風合いに仕上がる傾向にある。
【００１６】
洗濯後の引裂強度保持率については初期に対する洗濯５０回後の保持率が８０%以上、より好ましくは８５%以上である。洗濯処理についてはＪＩＳ Ｌ‐０２１７の１０３法に準じた方法で処理するものであり、洗濯を繰り返すにつれて布帛及び縫製部の強度が低下するが、洗濯回数５０回後の引裂強度保持率が８０%未満であれば、初期性能に対する強度低下が著しく、実用に供するには不都合なものとなる。
【００１７】
ポリエステル布帛に吸水・吸湿性能を付与するために、本発明ではビニルカルボン酸及び／又はビニルスルホン酸、及び一般式〔I〕、〔II〕、〔III〕、〔IV〕から選択される少なくとも一種類のジビニルモノマー若しくはトリビニルモノマーならびに重合開始剤からなる加工剤を繊維表面にパッドスチーム法等の手法を用いて付与するものでありビニルカルボン酸及び／またビニルスルホン酸モノマーとジビニルモノマー若しくはトリビニルモノマーが、１：１〜１：１０の割合で繊維に固着していることを特徴とする。
【化３】

【００１８】
繊維に固着するビニルカルボン酸及び／またビニルスルホン酸モノマーとジビニルモノマー若しくはトリビニルモノマーの重量分率について、後者の分量が前者対比１倍未満となるとカルボン酸又はスルホン酸末端へのアルカリ金属、若しくはアルカリ土類金属置換のため強アルカリによる末端基置換処理を行う必要があり、生地黄変や皮膚への影響（発疹や荒れなど）が懸念され好ましくない。また、後者の分量が前者対比１０倍以上となると皮膜強度が小さくなり過ぎ、洗濯耐久性の悪化など耐久性を考慮した場合、好ましくない。
【００１９】
なお、本発明における固着とは、化学的あるいは物理化学に結合し、洗濯などで容易には脱落しない状態を意味するものである。
【００２０】
ポリエステル等の疎水性繊維の表面を親水化するため、各種グラフト重合加工法で親水性成分を固着させることは公知であり、ラジカル重合の開始方法として紫外線、電子線、その他放射線を用いる方法や開始剤を使用する方法もよく知られており、本発明においてもこれらの方法を採用することができる。しかしながら放射線等を使用する方法は作業環境的にも装置的にも制約が大きいものであり、後者の開始剤法を採用することが望ましい。該開始剤については限定を加えるものではないが低温から中温領域、即ち、−１０〜１００℃程度で適用されるものが望ましく、過硫酸アンモニウムや過硫酸カリウム、硫酸アンモニウム等の無機系重合開始剤や２，２'−アゾビス（２−アミノプロパン）ジハイドロクロライド、２，２'−アゾビス（N，N'−ジメチレンイソブチルアミジン）ジハイドロクロライド、２−（カルバモイルアゾ）イソブチロニトリル等の有機系重合開始剤が例示出来るが、コストや取扱性の容易さから無機系開始剤の使用が好ましい。
【００２１】
また、ラジカル重合開始剤は一般に、比較的熱に弱い結合（結合解離エネルギーが小さい）を分子内に有する化合物であり、加熱によって分解し容易にラジカルを形成するものが望ましいとされている。ラジカル重合開始剤の添加量は、特に限定しないが加工剤中に０.１〜３.０重量％添加されていることが好ましく、０.１重量％未満であればラジカル重合反応が不十分なものに留まり、３.０重量％を超過する範囲であればコスト的に不利なものとなる。
【００２２】
重合開始剤及び架橋剤、グラフト重合の基剤となるモノマー等からなる加工剤を布帛に付与する方法としては、ローラーパディング法、スプレー法、染色吸尽法等の手法が挙げられるが、ローラーパディングした後に高圧スチーミングを実施し、グラフト重合を促進させる方法は、連続処理であり、工程速度やコスト面、品質面を考慮した場合にも非常に有効である。
上記高圧スチーミングはモノマーの蒸散を防ぎ、重合効率の低下を防ぐため、反応槽雰囲気温度が９０〜１３０℃、好ましくは９５〜１２０℃の条件で工程滞留時間が過度に長くならぬように調整することが望ましい。また加熱効率や加工剤中の樹脂のマイグレーションを抑制するために上記スチーミングに高周波加熱を併用することも好ましく採用される。
【００２３】
繊維表面を親水化するために上述の加工剤を付与し、繊維表面に親水性樹脂皮膜層を形成させるが、樹脂皮膜層をより強固なものにするためには核剤となり得るモノマーを併用することがより効果的である。核剤となり得る剤としては反応型ポリウレタン系樹脂が望ましく、例えば、第一工業製薬社製スーパーフレックスやエラストロン等が例示される。また樹脂皮膜層を更に強固なものにするために多官能の架橋剤を用い、三次元架橋を形成させることが好ましく、下記に代表されるオキサゾリン系或いはアジリジン系架橋剤が皮膜強度を強固にする上で有効であり好適に使用される。
【化４】

【００２４】
また、加工剤の水分散性を向上させるために疎水性成分を乳化均一分散させることが好ましい。特にアクリル酸やメタクリル酸成分などは水分散性が悪く、乳化分散剤を使用して加工液に均一分散することが好ましい。更に加工剤パディング、表面グラフト重合を促進させる為のスチーム処理を実施した後、ソーダ灰や苛性ソーダ等の水溶液に通じて酸末端へのアルカリ金属、アルカリ土類金属の導入（塩化）を実施する。酸末端塩化を実施した後、水洗を充分に実施し不要なアルカリ成分を除去する。コハク酸、クエン酸、リンゴ酸等の弱酸性水溶液を通じた後、水洗を繰り返すと余分なアルカリ成分が中和除去されるが、強酸を通じた場合は酸末端がアルカリ金属、アルカリ土類金属から再び水素に置換されるため吸水・吸湿機能が低下するため、弱酸性水溶液の水素イオン濃度（ｐH）調整が必要であり、処理後の布帛ｐＨが４.５〜９.０程度になるように調整することが望ましい。
【００２５】
更に、アクリル酸やメタクリル酸の酸末端アルカリ塩化をよりマイルドなものにするために、アクリル酸やメタクリル酸の処方量を少なく抑え、親水性ジビニルモノマー若しくは親水性トリビニルモノマーを多く共重合させることが好ましい。親水性ジビニルモノマー若しくは親水性トリビニルモノマーはエチレンオキサイド等、親水基含有化合物の付加モル数が多くなるほど、水分散性及び布帛に加工した際の吸湿・吸水性が向上し、好ましい。
【００２６】
摩擦帯電圧を減少させるには繊維表面を親水化し導電性を向上させることによりいくらかの改善は可能であるが、導電糸を織り込み帯電した静電気を積極的に除去することも好適に実施される。従来のポリエステル系布帛では摩擦帯電圧が大きくなり過ぎるために導電糸を細かなピッチでストライプ或いはチェック形状に織り込んでいたが、導電糸自体に色がついているために見栄えが悪く、導電糸自体も割高であった。しかも高い帯電防止効果を保つには導電糸間隔を２〜２０mmピッチで配列しなければならなかった。
【００２７】
本発明では布帛表面を親水化したために、布帛自体が帯電し難く導電糸配列を２０〜４０mm、より好ましくは２０〜３０mmとすることが出来る。導電糸ピッチが４０mmを超過する範囲では、職場環境にもよるが帯電し易い環境下では塵埃を付着したり、着心地が悪化するなどの弊害が生じる可能性が高くなる。また、２０mm未満となると従来市販されていた無塵衣と何ら変わらない外観となるのみならず、導電糸が多くなる分だけ布帛コストが高くなってしまう。また、導電糸は強度的に脆弱であるため引裂強力等、力学的性能面でもピッチを広くし導電糸使用本数を減少させるのが望ましい。
【００２８】
本発明により得られる無塵衣は、ポリエステル系合成繊維フィラメント(A)、回収ポリエステル含有ポリエステルフィラメント(B)及び導電性繊維フィラメント(C)を交織してなる布帛を用いて縫製されてなり、前記ポリエステルフィラメント(B)の重量比率が縫製品総重量の５０重量%以上を占めることが望ましい。日本環境協会が認証するエコマーク対応には回収ポリエステルが総重量の５０重量％以上を占めることが必要である。回収ポリエステルフィラメント(B)は、布帛中の混用率によっては、回収ポリエステル１００重量％のフィラメントの代わりに、回収ポリエステルの含有率を１００重量％未満〜５０重量％程度にした回収ポリエステルフィラメントを用いることが出来る。
【００２９】
回収ポリエステルフィラメント(B)以外のポリエステル系合成繊維フィラメント(A)は、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリテトラメチレンテレフタレート等のホモポリマー、ブレンドポリマー、又はこれらを主な構成単位とするコポリマーを溶融紡糸することによって製造することが出来る。また、必要に応じて二酸化チタン、硫酸バリウム、二酸化珪素、カオリナイト等の無機微粒子を混練して艶消糸としてもよいし、顔料やカーボンブラック等を混練して原着糸とすることも出来る。また、その他酸化防止剤や安定剤、帯電防止剤等々を混練してもよい。勿論、回収ポリエステルも洗浄、粉砕後に必要に応じて艶消剤等の無機物質を混練、再ペレット化した上で公知の溶融紡糸法により長繊維化することが出来る。
【００３０】
繊維の断面形状については特に限定を加えるものではなく、丸断面の他、三角断面、扁平断面、その他多角断面、異型断面を用いることが出来る。また中実断面の他中空断面であってもよい。繊維断面は一様である必要はなく、複数種の異型断面糸をミックスした形態であってもよいし、繊度についても一様である必要はなく異繊度混繊であってもよい。
