JP3963930B2 - Covering yarn and fabric with smooth surface - Google Patents

Description

The present invention relates to a fabric having shape stability and / or water resistance obtained by heat setting, and a core-sheath type composite fiber used therefor.

Conventionally, a fabric using a composite fiber having a core-sheath cross-sectional shape using a low-melting-point polymer as a sheath component (hereinafter referred to as a normal core-sheath type composite fiber), and the entanglement point of warp and weft by heat treatment The fusion bonded fabric is used for various purposes.
However, such a fabric has a poor texture (hard), and a low melting point polymer component appears on the surface of the fabric, so that the fastness to dyeing is deteriorated or the dyeability is inferior. There are many problems.
On the other hand, only a few examples of the fabric using a core-sheath type composite fiber using a low melting point polymer as a core component (hereinafter referred to as a reverse core-sheath type composite fiber) are recognized. For example, in JP-A-6-220770, an ethylene-vinyl acetate copolymer is used for the core component and a polyamide component is used for the sheath component in order to obtain a fabric having a clear ridge-like unevenness and color difference on the fabric surface. Inverted core-sheath type composite fiber is used, and JP-A-4-11006 discloses a reverse core-sheath type composite in which a low melting point polymer is arranged as a core component for the purpose of developing sports clothing having improved frictional melt resistance. Discloses the use of false twisted yarn made of fiber.

The former fabric is bent and heat-fixed. However, if the heat treatment conditions are not strictly controlled, the fiber feels worse or the bending portion is weakly fixed. It was not used for any specific purpose other than the product to which was given. The latter is intended for the development of clothing that does not have holes due to friction caused by sliding, etc., and although it uses a reversed core-sheath type composite fiber that uses a low-melting-point polymer as the core component, The composite fiber does not exhibit any peculiar effect on the formability of the fabric or clothing.

On the other hand, in order to obtain a waterproof cloth suitable for form stability such as pleating and hard finishing, and umbrellas, it has been essential to coat the surface of the cloth with a melamine resin, an acrylic resin, or the like.
However, these resin coatings have drawbacks that the texture becomes hard and that some resins may cause problems such as bad odor during thermoforming. In addition, in the coating of acrylic resin or the like, dye migration is likely to occur on the coating surface. For example, an umbrella left in the rear window portion of a passenger car causes a fatal defect as a product, such as dye transfer immediately, and the umbrella becomes uneven in color or the printed pattern becomes unclear.
In addition, as a method for obtaining a water-resistant fabric, it is generally known that heat and pressure treatment such as calendering is performed. However, even if calendering is performed on a fabric using a normal polyester yarn or the like, yarn entanglement is performed. It was difficult to completely fill the gaps between the dots and to obtain dramatic water resistance.
Japanese Patent Laid-Open No. 6-220770 JP 4-11006 A

The present invention provides a fabric using a core-sheath type composite fiber, and provides a fabric having good shape stability and / or high water resistance without using a resin coating or the like, and uses it. An object of the present invention is to provide a novel core-sheath type composite fiber.

Further, the present inventors have conceived that a very useful final product can be obtained by applying the shape stability of the core-sheath composite fiber to a specific application.

For example, a fabric excellent in surface smoothness can be obtained by subjecting a woven or knitted fabric using a covering yarn composed of the core-sheath type composite fiber and urethane elastic yarn to heat and pressure treatment. Such a fabric is conventionally coated with a urethane resin or the like on the surface of the fabric because the fluid resistance of the wear surface against air or water slows down the speed in swimming, skiing, snowboarding, cycling, speed skating, etc. Or a method of improving smoothness by laminating films.

However, since the conventional fabric has a resin layer or a film layer with very few gaps, it has poor moisture permeability and air permeability, and further has a problem of high density and large thickness. For this reason, as a sports material, a material that is light and thin and has moisture permeability and air permeability is preferred, and it is desired to obtain a fabric excellent in smoothness and water resistance without applying a resin coating or a film laminate. It was.

Furthermore, a durable embossed pattern can be formed by embossing the woven fabric using the core-sheath type composite fiber or the like. For embossing, generally, a heated hard engraving roll and a soft roll paired therewith are rotated under appropriate pressure conditions, and a fabric is introduced between the two rolls to make it easy to create an uneven pattern. However, the woven fabric using conventional polyester yarns has poor durability, and has the disadvantages that the unevenness can be easily reduced or lost by washing or the like.
In addition, conventionally, fibers have been known in which low melting point components on the surface are fused by heat treatment and exhibit shape stability, etc., but such fibers have the disadvantage that the texture is cured as described above, Its use was also limited.

