JPH0160561B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a nonwoven fabric sewn product with excellent sagging properties and seam strength. Conventionally, when trying to apply nonwoven fabrics to sewn products such as clothing in the same way as woven or knitted fabrics, they tend to tear or fray easily at the seams because they do not have strong interlacing points like woven or knitted fabrics. Therefore, sewing was impossible. For this reason, the applications of sewn products using nonwoven fabrics have been limited to interlining for clothing and sheet materials for non-clothing. It is well known that a technique was invented to impregnate non-woven fabrics with porous elastic polymers such as polyurethane resins, and it has remained a useful material for artificial leather clothing to this day. However, sewn products made of nonwoven materials impregnated with such elastic polymer resins inevitably have a rubbery feel and crackling sound caused by the rebound resilience of the elastic polymer, and therefore have a strong rebound texture.
There was a drawback that it tended to give a stiff feeling. Moreover, such sewn products have disadvantages such as poor sagging during sewing due to the strong resilience of the material, and for example, the curves at the sleeve and collar parts are not beautiful and unevenness can be seen. There were limitations in that it was completely unsuitable for designs that made heavy use of or that fitted the body. In an attempt to solve these drawbacks, modifications of elastic polymers and non-woven sewn products without impregnation of elastic polymers have been studied, but sewn products without such elastic polymers have problems, especially in terms of seam strength. The strong physical properties of
Moreover, it could hardly be used for sewn clothing products that require good texture, appearance, and beauty. The purpose of the present invention is to obtain a non-woven fabric sewn product which has been impossible in the past, and in particular, to obtain a non-woven fabric sewn product which is practical even though binder resin does not exist or even if it does exist, it exists only in a very small amount. The aim is to provide non-woven fabric sewn products. The objects of the invention can be achieved by the following. In other words, the sewn non-woven product of the present invention has ultrafine fibers of 0.5 denier or less and/or bundles thereof.
Part A is relatively loosely intertwined with a distance between fiber entanglement points of more than 20 microns, and ultrafine fibers and/or bundles thereof that are continuous or branched from the part A and/or the bundles thereof are 200 microns or less. Part B that is densely intertwined with the distance between fiber intertwining points
A nonwoven fabric having a fiber structure in which both A and B portions are unevenly distributed in the thickness direction is used,
The sewn nonwoven product is characterized in that it is sewn with the B portion side facing forward. That is, the sewn product of the present invention has a relatively loose intertwined part A, and a part B in which continuous or branched ultrafine fibers and/or bundles thereof are extremely densely intertwined.
As a result, the seam strength is at a level suitable for ordinary clothing sewing, and the general strength properties as a sewn product are also sufficient. Therefore, unlike conventional products, there is no need to impregnate a large amount of binder resin in order to maintain strength. Furthermore, since the amount of binder resin can be reduced, the sagging resistance and tear strength are extremely excellent. The nonwoven fabric of the sewn product of the present invention has a fiber structure in which loose intertwined parts A and dense intertwined parts B are distributed unevenly in the thickness direction, and is sewn with the B layer side facing forward. Therefore, it has excellent properties as a sewn product, such as easy passage of a sewing machine needle and strong seams due to the presence of the B layer. It also has a good texture and touch that conventional nonwoven fabrics lack, and dyed fabrics have a very beautiful appearance. If the nonwoven fabric sewn product consists only of layer A, the fibers will be entangled to the extent that can be obtained by conventional needle punching, so the seam strength will be insufficient and a practical sewn product will not be obtained. On the other hand, when a non-woven fabric sewn product consists of only the densely intertwined B layer, there are disadvantages such as difficulty in passing the sewing machine needle through, and the texture of the sewn product becoming stiff and stiff. , which is also not desirable. A layer and B
In the present invention, it is necessary that the layers exist unevenly in the thickness direction. Furthermore, structures in which the ultrafine fibers that make up part A and part B are substantially continuous, and the degree of intertwining continuously changes near the boundary between the two parts, create a sense of unity. have a combination,
It has favorable features such as the fact that portions A and B do not separate. The fiber structure in portion B of the nonwoven fabric constituting the front side of the sewn product of the present invention requires that ultrafine fibers and/or bundles thereof are tightly intertwined with each other. In other words, the fiber entanglement density is high. One way to measure the intertwining density of fibers is to
There is a method to measure the distance between fiber entanglement points, which will be described later, but for the fibers in part B, the measured value is 200μ by this method.
It is necessary to have the following entanglement density.