【００３１】
また、本発明において、ポリエステル無塵衣に使用するポリエステル長繊維の形態は捲縮のないフラットヤーンであってもよいし、捲縮を付与した仮撚加工糸、高圧流体交絡処理或いは高圧流体攪乱処理を実施したエアー加工糸であってもよく、用途や風合いに応じて適宜選定すればよい。また必要に応じて公知の撚糸装置を使用し撚糸を施すことも出来る。特に撚糸回数は特定されるものでないが、下記式にて求められる撚係数Kが５００〜３０００、好ましくは６００〜２５００の甘撚領域が好適に使用される。
K＝Tw×√（D×０.９０）
但し、Kは撚係数、Dはポリエステル長繊維の総繊度（dtex）、Twは１ｍ当りの撚数（回／ｍ）を示す。
【００３２】
本発明において、ポリエステル無塵衣を製織する織機については特に限定を加えるものではなく、エアージェットルーム、ウォータージェットルーム、レピアルーム、プロジェクタイルルーム等、公知の織機を使用して生産することが出来る。織組織についても特に限定を加えるものではなく、平織（プレーンウィーブ）の他、綾織（ツイルウィーブ）、朱子織（サテンウィーブ）等、公知の組織で製織することが出来る。無塵衣は肌や肌着から発生する塵埃等を空気中に飛散させないようなフィルター性を保持する必要があり、作業着として表面擦過にも充分耐え得る組織とする必要があることから、３/１や３/２、２/２の綾織が特に好ましく採用される。
【００３３】
本発明により得られるポリエステル無塵衣はポリエステル長繊維を経緯糸に用いてなるものである。総繊度及び単糸繊度については特に限定を加えるものではないが、無塵衣として好適な総繊度としては大略５０〜４００デシテックス、より好ましくは８０〜２５０デシテックスであり、好適な単糸繊度は０.３〜１０デシテックス、より好ましくは０.５〜５デシテックスの範囲が好ましく用いられる。
【００３４】
無塵衣は上記のポリエステル布帛を縫製して製造されるものであるが、自己発塵を抑制するために裁断はレーザー裁断や溶融裁断とすることが望ましい。通常の機械裁断であれば、布帛端面より布帛を形成する糸が抜け落ちる等の作用により発塵の原因になる可能性があり好ましくない。また縫製も布帛端面が露出しないように片倒しステッチやパイピングを採用し発塵要因を軽減することが望ましい。尚、本発明の無塵衣は作業着（ワンピース、ツーピース）本体の他、フェイスカバーマスクや手袋、フード類、帽子、靴表層材その他付属縫製品が全て包括される。
【００３５】
【実施例】
以下、実施例に従い本発明を更に詳しく説明する。尚、本文中及び実施例中に記載の特性値、物性値は以下の測定方法に基づき評価したものである。
（吸湿性）
下記関係式に基づき吸湿率Hを算出した。
H＝｛（H1−H0）／H0｝×１００ （%）
ここでH0はサンプル（布帛）の絶乾重量であり、サンプルを１２０℃で３時間乾燥した後の重量を表す。またH1はサンプル（布帛）の吸湿重量であり、上記乾燥後に所定の温湿度雰囲気下に６時間以上放置して調湿した後の重量である。温湿度雰囲気としては、衣服内気候に相当する３０℃、９５%RHと外気に相当する２０℃、６５%RHとの２種類に設定した。
【００３６】
（吸放湿性）
２０℃、６５％RH環境下と３０℃、９５％RH環境下での吸湿量の差で表す。算出式は下記の通りであり、実験回数５回の平均値を以ってその測定値とした。
吸放湿性＝（３０℃×９５%RH環境下に２４時間放置した際の重量増加率）
−（２０℃×６０%RH環境下に２４時間放置した際の重量増加率）
【００３７】
（吸水性）
JIS L−１０９６ ６−２６−１ A法（滴下法）に準じた方法で評価した。
【００３８】
（速乾性）
水に浸漬した試料を吸取紙或いは濾紙上に展開し余分な水分を除去した後、試料を秤量（Kｇ）し、２０℃、６５%RH環境下で３０分間の吊り干しを実施した後の試料の秤量（Ｌｇ）を行い、下記数式に従い生地の速乾性を評価した。測定回数５回の平均値を以ってその特性値とした。
速乾性（%）＝〔（Ｌ−Ｚ）／（Ｋ−Ｚ）〕×１００
但し、Ｚは試料の絶乾重量（ｇ）を示すものである。
（制電性）
JIS L−１０９４に準じ２０℃×４０%RH環境における摩擦帯電圧を評価した。
【００３９】
（発塵量）
JIS B−９９２３（発塵装置：タンブリング法）に準じて、光散乱式自動粒子係数器（JIS B−９９２１に準じた方式）を使用し、洗濯５０回後の試料に対する粒径（大きさ）０.５μｍ以上の粒子の発塵量（個／ft³・100ｃｍ²）を評価した。
（引裂強度）
JIS L−１０９６ ８−１５−５ D法（ペンジュラム法）に準じた方法で評価した。
【００４０】
（洗濯方法）
JIS L−０２１７の１０３法に準じて実施した。繰り返し洗濯については洗濯処理１回毎に吊り干しにて風乾し、基準の洗濯回数（５０回）の処理を施した。
（無塵衣着用感官能評価）
クリーンルーム（２０℃、４０％RH環境）内で作業者１０名に縫製品を着用してもらい、各官能値における５段階評価を実施し、その実績を積算、平均値を割り出し、◎〜×の総合評価を行った。
（◎＝好適、○＝適、△＝やや不良、×＝不適）
【００４１】
（実施例１）
回収ＰＥＴボトルを粉砕・洗浄した後、溶融・濾過し不純物を除去しアナタ−ゼ型二酸化チタン０.３重量%を混練して再ペレット化した。該ペレットを使用し、公知の溶融紡糸法にて再生ポリエステルセミダル丸断面８４デシテックス２４フィラメント(B)を得、公知の撚糸機を使用しＳ撚方向に２５０回／ｍの撚糸を挿入した。該撚糸条及び、ポリエステル系白色導電糸２８デシテックス２フィラメントとポリエステルセミダルマルチフィラメント仮撚加工糸（DTY）８４デシテックス３６フィラメントの合撚糸（Z撚 ２００回／ｍ）を１３５本：１本の割合で整経を施し、織物の経糸とした。（仕上生地の導電糸ストライプ間隔は２１．６mm。）
【００４２】
また緯糸はポリエステルセミダル丸断面マルチフィラメント１６７デシテックス４８フィラメント(A)と、経糸として使用した再生ポリエステルフィラメント(B)を２本合糸し、１６７デシテックスとした糸条を１本：１本の割合で緯打ち、ウォータージェットルームを用いて３／２綾組織に製織した。該布帛の回収ポリエステルからなる繊維の重量は布帛総重量の７２重量%を占める。この布帛を公知の方法で連続精練リラックス、プレセット及びプラストカレンダーによる裏面カレンダー処理を実施した後、分散染料による染色を施した。
【００４３】
該染色加工布を乾燥状態で下記処方による薬液（水分散液）を３０重量％パディングし、樹脂のマイグレーションを抑制するために１００℃の予備加熱を実施した後、１１０℃のスチーム処理を施した。
（薬液処方）
(1)第一工業製薬社製BPE30；23wt％ （化学式〔II〕のもの）
(2)メタクリル酸(試薬特級)；10wt％
(3)第一工業社製スーパーフレックスR5000(反応性ウレタン樹脂)；7wt％
(4)北広ケミカル社製ノヘ゛ールTD-888(浸透剤)；5wt％
(5)ヘ゜ルソオキソニ硫酸ナトリウム(試薬、重合開始剤)；1.7wt％
(6)日本触媒社製エホ゜クロスW700(オキサソ゛リン系架橋剤)；7wt％
(7)第一工業社製ハイテノールNF13(分散剤)；7wt％
その後、ソーダ灰(繊維重量あたり10wt％)を用いて70℃×10分にてナトリウム塩化を実施、水洗、乾燥を実施した。
【００４４】
得られた布帛の２０℃、６５％ＲＨ環境における吸湿率は２．１％、乾燥率が８６％、吸放湿度差が４．３％、ウィッキング法による吸水速度が０．２秒であり、加工剤分散液の分散性も良好で加工も容易であった。該加工布のペンジュラム法による引裂強度は１９．５Ｎ（洗濯初期値）であり、該加工布を用いてワンピースの無塵衣を縫製した。工業洗濯５０回後の摩擦帯電圧は３５０V、発塵量が２５０個／ft³・100ｃｍ²、ペンジュラム法による引裂強度は１６．３Ｎ（初期値に対する強度保持率８３．６％）であった。作業員１０名に無塵衣の着用感についてアンケート（官能評価）を依頼し、表１に結果を纏めた。従来のポリエステル無塵衣と比較し着用快適性は改善が認められ、べとつき感や蒸れ感を伴わない快適な無塵衣が得られた。
【００４５】
（実施例２）実施例１で得られた染色加工布を用い、乾燥状態で下記処方による薬液(水分散液)を３０重量％パディングし、樹脂のマイグレーションを抑制するために１００℃の予備加熱を実施した後、１１０℃のスチーム処理を施した。
（薬液処方）
(1)第一工業製薬社製TMP24；23wt％ （化学式〔IV〕のもの）
(2)メタクリル酸(試薬特級)；10wt％
(3)第一工業社製スーパーフレックスR5000(反応性ウレタン樹脂)；7wt％
(4)北広ケミカル社製ノヘ゛ールTD-888(浸透剤)；5wt％
(5)ヘ゜ルソオキソニ硫酸ナトリウム(試薬、重合開始剤)；1.7wt％
(6)日本触媒社製エホ゜クロスW700(オキサソ゛リン系架橋剤)；7wt％
(7)第一工業社製ハイテノールNF13(分散剤)；7wt％