Another object of the present invention is to apply a specific core-sheath-type conjugate fiber to a specific application, thereby producing unique effects based on the shape stability of the core-sheath-type conjugate fiber. The object is to provide a very useful end product that could not be obtained with mold composite fibers.

The present invention relates to a core-sheath type composite fiber composed of different polymers, wherein the softening point of the core component measured by the thermomechanical analysis method of JIS K 7196 is 20 ° C. or more lower than the softening point of the sheath component, and the core component is And consisting of a substantially amorphous polymer that does not produce a melting point peak in a differential thermal analysis method heated at a rate of temperature increase of 10 ° C./min in a nitrogen atmosphere (hereinafter referred to as an amorphous inverted core-sheath type composite fiber) ).

The present invention also relates to a fabric, artificial flower, and wig having shape stability using such an amorphous inverted core-sheath composite fiber.

Such amorphous inverted core-sheath type composite fibers use a substantially amorphous polymer having a low crystallinity as a core component, and therefore soften reversibly even if heating and cooling are repeated. Solidification can be repeated, and the setability such as flattening of the yarn by heating under pressure is very good.

In addition, the present invention relates to an embossed woven fabric obtained by pressing a heated engraving roll on a fabric woven from multifilaments of thermoplastic synthetic fibers. Embossing with excellent morphological stability, characterized by using multifilaments composed of amorphous inverted core-sheath type composite fibers and the sum of the warp and weft cover factors in the range of 800-2500 It is a woven fabric.

Such a woven fabric does not depend on the unevenness of the fabric by pressurization under heating, but a sheath component made of an amorphous polymer with a low softening point is pressed by a hard heating roll of an embossing machine, Since a convex pattern drawn on the heating roll is formed on the fabric by deforming and increasing the filament diameter, a durable embossed pattern is obtained.

Furthermore, the present invention is a fabric using at least a part of a reversible core-sheath composite fiber in which the melting point of the core component is lower than the melting point of the sheath component, at a temperature above the softening point of the core component and below the melting point of the sheath component, A fabric having water resistance, wherein the fabric is formed into a flat state by heat setting under pressure.

Such a fabric has no gap at the intersection of the yarns constituting the fabric, and becomes a fabric having water resistance.

(1) Description of amorphous inverted core-sheath type composite fiber The amorphous inverted core-sheath type composite fiber of the present invention, that is, the softening point of the core component measured by the thermomechanical analysis method of JIS K 7196 is the softening of the sheath component. A core-sheath type composite fiber having a core-sheath type composite fiber that is 20 ° C. or lower lower than the point, and the core component is substantially amorphous and does not cause a melting point peak in a differential thermal analysis method that is heated at a rate of temperature increase of 10 ° C./min. The composite fiber made of a polymer is particularly made of a copolyester polymer in which the sheath component is made of polyester, the core component has a glass transition point of 60 to 80 ° C., and the softening point is 200 ° C. or less. A core-sheath type composite fiber is used.

Typical examples of such copolymer polyesters include terephthalic acid and ethylene glycol as main components, and as a copolymer component, oxalic acid, malonic acid, succinic acid, adipic acid, azelaic acid, sebacic acid, phthalic acid, One or more of known dicarboxylic acid components such as isophthalic acid, naphthalenedicarboxylic acid, diphenyl ether dicarboxylic acid, etc., and 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, propylene glycol, One or more of known diol components such as trimethylene glycol, tetramethylene glycol, hexamethylene glycol, diethylene glycol, polyalkylene glycol, 1,4-cyclohexanedimethanol, etc. are used, and the ratio is 50 mol% or less Preferably those copolymerized diethylene glycol as other copolymerizable components, polyethylene glycol and the like may be added.

Further, the copolymer polyester may be a copolymer component as described above, which is appropriately selected and used within a range of physical properties that do not impair spinning and processing operability so as to have a desired softening point. Those using ethylene glycol as a main component and using isophthalic acid as a copolymerization component are preferred because they are industrially inexpensive and can be stably obtained and have good polymer properties. In such an isophthalic acid copolymer polyester, the isophthalic acid component is preferably 20 to 40 mol%, and the core / sheath ratio of the core-sheath type composite fiber is 5/1 to 1/5 in volume ratio, particularly It is preferably about 3/1 to 1/2. The cross-sectional shape of the composite fiber may be any of a circle, an ellipse, a polygon, a star, etc., and the core and the sheath may be arranged concentrically or eccentrically. It is preferable to use a circular shape having a core and a sheath arranged concentrically, and the core component has a core-sheath structure that is not exposed to the outside.