その後、ソーダ灰(繊維重量あたり10wt％)を用いて70℃×10分にてナトリウム塩化を実施、水洗、乾燥を実施した。得られた布帛の２０℃、６５％ＲＨ環境における吸湿率は１．９％、乾燥率が８１％、吸放湿度差が３．８％、ウィッキング法による吸水速度が０．６秒であり、加工剤分散液の分散性も良好で加工も容易であった。また該加工布のペンジュラム法による引裂強度は２１．５Ｎ（洗濯初期値）であった。該加工布を使用しワンピースの無塵衣を縫製した。工業洗濯５０回後の摩擦帯電圧は５００V、発塵量が３６０個／ft³・100ｃｍ²、ペンジュラム法による引裂強度は１８．５Ｎ（初期値に対する強度保持率８６．０％）であった。作業員１０名に無塵衣の着用感についてアンケート（官能評価）を依頼し、表１に結果を纏めた。従来のポリエステル無塵衣と比較し着用快適性は改善が認められ、べとつき感や蒸れ感を伴わない快適な無塵衣が得られた。
【００４６】
（実施例３）実施例１で得られた染色加工布を用い、乾燥状態で下記処方による薬液(水分散液)を３０重量％パディングし、樹脂のマイグレーションを抑制するために１００℃の予備加熱を実施した後、１１０℃のスチーム処理を施した。
（薬液処方）
(1)第一工業製薬社製TMP24；30wt％ （化学式〔IV〕のもの）
(2)メタクリル酸(試薬特級)；3wt％
(3)第一工業社製スーパーフレックスR5000(反応性ウレタン樹脂)；7wt％
(4)北広ケミカル社製ノヘ゛ールTD-888(浸透剤)；5wt％
(5)ヘ゜ルソオキソニ硫酸ナトリウム(試薬、重合開始剤)；1.7wt％
(6)日本触媒社製エホ゜クロスW700(オキサソ゛リン系架橋剤)；7wt％
(7)第一工業社製ハイテノールNF13(分散剤)；7wt％
その後、ソーダ灰(繊維重量あたり10wt％)を用いて70℃×10分ナトリウム塩化を実施、水洗、乾燥を実施した。得られた布帛の２０℃、６５％ＲＨ環境における吸湿率は１．８％、乾燥率が７４％、吸放湿度差が３．４％、ウィッキング法による吸水速度が０．８秒であり、加工剤分散液の分散性も良好で加工も容易であった。また該加工布のペンジュラム法による引裂強度は２２．５Ｎ（洗濯初期値）であった。該加工布を使用しワンピースの無塵衣を縫製した。工業洗濯５０回後の摩擦帯電圧は７８０V、発塵量が４７０個／ft³・100ｃｍ²、ペンジュラム法による引裂強度は１９．５Ｎ（初期値に対する強度保持率８６．７％）であった。作業員１０名に無塵衣の着用感についてアンケート（官能評価）を依頼し、表１に結果を纏めた。従来のポリエステル無塵衣と比較し着用快適性は改善が認められ、べとつき感や蒸れ感を伴わない快適な無塵衣が得られた。
【００４７】
（比較例１）実施例１で得られた染色加工布を用い、乾燥状態で下記処方による薬液(水分散液)を３０重量％パディングし、樹脂のマイグレーションを抑制するために１００℃の予備加熱を実施した後、１１０℃のスチーム処理を施した。
（薬液処方）
(1)メタクリル酸(試薬特級)；30wt％
(2)第一工業社製スーパーフレックスR5000(反応性ウレタン樹脂)；7wt％
(3)北広ケミカル社製ノヘ゛ールTD-888(浸透剤)；5wt％
(4)ヘ゜ルソオキソニ硫酸ナトリウム(試薬、重合開始剤)；1.7wt％
(5)日本触媒社製エホ゜クロスW700(オキサソ゛リン系架橋剤)；7wt％
(6)第一工業社製ハイテノールNF13(分散剤)；7wt％
その後、ソーダ灰(繊維重量あたり10wt％)を用いて70℃×10分にてナトリウム塩化を実施、水洗、乾燥を実施した。得られた布帛の２０℃、６５％ＲＨ環境における吸湿率は０．９％、乾燥率が６５％、吸放湿度差が２．２％、ウィッキング法による吸水速度が１．４秒であった。また該加工布のペンジュラム法による引裂強度は２３．０Ｎ（洗濯初期値）であった。該加工布を使用しワンピースの無塵衣を縫製した。工業洗濯５０回後の摩擦帯電圧は９８０V、発塵量が６３０個／ft³・100ｃｍ²、ペンジュラム法による引裂強度は１９．１Ｎ（初期値に対する強度保持率８３．０％）であった。作業員１０名に無塵衣の着用感についてアンケート（官能評価）を依頼し、表１に結果を纏めた。従来のポリエステル無塵衣と同様、着用時の蒸れ感やべとつき感を感じるものとなり、着用快適な無塵衣にはならなかった。
【００４８】
（比較例2）実施例１で得られた染色加工布を用い、乾燥状態で下記処方による薬液(水分散液)を３０重量％パディングし、樹脂のマイグレーションを抑制するために１００℃の予備加熱を実施した後、１１０℃のスチーム処理を施した。
（薬液処方）
(1)第一工業製薬社製PEM200；30wt%
(2)メタクリル酸(試薬特級)；3wt％
(3)北広ケミカル社製ノヘ゛ールTD-888(浸透剤)；5wt％
(4)ヘ゜ルソオキソニ硫酸ナトリウム(試薬、重合開始剤)；1.7wt％
(5)日本触媒社製エホ゜クロスW700(オキサソ゛リン系架橋剤)；7wt％
(6)第一工業社製ハイテノールNF13(分散剤)；7wt％
その後、ソーダ灰(繊維重量あたり10wt％)を用いて70℃×10分にてナトリウム塩化を実施、水洗、乾燥を実施した。得られた布帛の２０℃、６５％ＲＨ環境における吸湿率は０．６％で、乾燥率が５９％、吸放湿度差が１．５％、ウィッキング法による吸水速度が２．５秒であった。また該加工布のペンジュラム法による引裂強度は２２．８Ｎ（洗濯初期値）であった。加工剤分散液の分散性が非常に悪く、加工が困難であり布帛も実用に供する品位には仕上がらなかった。また工業洗濯５０回後の摩擦帯電圧は１３５０V、発塵量が８９０個／ft³・100ｃｍ²、ペンジュラム法による引裂強度は１８．７Ｎ（初期値に対する強度保持率８２．０％）であり摩擦帯電圧、発塵量共に高い数値を示すものとなり無塵衣としての要求を満足するものにはならなかった。
【００４９】
表１は、縫製した無塵衣の着用感アンケート（官能評価）の結果を示したものである。
【表１】

【００５０】
【発明の効果】
本発明によると自己発塵性が極めて低く、洗濯耐久性や着用時のソフト感にも優れ、着用時の衣服内湿度を快適領域に留め、作業時の不快感を伴わない無塵衣を得ることが可能となり、作業者の作業環境面の改善及び精神衛生面での改善を図ることが出来る等の効果を奏する。更には無塵衣（縫製品）総重量の５０重量%以上を回収ＰＥＴボトル等からなる再生ポリエステルフィラメントを使用したことによりエコマーク対応、グリーン購入法対応の快適無塵衣とすることが可能である。[0001]
BACKGROUND OF THE INVENTION
The present invention is a dust-free garment made of polyester fibers having excellent hygroscopicity.Manufacturing methodIn detail, comfortable polyester dust-free clothing that is friendly to the global environment, using polyester filaments with recovered polyesterManufacturing methodIt is about.
[0002]
[Prior art]
Conventionally, wearing work clothes that generate dust in precision machine manufacturing / assembly industry or food processing industry, pharmaceutical manufacturing industry, semiconductor manufacturing industry, etc. is not preferable due to the nature of the product, and generates dust. It is necessary to wear dust-free clothing and engage in work. However, the dust-free garment should not release sweat and other excretions generated from the body, sebum, keratin, textile waste generated from underwear, dust, etc. into the work environment, and itself should not be self-dusting. It is. For this reason, it is difficult to use cotton, cellulosic fibers and other natural fibers that are comfortable to wear, and the breathability is poor. Met.
[0003]
In addition, with the recent ecology boom and increased recycling activities, the movement of using recycled polyester products to be recycled as fibers after washing, pulverizing and re-pelletizing collected polyester such as PET bottles, It is becoming more active at business establishments. Dust-free garments made from recycled PET bottle fibers that comply with the Green Purchasing Law and the Eco Mark certified by the Japan Environment Association have extremely high social demands.