Since such a composite fiber uses a substantially amorphous polymer having a low crystallinity as a core component, it can be reversibly softened and solidified even if heating and cooling are repeated. Also, the setability such as flattening of the yarn by heating under pressure is very good.

Therefore, the fabric using such a composite fiber has the following advantages.
(1) The shape once heat-set can be released again by heating and heat-set to a new shape. For example, after manufacturing a pleated curtain with a 5 cm wide crease by heat setting, this pleat is removed by heating and set again on a pleated curtain with a different crease (for example, a crease with a width of 3 cm). , Quality is possible.
(2) Even without resin coating, the product can be made into a water-resistant product that can be efficiently used for umbrellas, waterproof clothing, etc., only by a pressurized heat set by ordinary calendering or the like. However, a resin coating can be used in combination depending on the application.
(3) The water resistance and form retainability obtained in this way have high washing durability.
(4) Since the core component of the composite fiber does not appear on the surface of the fabric, the texture does not become hard, and problems such as a decrease in dyeing fastness and a decrease in levelness are unlikely to occur.

[ Reference Example 1]
The following three types of raw yarns were prepared.
Raw yarn (a1) -isophthalic acid (IPA) occupies 12 mol% of the acid component, the core is copolymerized polyethylene terephthalate having a melting point of 227 ° C. (DSC method) and a softening point of 197 ° C., and the acid component is terephthalic acid A core-sheath type composite fiber having a sheath of 100% polyethylene terephthalate (melting point: 255 ° C., softening point: 240 ° C.) was spun at a core-sheath ratio (volume ratio) of 1: 1 to obtain a yarn of 50d / 12f.
Original yarn (b1)-50d / 12f yarn in which the core component and sheath component of the original yarn (a1) are reversed.
Original yarn (c1)-50d / 12f yarn of regular polyester whose acid component is 100% terephthalic acid.

These three types of yarns are used as wefts for fabrics made from 50d / 24f yarns of regular polyester whose acid component is 100% terephthalic acid, and the processed weft density is 110 yarns / in × 94 yarns. A plain woven fabric (A1, B1, C1) is woven so as to be / in, and the obtained fabric is dyed (liquid flow type dyeing machine) and finished in the same process and conditions as the processing of a normal polyester plain woven fabric. .

At this stage, the fabric (A1) of the present invention and the fabric (C1), which is a normal polyester fabric, were able to obtain a uniform dyed fabric. The weft fabric (B1) had stained spots, wrinkles and poor appearance.

Next, the dyed fabric thus obtained is subjected to normal water-repellent processing using a fluorine-based water repellent and subjected to heat treatment (calendar processing) at 200 ° C. under a pressure of 35 kg / cm ^2. The water pressure resistance immediately after processing and after 10 washings was measured.
The results are shown in Table 1.

The fabric (A1) according to the present invention has a soft texture and a high water pressure resistance, and can be used as an umbrella even without a resin coating. On the other hand, the fabric (B1) has a higher water pressure resistance than the normal polyester fabric (C1), but its value is insufficient for use in umbrellas, etc. The remaining texture became stiff and was not practical.

[ Reference Example 2]
The following three types of raw yarns were prepared.
The raw yarn (a2) -isophthalic acid (IPA) accounts for 25 mol% of the acid component, and has a melting point peak as measured by DSC method, and has a softening point of about 150 ° C. as a core, A core-sheath type composite fiber having a core-sheath ratio (volume ratio) of 1: 1 was spun with polyethylene terephthalate (melting point: 255 ° C., softening point: 240 ° C.) having an acid component of 100% terephthalic acid as a sheath. It was a thread.
Original yarn (b2)-50d / 12f yarn in which the core component and sheath component of the original yarn (a2) are reversed.
Raw yarn (c2)-50d / 12f yarn of regular polyester whose acid component is 100% terephthalic acid.

These three types of yarns are used for the wefts of fabrics made from 50d / 48f yarns of regular polyester whose acid component is 100% terephthalic acid, and the processed weft density is 175 yarns / in × 105 yarns. Plain fabrics (A2, B2, C2) were woven so as to be / in, and these fabrics were dyed (liquid flow type dyeing machine) and finished in the same process and conditions as those for ordinary polyester plain fabrics. Next, the dyed fabric thus obtained was subjected to normal water repellent treatment using a fluorine-based water repellent.

Table 2 shows the results of measuring the form stability of each fabric after the water-repellent processing and the results of measuring the water pressure resistance and the form stability of the fabric subjected to pressure heat treatment at 160 ° C. after the water-repellent processing.

(2) Description of Urethane Covering Yarn and Surface Smooth Fabric Amorphous inverted core-sheath composite fiber can be used in sportswear or the like by using it together with a urethane elastic body. In this case, the urethane elastic yarn may be a commonly used one. The urethane resin used for the elastic yarn may be polyester or polyether, but if the heat treatment time in the later process is long and it is necessary to increase the heat resistance, it will be more heat resistant. It is preferable to use an excellent polyester-based polyurethane. The spinning method of the polyurethane fiber is not particularly limited, and usual methods such as melt spinning and dry spinning are preferably used.

As a method for making a woven or knitted fabric using these fibers, specifically, a method for producing a covering yarn using a urethane elastic yarn as a core yarn and an amorphous inverted core-sheath type composite fiber as a sheath yarn, and using the same as a woven or knitted fabric , A method of making a woven or knitted fabric using both an amorphous inverted core-sheath type composite fiber and a urethane elastic yarn, and a method of making a woven or knitted fabric as a blended yarn of an amorphous inverted core-sheath type composite fiber and a urethane elastic yarn Etc. can be used.

When using a covering yarn having a urethane elastic yarn as a core yarn and an amorphous inverted core-sheath type composite fiber as a sheath yarn, a generally used method can be suitably used as the method for producing the covering yarn. The wrapping of the sheath yarn may be single or double. Further, such a composite mixed yarn may be a woven fabric or a knitted fabric, and the method for producing the woven or knitted fabric is not limited.

As a method for producing a woven or knitted fabric using both the amorphous inverted core-sheath composite fiber and the urethane elastic yarn at the same time, a known method can be suitably used, which is desirable from the required form stability and stretchability. A woven or knitted form can be selected. Specifically, normal warp knitting, weft knitting or weaving simultaneously using amorphous inverted core-sheath composite fiber and urethane elastic yarn, warp structure and urethane using amorphous inverted core-sheath composite fiber Examples thereof include a knitted fabric composed of weft structures using elastic yarns.

A known method can be used as a method for producing a mixed fiber of amorphous inverted core-sheath composite fiber and urethane elastic yarn. Specific examples include a method in which a urethane elastic yarn is combined with a processed yarn made of a composite fiber, and a method in which a composite fiber and a urethane elastic yarn are combined and then subjected to false twisting to obtain a processed yarn. Further, such a composite mixed yarn may be a woven fabric or a knitted fabric, and the method for producing the woven or knitted fabric is not limited.

Furthermore, the fabric having surface smoothness of the present invention is obtained by subjecting the woven or knitted fabric obtained by the above method to a heat and pressure treatment to smooth the surface. In order to make sportswear with excellent surface smoothness, it is possible to perform such treatment, transform the cross section of the composite fiber into a flat shape, reduce the bulge of the surface of the woven or knitted fabric, and close the gap is necessary. The heat and pressure treatment can be performed by a method usually used, for example, calendar processing.

It is preferable that the heating temperature in such a heating and pressurizing treatment is 150 ° C to 200 ° C, and more preferably 160 ° C to 180 ° C. Amorphous inverted core-sheath composite fiber has a low melting point and low crystallinity at the core, so it is possible to deform the fiber cross-sectional shape at a low temperature, resulting in thermal degradation of the urethane elastic yarn in the heat treatment process. This will be significantly reduced, which is preferable. When heated at a temperature higher than 200 ° C., heat deterioration of the urethane elastic yarn occurs, or the core component is exposed to the outside due to melting of the sheath component of the amorphous inverted core-sheath composite fiber, and the texture of the fabric is impaired. Therefore, it is not preferable. Further, the heat and pressure treatment at a temperature lower than 150 ° C. does not sufficiently deform the yarn shape, and sufficient smoothness cannot be obtained.

[Example 1 ]
Each physical property value was measured by the following method.
Water pressure resistance: JIS L-1092A method (hydrostatic pressure method)
Softening point: Manufacture of JIS K-7196 method knitting tricot: Copolyethylene terephthalate having 25 mol% of isophthalic acid, having substantially no melting point as measured by DSC method, and having a softening point of 197 ° C. A core-sheath type composite fiber having a core-sheath ratio (volume ratio) of 1: 1 with a sheath of polyethylene terephthalate (melting point: 255 ° C., softening point: 240 ° C.) having an acid component of 100% terephthalic acid, The yarn was 45d / 10f, and then false twisted to give a processed yarn. Using such processed yarn and 40d urethane elastic yarn, a knitted tricot was formed.