[0004]
[Problems to be solved by the invention]
The present invention eliminates the conventional drawbacks and is a dust-free garment that can work comfortably without causing discomfort when worn.Manufacturing methodIn more detail, the self-dusting property is extremely low, the washing durability and the soft feeling during wearing are excellent, the humidity in the clothes during wearing is kept in a comfortable area, Dust-free clothing compatible with Eco Mark and Green Purchasing Law without discomfortManufacturing methodIt is a problem to provide.
[0005]
[Means for Solving the Problems]
The present invention has the following configuration.
1. Cloth comprising polyester-based synthetic fiber filament (A), recovered polyester-containing polyester filament (B), and conductive fiber filament (C)Vinyl carboxylic acid and / or vinyl sulfonic acid, and general formula [ I ], [ II ], [ III ], [ IV A vinyl carboxylic acid and / or vinyl sulfonic acid monomer and a divinyl monomer or a trivinyl monomer in a ratio of 1: 1 to 1:10 by weight. After fixing the fiber with acid and introducing acid-terminated alkali metal or alkaline earth metal (salt),SewingShiThe weight ratio of the polyester filament (B) accounts for 50% by weight or more of the total weight of the sewing product and satisfies the following requirements (1) to (4):MakeDust-free clothing using recovered polyester with excellent wearing comfortManufacturing method.
(1) Moisture absorption at 20 ° C and 65% RH environment is 1.5% or more
(2) Humidity difference between 20 ° C and 65% RH environment and 30 ° C and 95% RH environment is 3% or more
(3) Water absorption rate by wicking method is less than 1 second
(4) Drying rate of 70% or more by air-drying at 20 ° C and 65% RH for 30 minutes
[0006]
2. Conductive fiber filaments are disposed on at least one of warp and / or weft, and the spacing between the conductive fiber filaments is 20 to 40 mm,Of dustless clothes obtainedThe polyester dust-free garment using the recovered polyester excellent in wearing comfort, characterized in that the performance after 50 times of industrial washing according to JIS L0217 103 method satisfies the following requirements (5) to (7):Manufacturing method.
(5) Friction voltage is 1 kV or less
(6) The amount of dust generated by JIS B9923 (tumbling method) with a particle size of 0.5 μm or more is 100 to 500 particles / ft.^Three・ 100cm²
(7) Tear strength by pendulum method is 9.8N or more, tear strength retention rate at the beginning of washing is 80% or more
[0008]
4). Using a reactive polyurethane binder as a nucleating agent for the coating layer on the fiber, at least one selected from vinyl carboxylic acid and / or vinyl sulfonic acid monomer, general formula [I], [II], [III], [IV] A first type of vinyl monomer obtained by forming a cross-linked film of various types of vinyl monomers via an oxazoline-based or aziridine-based crosslinking agent.Or secondA dust-free garment using recovered polyester with excellent wearing comfortManufacturing method.
[Chemical formula 2]

[0009]
DETAILED DESCRIPTION OF THE INVENTION
The present inventionObtained byThe polyester dust-free garment has a moisture absorption rate of 1.5% or more, more preferably 2% or more, and still more preferably 2.5% or more in an environment of 20 ° C. and 65% RH. If the hygroscopicity is less than 1.5%, high hygroscopicity cannot be realized even if the dustless garment is worn in a clean room. The upper limit of the moisture absorption rate is not particularly specified, but if the hygroscopicity is too high, it becomes difficult to dry, and it is preferable because it causes wrinkles, a feeling of weight when worn, and a feeling of cohesion. I can not say. It is preferable to keep the moisture absorption rate to about 10%.
[0010]
Further, it is desired that the difference in moisture absorption and desorption in a 20 ° C., 65% RH environment and a 30 ° C., 95% RH environment is 3% or more, more preferably 5% or more. Here, the 20 ° C. and 65% RH environment represents the standard environment of the outside air, and the 30 ° C. and 95% RH environment represents the air environment (in-clothing environment) existing between the dust-free garment and the skin. If the difference in moisture absorption and desorption is less than 3%, it is not possible to obtain a bodily sensation of “sucking and releasing moisture (sweat)” when actually worn, and it is not possible to feel a smooth feeling on the skin surface.
[0011]
In addition, the present inventionObtained byThe water absorption speed of the polyester dust-free garment using the recovered polyester is preferably 1 second or less by the wicking method. The water absorption speed is a measure of how water droplets diffuse into the fabric surface and inside, and the slower the water droplets, the more easily the water droplets are scattered on the floor surface and other work environments, which may cause an unexpected major accident. In addition, the slower the water absorption rate, the longer the wetness of the skin surface, and the more comfortable work clothes (dust-free clothes) will be. Increasing the water absorption rate can be achieved by improving the capillary action of the fiber and the wettability of the fiber surface.
[0012]
The quick drying property is 70% or more, more preferably 80% or more by air drying for 30 minutes in an environment of 20 ° C. and 65% RH. In the case of actual wearing, the degree of drying varies depending on factors such as the environmental temperature and humidity, air movement state, heat transfer from the skin surface, etc., but the drying rate is 30 minutes air drying in an environment of 20 ° C and 65% RH. If it is less than 70%, the ability to retain absorbed and perspired moisture is too high, and it will become moistened forever, causing sticking to the skin and the accompanying deterioration in exercise performance, and significantly impairing work efficiency and wearing feeling. . Although there is no particular limitation on the upper limit value, the quick drying property improves as the drying rate approaches 100%, so that a smooth touch can be obtained forever.
[0013]
In terms of the characteristics of the dust-free garment, it is preferable to maintain the performance of 1 KV or less, more preferably 0.7 KV or less, and still more preferably 0.5 KV or less as measured in the frictional voltage. If the frictional voltage exceeds 1 KV, dust in the air can be easily adsorbed, and in workplaces where volatile organic solvents are used, it can cause ignition by static electricity, which is not preferable for work. Furthermore, since the feeling of wearing is not preferable, it is accompanied by mental pain.
[0014]
About dust generation amount 100-500 pieces / ft^Three・ 100cm²Range, more preferably 100 to 350 pieces / ft^Three・ 100cm²Range. In the food / pharmaceutical field, precision machine manufacturing field, other machinery and chemical fields, etc., the amount of dust generation is small, but it is 100% / ft.^Three・ 100cm²In the ultra-clean field below, process mechanization has progressed, and it has disappeared in the field where humans work directly. It is expensive in terms of the production cost and cleaning cost of dust-free garments, and the price for obtaining excessive performance is large.
500 / ft^Three・ 100cm²In a region exceeding the limit, the generation amount of dust is too large, and the yield of the product is deteriorated and the problem of foreign matters is likely to occur.
[0015]
The present inventionInThe tear strength of the fabric used for the polyester dust-free garment is 9.8 N or more, more preferably 15.0 N or more. When the tear strength is less than 9.8 N, when worn as a dust-free garment or work clothes, especially bent parts such as elbows and knees are accompanied by a large deformation of the fabric, it is easy to tear and cannot be put to practical use. Although it is desirable that the tear strength has a large value, it is necessary to improve the degree of orientation of the fibers constituting the fabric in the fiber axis direction to form a high-strength yarn. There is a tendency to finish in texture.
[0016]
Regarding the tear strength retention after washing, the retention after 50 washes with respect to the initial stage is 80% or more, more preferably 85% or more. The washing process is carried out in accordance with method 103 of JIS L-0217. As the washing is repeated, the strength of the fabric and the sewing part decreases, but the tear strength retention after 50 washings is 80%. If it is less than the above, the strength is greatly reduced with respect to the initial performance, which is inconvenient for practical use.
[0017]
In order to impart water absorption and moisture absorption performance to the polyester fabric, in the present invention, at least one selected from vinyl carboxylic acid and / or vinyl sulfonic acid, and general formulas [I], [II], [III], and [IV] is used. A type of divinyl monomer or trivinyl monomer and a processing agent comprising a polymerization initiator are applied to the fiber surface using a technique such as the pad steam method. Vinyl carboxylic acid and / or vinyl sulfonic acid monomer and divinyl monomer or trivinyl The monomer is fixed to the fiber at a ratio of 1: 1 to 1:10.
[Chemical Formula 3]

[0018]
Regarding the weight fraction of vinyl carboxylic acid and / or vinyl sulfonic acid monomer and divinyl monomer or trivinyl monomer fixed to the fiber, if the latter amount is less than 1 time compared to the former, the alkali metal to the carboxylic acid or sulfonic acid end, or It is necessary to carry out terminal group substitution treatment with strong alkali for alkaline earth metal substitution, which is not preferred because of concern about yellowing of the fabric and effects on skin (rash, roughening, etc.). On the other hand, if the amount of the latter is 10 times or more compared with the former, the film strength becomes too small, which is not preferable in consideration of durability such as deterioration of washing durability.
[0019]
The term “fixation” in the present invention means a state in which it is chemically or physically bonded and does not easily fall off by washing or the like.
[0020]
In order to hydrophilize the surface of hydrophobic fibers such as polyester, it is known to fix hydrophilic components by various graft polymerization processing methods. As a method for initiating radical polymerization, methods using ultraviolet rays, electron beams, or other radiation, and starting Methods using the agent are also well known, and these methods can be employed in the present invention. However, the method of using radiation or the like is greatly restricted in terms of work environment and apparatus, and it is desirable to employ the latter initiator method. The initiator is not limited, but is preferably applied in a low to medium temperature range, that is, about −10 to 100 ° C., such as inorganic polymerization initiators such as ammonium persulfate, potassium persulfate, and ammonium sulfate; , 2'-azobis (2-aminopropane) dihydrochloride, 2,2'-azobis (N, N'-dimethyleneisobutylamidine) dihydrochloride, 2- (carbamoylazo) isobutyronitrile, etc. Although a polymerization initiator can be illustrated, use of an inorganic initiator is preferable from the viewpoint of cost and ease of handling.
[0021]
In general, the radical polymerization initiator is a compound having a bond relatively weak to heat (low bond dissociation energy) in the molecule, and it is desirable to be one that decomposes by heating and easily forms a radical. The addition amount of the radical polymerization initiator is not particularly limited, but is preferably 0.1 to 3.0% by weight in the processing agent, and if it is less than 0.1% by weight, the radical polymerization reaction is insufficient. If it is within a range exceeding 3.0% by weight, it is disadvantageous in terms of cost.
[0022]
Examples of methods for applying a processing agent comprising a polymerization initiator, a crosslinking agent, and a monomer as a base for graft polymerization to the fabric include methods such as roller padding, spraying, and dye exhaustion. After that, the method of carrying out high-pressure steaming to promote graft polymerization is a continuous process, and is very effective in consideration of process speed, cost, and quality.
The high-pressure steaming prevents the monomer from evaporating and prevents a decrease in polymerization efficiency, so that the process residence time is adjusted not to be excessively long under the conditions of the reactor temperature of 90 to 130 ° C, preferably 95 to 120 ° C. It is desirable to do. In addition, in order to suppress the heating efficiency and the migration of the resin in the processing agent, it is also preferable to use high frequency heating in combination with the above steaming.