[Example 2 ]
Production of covering yarn: Isophthalic acid occupies 25 mol% of the acid component, has substantially no melting point as measured by DSC method, and has a softening point of 197 ° C as a core, and the acid component is terephthalic acid 100% polyethylene terephthalate (melting point 255 ° C., softening point 240 ° C.) as a sheath, core-sheath type composite fiber is spun at a core-sheath ratio (volume ratio) of 1: 1 to obtain a yarn of 50d / 12f, and interlace After granting, it was scraped off. Next, a single covering yarn was manufactured using the 20d urethane elastic yarn as a core yarn and the composite fiber as a sheath yarn under the conditions shown in the table below.

上記カバリング糸を用いて、常法に従ってトリコット編物を製造した。

Using the covering yarn, a tricot knitted fabric was produced according to a conventional method.

[Example 3 ]
Production method of blended yarn: isophthalic acid accounts for 25 mol% of the acid component, has substantially no melting point as measured by DSC method, and has a softening point of 197 ° C. A core-sheath type composite fiber with a sheath of polyethylene terephthalate (melting point: 255 ° C., softening point: 240 ° C.) whose terephthalic acid is 100% is spun at a core-sheath ratio (volume ratio) of 1: 1, did. The above composite fiber and 20d urethane elastic yarn were used as a mixed fiber composite processed yarn under the conditions shown in Table 4.

上記混繊糸を用い、常法に従ってトリコット編物を製造した。

A tricot knitted fabric was produced according to a conventional method using the above mixed yarn.

The elastic knitted fabric produced by the methods of Examples 1 to 3 was calendered at a pressure of 700 mmH ₂ O and a heating temperature of 170 ° C., and the cross section and surface of the obtained fabric were observed with an electron microscope. The cross-section of the composite fiber constituting the fabric thus obtained is flatly deformed, the gap of the fabric is clogged, and the surface smoothness is excellent. Further, from the plane photograph, the core-sheath structure of the composite fiber is maintained, the core component is not exposed to the outside, and no fusion between the composite fibers occurs. For this reason, the texture of the fabric is not impaired while having water resistance. Further, since calendering at a low temperature is possible, the physical properties of the urethane elastic yarn are not impaired by the heat treatment. Moreover, the water resistance of the fabric obtained by the said Examples 1-3 is all 30.0 cm or more, and shows favorable water resistance.

[The invention's effect]
As described above, the conjugate fiber of the present invention has excellent shape stability and can be used for various applications, for example, pleated curtains and clothing, artificial flowers, fans, electric umbrellas, raincoats, It can be used very efficiently for windbreakers, umbrellas, tents, car covers, saddles, gloves, streamers, lanterns, etc. Obtainable. In particular, when it is used as a covering yarn of urethane elastic yarn, artificial flower material, artificial hair of wig, embossed fabric, etc., a very remarkable effect can be obtained.

Furthermore, a fabric using such a composite fiber can also obtain excellent water resistance by performing heat setting under pressure.

In the present invention, the fabric means any of a woven fabric, a knitted fabric, and a non-woven fabric, and the core-sheath type composite fiber as described above may be used for at least a part of the yarns constituting these fabrics. . However, in order to obtain a water-resistant product by heat setting, it is necessary to uniformly arrange the entire fabric.

Claims (2)

A core-sheath type composite fiber in which the softening point of the core component measured by a thermomechanical analysis method of JIS K 7196 is 20 ° C. or more lower than the softening point of the sheath component, and the core component is heated at 10 ° C./min in a nitrogen atmosphere. A composite fiber having a core-sheath structure that is not exposed to the outside is used as a sheath yarn, and a urethane elastic yarn is made of a substantially amorphous polyester-based polymer that does not generate a melting point peak by differential thermal analysis that is heated at a speed. Covering yarn as core yarn. A core-sheath type composite fiber in which the softening point of the core component measured by a thermomechanical analysis method of JIS K 7196 is 20 ° C. or more lower than the softening point of the sheath component, and the core component is heated at 10 ° C./min in a nitrogen atmosphere. A woven or knitted fabric composed of a composite fiber having a core-sheath structure that is not exposed to the outside, and a substantially elastic polyester-based polymer that does not generate a melting point peak by differential thermal analysis heated at a speed. Further, a fabric which has been given surface smoothness by applying a heat and pressure treatment after weaving and knitting.