[0023]
In order to make the fiber surface hydrophilic, the above-mentioned processing agent is applied to form a hydrophilic resin film layer on the fiber surface, but in order to make the resin film layer stronger, a monomer that can be a nucleating agent is used in combination. Is more effective. As the agent that can be a nucleating agent, a reactive polyurethane resin is desirable, and examples thereof include Superflex and Elastron manufactured by Daiichi Kogyo Seiyaku Co., Ltd. In order to further strengthen the resin film layer, it is preferable to use a polyfunctional crosslinking agent to form a three-dimensional crosslinking, and an oxazoline-based or aziridine-based crosslinking agent represented by the following strengthens the film strength. It is effective in the above and is preferably used.
[Formula 4]

[0024]
Further, in order to improve the water dispersibility of the processing agent, it is preferable to uniformly emulsify the hydrophobic component. In particular, acrylic acid and methacrylic acid components have poor water dispersibility, and it is preferable to uniformly disperse them in the processing liquid using an emulsifying dispersant. Further, after performing processing agent padding and steam treatment for promoting surface graft polymerization, introduction (chlorination) of alkali metals and alkaline earth metals into acid ends is carried out through aqueous solutions of soda ash and caustic soda. After carrying out acid-terminal chlorination, washing with water is carried out sufficiently to remove unnecessary alkali components. After passing through a weakly acidic aqueous solution such as succinic acid, citric acid, malic acid, etc., repeated washing with water will neutralize and remove excess alkali components. Since it is replaced with hydrogen, the water absorption / moisture absorption function is lowered, so it is necessary to adjust the hydrogen ion concentration (pH) of the weakly acidic aqueous solution, and the fabric pH after treatment is adjusted to about 4.5 to 9.0. It is desirable to do.
[0025]
In addition, in order to make the acid-terminated alkaline chloride of acrylic acid and methacrylic acid milder, the amount of acrylic acid and methacrylic acid should be kept small and a large amount of hydrophilic divinyl monomer or hydrophilic trivinyl monomer should be copolymerized. Is preferred. A hydrophilic divinyl monomer or a hydrophilic trivinyl monomer is more preferable as the number of added moles of a hydrophilic group-containing compound such as ethylene oxide is improved because water dispersibility and moisture absorption and water absorption when processed into a fabric are improved.
[0026]
In order to reduce the frictional voltage, some improvement is possible by making the fiber surface hydrophilic and improving the conductivity. However, it is also preferable to actively remove the static electricity charged by weaving the conductive yarn. In the conventional polyester fabric, the conductive yarn is woven into a stripe or check shape at a fine pitch because the frictional voltage becomes too large. However, since the conductive yarn itself is colored, it looks bad and the conductive yarn itself It was expensive. Moreover, in order to maintain a high antistatic effect, the conductive yarn intervals had to be arranged at a pitch of 2 to 20 mm.
[0027]
In the present invention, since the fabric surface is made hydrophilic, the fabric itself is difficult to be charged, and the conductive yarn array can be 20 to 40 mm, more preferably 20 to 30 mm. In the range in which the conductive yarn pitch exceeds 40 mm, there is a high possibility that adverse effects such as adhesion of dust and deterioration of wearing comfort will occur in an environment that is easily charged although it depends on the workplace environment. On the other hand, when the thickness is less than 20 mm, the appearance is not different from that of a dustless garment that has been commercially available in the past, and the fabric cost increases as the conductive yarn increases. Further, since the conductive yarn is weak in strength, it is desirable to reduce the number of conductive yarns used by widening the pitch in terms of mechanical performance such as tearing strength.
[0028]
The present inventionObtained byThe dust-free garment is sewn using a cloth formed by interweaving a polyester-based synthetic fiber filament (A), a recovered polyester-containing polyester filament (B) and a conductive fiber filament (C), and the polyester filament (B) It is desirable that the weight ratio occupies 50% by weight or more of the total weight of the sewing product. In order to comply with the Eco Mark certified by the Japan Environment Association, it is necessary that the recovered polyester accounts for 50% by weight or more of the total weight. The recovered polyester filament (B) may be a recovered polyester filament having a recovered polyester content of less than 100% by weight to about 50% by weight, instead of the recovered polyester 100% by weight filament, depending on the mixing ratio in the fabric. I can do it.
[0029]
Polyester synthetic fiber filaments (A) other than the recovered polyester filament (B) are melt-spun from homopolymers such as polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, blend polymers, or copolymers containing these as main structural units. Can be manufactured. Further, if necessary, inorganic fine particles such as titanium dioxide, barium sulfate, silicon dioxide, and kaolinite may be kneaded to make a matting yarn, or a pigment, carbon black, or the like may be kneaded to make an original yarn. . In addition, antioxidants, stabilizers, antistatic agents, and the like may be kneaded. Of course, the recovered polyester can also be made into long fibers by a known melt spinning method after kneading and re-pelletizing an inorganic substance such as a matting agent as necessary after washing and pulverization.
[0030]
The cross-sectional shape of the fiber is not particularly limited, and a triangular cross-section, a flat cross-section, other polygonal cross-sections, and an irregular cross-section can be used in addition to a round cross-section. Further, it may be a hollow section other than a solid section. The fiber cross-section need not be uniform, and may be a form in which a plurality of types of irregular cross-section yarns are mixed, and the fineness need not be uniform and may be mixed with different fineness.
[0031]
In addition, the present inventionInPolyester filaments used in polyester dust-free garments may be flat yarns without crimps, false twisted yarns with crimps, high-pressure fluid entanglement treatment or air processing with high-pressure fluid disturbance treatment It may be a yarn and may be appropriately selected according to the use and texture. If necessary, twisting can be performed using a known twisting device. Although the number of twists is not particularly specified, a sweet twist region having a twist coefficient K determined by the following formula of 500 to 3000, preferably 600 to 2500 is preferably used.
K = Tw × √ (D × 0.90)
However, K is a twist coefficient, D is the total fineness (dtex) of the polyester long fiber, and Tw is the number of twists per meter (times / m).
[0032]
The present inventionInThe loom for weaving the polyester dust-free garment is not particularly limited, and can be produced using a known loom such as an air jet room, a water jet room, a rapier room, or a projector room. The weaving structure is not particularly limited, and it can be woven with a known structure such as plain weave, twill weave, satin weave or the like. The dust-free garment needs to maintain a filter property that prevents dust and the like generated from the skin and underwear from being scattered in the air, and it is necessary to have a structure that can sufficiently withstand surface abrasion as work clothes. A twill weave of 1 or 3/2 or 2/2 is particularly preferably employed.
[0033]
The present inventionObtained byThe polyester dust-free garment is made of polyester long fibers for warp and weft. The total fineness and single yarn fineness are not particularly limited, but the total fineness suitable as a dust-free garment is approximately 50 to 400 dtex, more preferably 80 to 250 dtex, and the preferred single yarn fineness is 0. The range of 0.3 to 10 dtex is more preferably used, and more preferably 0.5 to 5 dtex.
[0034]
The dust-free garment is manufactured by sewing the above-mentioned polyester fabric, but it is desirable that the cutting is laser cutting or melt cutting in order to suppress self-dusting. Ordinary mechanical cutting is not preferable because it may cause dust generation due to an action such as the yarn forming the fabric coming off from the end surface of the fabric. In addition, it is desirable to reduce the cause of dust generation by sewing stitches and piping so that the end face of the fabric is not exposed. In addition, the dust-free garment of the present invention includes not only work clothes (one-piece, two-piece) bodies but also face cover masks, gloves, hoods, hats, shoe surface materials and other attached sewing products.
[0035]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples. The characteristic values and physical property values described in the text and in the examples are evaluated based on the following measuring methods.
(Hygroscopic)
The moisture absorption H was calculated based on the following relational expression.
H = {(H1−H0) / H0} × 100 (%)
Here, H0 is the absolute dry weight of the sample (fabric) and represents the weight after drying the sample at 120 ° C. for 3 hours. H1 is a moisture absorption weight of the sample (fabric), and is a weight after conditioning after being dried and left in a predetermined temperature and humidity atmosphere for 6 hours or more. Two temperature and humidity atmospheres were set, 30 ° C. and 95% RH corresponding to the climate in clothes and 20 ° C. and 65% RH corresponding to the outside air.
[0036]
(Hygroscopic)
This is expressed as a difference in moisture absorption between a 20 ° C. and 65% RH environment and a 30 ° C. and 95% RH environment. The calculation formula is as follows, and the measured value was determined by taking an average value of five times of experiments.
Hygroscopicity = (weight increase rate when left in a 30 ° C x 95% RH environment for 24 hours)
-(Weight increase rate when left in an environment of 20 ° C x 60% RH for 24 hours)
[0037]
(Water absorption)
Evaluation was performed by a method according to JIS L-1096 6-26-1 A method (drop method).
[0038]
(Quick-drying)
After the sample soaked in water is spread on blotting paper or filter paper to remove excess water, the sample is weighed (Kg) and suspended for 30 minutes in a 20 ° C, 65% RH environment. Was weighed (Lg), and the quick drying property of the dough was evaluated according to the following formula. The characteristic value was determined by taking an average value of five measurements.
Quick drying (%) = [(L−Z) / (K−Z)] × 100
However, Z shows the absolute dry weight (g) of a sample.
(Antistatic)
According to JIS L-1094, the frictional voltage in a 20 ° C. × 40% RH environment was evaluated.
[0039]
(Dust generation)
According to JIS B-9923 (dust generation device: tumbling method), a light scattering type automatic particle coefficient device (method according to JIS B-9921) is used, and the particle size (size) for the sample after 50 washings. Dust generation amount of particles over 0.5μm (pieces / ft^Three・ 100cm²) Was evaluated.
(Tear strength)
Evaluation was performed by a method according to JIS L-1096 8-15-5 D method (pendulum method).
[0040]
(Washing method)
This was carried out in accordance with method 103 of JIS L-0217. About repeated washing, it air-dried by hanging and drying for every washing process, and the process of the reference | standard washing frequency (50 times) was given.
(Density-free wearing sensory evaluation)
In a clean room (20 ° C, 40% RH environment), ask 10 workers to wear sewn products, perform a five-level evaluation for each sensory value, integrate the results, calculate the average value, A comprehensive evaluation was conducted.
(◎ = preferred, ○ = suitable, Δ = slightly poor, x = unsuitable)
[0041]
Example 1
The recovered PET bottle was pulverized and washed, then melted and filtered to remove impurities, and 0.3% by weight of anatase-type titanium dioxide was kneaded and re-pelletized. Using the pellets, a recycled polyester semi-dull round cross section 84 dtex 24 filament (B) was obtained by a known melt spinning method, and a twist of 250 times / m was inserted in the S twist direction using a known twister. A ratio of 135 twisted yarns (polyester white conductive yarn 28 dtex 2 filaments and polyester semi-dal multifilament false twisted yarn (DTY) 84 dtex 36 filaments) (z twist 200 times / m) Warping was applied to make a warp of the woven fabric. (The conductive yarn stripe spacing of the finished fabric is 21.6 mm.)
[0042]
The weft yarn is a polyester semi-dal round cross-section multifilament 167 dtex 48 filament (A) and two recycled polyester filaments (B) used as warp yarns. And weaved into a 3/2 twill structure using a water jet loom. The weight of the fiber made from the recovered polyester of the fabric accounts for 72% by weight of the total weight of the fabric. This fabric was subjected to continuous scouring relaxation, presetting, and backside calender treatment by a plast calender by a known method, followed by dyeing with a disperse dye.
[0043]
The dyed cloth was dried and padded with 30% by weight of a chemical solution (aqueous dispersion) according to the following formulation, preheated at 100 ° C to suppress resin migration, and then steamed at 110 ° C. .
(Chemical solution prescription)
(1) Daiichi Kogyo Seiyaku BPE30; 23wt% (chemical formula [II])
(2) Methacrylic acid (special grade reagent); 10wt%
(3) Daiichi Kogyo Superflex R5000 (reactive urethane resin); 7wt%
(4) Kitahiro Chemical Nobel TD-888 (penetrant); 5wt%
(5) Sodium hesooxodisulfate (reagent, polymerization initiator); 1.7 wt%
(6) Nippon Shokubai Ekocross W700 (oxazoline-based crosslinking agent); 7wt%
(7) Daiten Kogyo Hitenol NF13 (dispersant): 7wt%
Thereafter, sodium chloride was performed using soda ash (10 wt% per fiber weight) at 70 ° C. for 10 minutes, followed by washing with water and drying.
[0044]
The resulting fabric has a moisture absorption rate of 2.1% at 20 ° C. and 65% RH, a drying rate of 86%, a moisture absorption / release difference of 4.3%, and a water absorption rate by the wicking method of 0.2 seconds. The dispersibility of the processing agent dispersion was good and processing was easy. The tear strength of the work cloth by the pendulum method was 19.5 N (initial value for washing), and a one-piece dust-free garment was sewn using the work cloth. Friction band voltage after industrial washing 50 times is 350V, dust generation amount is 250 pieces / ft^Three・ 100cm²The tear strength according to the pendulum method was 16.3 N (strength retention 83.6% relative to the initial value). 10 workers were asked for a questionnaire (sensory evaluation) on the feeling of wearing the dust-free garments, and the results are summarized in Table 1. Compared to the conventional polyester dust-free garment, the wearing comfort was improved, and a comfortable dust-free garment without stickiness and stuffiness was obtained.
[0045]
(Example 2) Using the dyed fabric obtained in Example 1, 30% by weight of a chemical solution (aqueous dispersion) having the following formulation was padded in a dry state, and preheated at 100 ° C to suppress resin migration After performing, the steam process of 110 degreeC was performed.
(Chemical solution prescription)
(1) Daiichi Kogyo Seiyaku Co., Ltd. TMP24; 23wt% (chemical formula [IV])
(2) Methacrylic acid (special grade reagent); 10wt%
(3) Daiichi Kogyo Superflex R5000 (reactive urethane resin); 7wt%
(4) Kitahiro Chemical Nobel TD-888 (penetrant); 5wt%
(5) Sodium hesooxodisulfate (reagent, polymerization initiator); 1.7 wt%
(6) Nippon Shokubai Ekocross W700 (oxazoline-based crosslinking agent); 7wt%
(7) Daiten Kogyo Hitenol NF13 (dispersant): 7wt%
Thereafter, sodium chloride was performed using soda ash (10 wt% per fiber weight) at 70 ° C. for 10 minutes, followed by washing with water and drying. The resulting fabric has a moisture absorption rate of 1.9% at 20 ° C. and 65% RH, a drying rate of 81%, a moisture absorption / release difference of 3.8%, and a water absorption rate by the wicking method of 0.6 seconds. The dispersibility of the processing agent dispersion was good and processing was easy. Further, the tear strength of the processed fabric by the pendulum method was 21.5 N (initial value for washing). A one-piece dust-free garment was sewn using the processed cloth. Friction band voltage after industrial washing 50 times is 500V, dust generation amount is 360 pieces / ft^Three・ 100cm²The tear strength by the pendulum method was 18.5 N (strength retention rate relative to the initial value: 86.0%). 10 workers were asked for a questionnaire (sensory evaluation) on the feeling of wearing the dust-free garments, and the results are summarized in Table 1. Compared to the conventional polyester dust-free garment, the wearing comfort was improved, and a comfortable dust-free garment without stickiness and stuffiness was obtained.
[0046]
(Example 3) Using the dyed cloth obtained in Example 1, 30% by weight of a chemical solution (aqueous dispersion) according to the following formulation was padded in a dry state, and preheated at 100 ° C to suppress resin migration After performing, the steam process of 110 degreeC was performed.
(Chemical solution prescription)
(1) Daiichi Kogyo Seiyaku Co., Ltd. TMP24; 30wt% (chemical formula [IV])
(2) Methacrylic acid (special grade reagent); 3wt%
(3) Daiichi Kogyo Superflex R5000 (reactive urethane resin); 7wt%
(4) Kitahiro Chemical Nobel TD-888 (penetrant); 5wt%
(5) Sodium hesooxodisulfate (reagent, polymerization initiator); 1.7 wt%
(6) Nippon Shokubai Ekocross W700 (oxazoline-based crosslinking agent); 7wt%
(7) Daiten Kogyo Hitenol NF13 (dispersant): 7wt%
Then, sodium chloride was performed at 70 ° C. for 10 minutes using soda ash (10 wt% per fiber weight), washed with water, and dried. The resulting fabric has a moisture absorption rate of 1.8% at 20 ° C. and 65% RH, a drying rate of 74%, a moisture absorption / release difference of 3.4%, and a water absorption rate by the wicking method of 0.8 seconds. The dispersibility of the processing agent dispersion was good and processing was easy. Further, the tear strength of the processed fabric by the pendulum method was 22.5 N (initial value for washing). A one-piece dust-free garment was sewn using the processed cloth. Friction band voltage after 50 times of industrial washing is 780V, dust generation amount is 470 pieces / ft^Three・ 100cm²The tear strength by the pendulum method was 19.5 N (strength retention rate relative to the initial value: 86.7%). 10 workers were asked for a questionnaire (sensory evaluation) on the feeling of wearing the dust-free garments, and the results are summarized in Table 1. Compared to the conventional polyester dust-free garment, the wearing comfort was improved, and a comfortable dust-free garment without stickiness and stuffiness was obtained.
[0047]
(Comparative Example 1) Using the dyed fabric obtained in Example 1, 30% by weight of a chemical solution (aqueous dispersion) having the following formulation was padded in a dry state, and preheated at 100 ° C to suppress resin migration After performing, the steam process of 110 degreeC was performed.
(Chemical solution prescription)
(1) Methacrylic acid (special grade reagent); 30wt%
(2) Daiichi Kogyo Superflex R5000 (reactive urethane resin): 7wt%
(3) Kitahiro Chemical Nobel TD-888 (penetrant); 5wt%
(4) Sodium hesooxodisulfate (reagent, polymerization initiator); 1.7 wt%
(5) Nippon Shokubai Ekocross W700 (Oxazoline-based crosslinking agent); 7wt%
(6) Daiten Kogyo Hitenol NF13 (dispersant): 7wt%
Thereafter, sodium chloride was performed using soda ash (10 wt% per fiber weight) at 70 ° C. for 10 minutes, followed by washing with water and drying. The obtained fabric had a moisture absorption rate of 0.9% at 20 ° C. and 65% RH, a drying rate of 65%, a difference in moisture absorption and desorption of 2.2%, and a water absorption rate by the wicking method of 1.4 seconds. It was. Further, the tear strength of the processed fabric by the pendulum method was 23.0 N (initial value for washing). A one-piece dust-free garment was sewn using the processed cloth. Friction band voltage after 50 times of industrial washing is 980V, dust generation amount is 630 pieces / ft^Three・ 100cm²The tear strength by the pendulum method was 19.1 N (strength retention 83.0% relative to the initial value). 10 workers were asked for a questionnaire (sensory evaluation) on the feeling of wearing the dust-free garments, and the results are summarized in Table 1. Like the conventional polyester dust-free garment, it feels stuffy and sticky when worn, and did not become a comfortable dust-free garment.
[0048]
(Comparative Example 2) Using the dyed fabric obtained in Example 1, 30% by weight of a chemical solution (aqueous dispersion) having the following formulation was padded in a dry state and preheated at 100 ° C to suppress resin migration After performing, the steam process of 110 degreeC was performed.
(Chemical solution prescription)
(1) Daiichi Kogyo Seiyaku PEM200; 30wt%
(2) Methacrylic acid (special grade reagent); 3wt%
(3) Kitahiro Chemical Nobel TD-888 (penetrant); 5wt%
(4) Sodium hesooxodisulfate (reagent, polymerization initiator); 1.7 wt%
(5) Nippon Shokubai Ekocross W700 (Oxazoline-based crosslinking agent); 7wt%
(6) Daiten Kogyo Hitenol NF13 (dispersant): 7wt%
Thereafter, sodium chloride was performed using soda ash (10 wt% per fiber weight) at 70 ° C. for 10 minutes, followed by washing with water and drying. The obtained fabric has a moisture absorption rate of 0.6% at 20 ° C. and 65% RH, a drying rate of 59%, a moisture absorption / release difference of 1.5%, and a water absorption rate by the wicking method of 2.5 seconds. there were. Further, the tear strength of the processed fabric by the pendulum method was 22.8 N (initial value for washing). The dispersibility of the processing agent dispersion was very poor, the processing was difficult, and the fabric was not finished to a quality of practical use. Also, after 50 times of industrial washing, the frictional voltage is 1350V and the dust generation amount is 890 pieces / ft.^Three・ 100cm²The tear strength by the pendulum method is 18.7N (strength retention rate relative to the initial value: 82.0%). Both the frictional voltage and the amount of dust generation are high, which satisfies the requirements for a dust-free garment. did not become.
[0049]
Table 1 shows the results of a questionnaire (sensory evaluation) on the feeling of wearing dustless clothes.
[Table 1]

[0050]
【The invention's effect】
According to the present invention, the self-dusting property is extremely low, the washing durability and the soft feeling at the time of wearing are excellent, the moisture in the clothes at the time of wearing is kept in a comfortable area, and a dust-free garment without discomfort during work is obtained. This makes it possible to improve the working environment of the worker and to improve mental health. Furthermore, by using recycled polyester filaments made of collected PET bottles, etc., with a minimum of 50% by weight of the total weight of dust-free clothing (sewn products), it is possible to make it a comfortable dust-free clothing that complies with the Eco Mark and Green Purchasing Law. is there.

Claims (3)

Polyester synthetic fiber filaments (A), recovered polyester-containing polyester filaments (B), and conductive fiber filaments (C) are interwoven into fabric fibers comprising vinyl carboxylic acid and / or vinyl sulfonic acid, and general formula [ I ], [ II ], [ III ], at least one vinyl monomer selected from [ IV ] and a polymerization initiator, vinyl carboxylic acid and / or vinyl sulfonic acid monomer and divinyl monomer or trivinyl monomer are The fiber is fixed to the fiber at a ratio of 1: 1 to 1:10 as a fraction, and after introduction of acid-terminated alkali metal or alkaline earth metal (chlorination), sewing is performed, and the weight ratio of the polyester filament (B) is It accounted for more than 50 wt% of the total weight garment, and the following requirements (1) to (4) excellent times the wearing comfort, characterized in that makes satisfied Muchirikoromo manufacturing method of using a polyester.
(1) Moisture absorption at 20 ° C and 65% RH environment is 1.5% or more
(2) Humidity difference between 20 ° C and 65% RH environment and 30 ° C and 95% RH environment is 3% or more
(3) Water absorption rate by wicking method is less than 1 second
(4) Drying rate of 70% or more by air-drying at 20 ° C and 65% RH for 30 minutes Arrangement interval of the conductive fiber filaments becomes conductive fiber filaments are arranged in at least the warp and / or weft is 20 to 40 mm, after industrial washing 50 times by JIS L0217 103 Method obtained Muchirikoromo The method for producing a polyester dust-free garment using the recovered polyester excellent in wearing comfort according to claim 1, wherein the performance satisfies the following requirements (5) to (7) :
(5) Friction voltage is 1 kV or less
(6) JIS B9923 (tumbling method) produces a particle generation of 100-500 particles / ft ³ · 100 cm ^{2 with} a particle size of 0.5 μm or more.
(7) Tear strength by pendulum method is 9.8N or more, tear strength retention rate at the beginning of washing is 80% or more Using a reactive polyurethane binder as a nucleating agent for the coating layer on the fiber, at least one selected from vinyl carboxylic acid and / or vinyl sulfonic acid monomer, general formula [I], [II], [III], [IV] Muchirikoromo manufacturing method using the recovered polyester having excellent wearing comfort of claim 1 or 2, characterized in that the type of the vinyl monomer and crosslinking coating of via oxazoline or aziridine crosslinking agent .