If this value is greater than 200μ, for example, if the fibers are entangled with each other only by needle punching, and the fibers are less entangled, the seam strength of the sewn product will be low and it will tear easily, and it will also be subject to repeated shearing forces. This is not preferable because the surface tends to become fluffy or cracks occur. In order to eliminate these drawbacks, the distance between fiber entanglement points in part B must be
It must be less than 200μ. More favorable results can be obtained when the thickness is 100μ or less. On the other hand, it is preferable for the fibers in portion A to be more loosely intertwined than this in terms of the texture of the sewn product, the beauty of the finish of the embossed areas, and the ease with which a sewing machine needle passes through the fabric. Such loose entanglement in which the distance between fiber entanglement points exceeds 200μ can be obtained by an ordinary entanglement treatment such as needle punching. Here, the distance between fiber entanglement points is a value obtained by the following method, and is a measure of the denseness of fiber entanglement, and the smaller the value, the more dense the entanglement is. . FIG. 4 is an enlarged schematic diagram of the constituent fibers in portion B when observed from the surface side. The constituent fibers are f ₁ , f ₂ , f ₃ ,...
...and let the point where any two of them intertwine, f ₁ and f ₂ , be a ₁ and trace it to the point where the fiber f ₂ , which is above a ₁ , intersects with the other fiber below. Let the point where they intersect be a ₂ (intersection point of f ₂ and f ₃ ). Similarly, let a ₃ , a ₄ , a ₅ , .... Next, the linear horizontal distance between the intersecting points obtained in this way a ₁ a ₂ , a ₂ a ₃ ,
a ₃ a ₄ , a ₄ a ₅ , a ₅ a ₆ , a ₆ a ₇ , a ₇ a ₃ , a ₃ a ₈ , a ₈ a ₇ ,
Measure a ₇ a ₉ , a ₉ a ₆ , ..., find the average value of these many measured values, and use this as the distance between fiber entanglement points. The distance between the intertwined fiber points of part A can be measured before forming part B or after slicing to expose part A, but all intertwining conditions such as needle punching exceed 200μ. Therefore, the key point is to practically measure whether part B is 200μ or less. In terms of sewing properties such as seam strength, drapability, appearance quality, and sagging resistance of the sewn product of the present invention, it is better to include the ultrafine fiber bundle portion in part A.
Shows better properties than those with randomly intertwined microfibers. Such an ultra-fine fiber bundle is one in which a large number of staple or filament-like ultra-fine fibers of different or similar types are arranged in parallel with each other, and the intertwined structure of sewn products is such that this arrangement is substantially disrupted. A part A in which ultrafine fibers are intertwined in a bundle and three-dimensionally with each other, and a part A in which ultrafine fibers branched from the ultrafine fiber bundle and/or their bundles (bundles thinner than the fiber bundle in part A) are mainly densely intertwined. It consists of part B, and has a structure in which both parts are distributed unevenly in the thickness direction. Furthermore, the fibers that make up such sewn products have a structure in which the ultra-fine fibers form a bundle in some parts and branch out in other parts, so that they cannot be separated into single fibers and bundles. It is something. Further, a bundle in which the ultrafine fibers constituting the ultrafine fiber bundle are arranged without being bonded to each other has better properties in terms of passability through a sewing machine needle and flexibility. FIG. 1 shows a model diagram of the nonwoven fabric fiber structure of the sewn product of the present invention. In FIG. 1A, A is mainly a part where ultrafine fiber bundles are entangled, and B, which is the front side of the sewn product, is mainly a part where ultrafine fibers branched from the ultrafine fiber bundles and their bundles are intertwined. Further, various examples of embodiments in which portions A and B are unevenly distributed in the thickness direction are shown in A, B, C, and D of FIG.
In Figure 1B, both A and B are the parts where ultrafine fibers are intertwined, and B is the distance between the fiber entanglement points.
Below 200μ, A schematically shows the portion exceeding 200μ. The most preferable mode of uneven distribution is the modes A to D in FIG. 2 from the viewpoint of ease of passage of a sewing machine needle during sewing, texture of the sewn product, ease of sagging, and the like. The ultrafine fibers that can be used in the present invention are made of polymeric substances that have fiber-forming ability, such as nylon 6,
Polyamides such as nylon 66, nylon 12, copolymerized nylon, polyesters such as polyethylene terephthalate, copolymerized polyethylene terephthalate, polybutylene terephthalate, copolymerized polybutylene terephthalate, polyolefins such as polyethylene and polypropylene, polyurethane, polyacrylonitrile and vinyl polymers, etc. can be given. As a method for forming ultrafine fibers using these polymeric substances, various methods can be employed, such as a method of discharging from small holes, a method using a super draw phenomenon, and a jet spinning method using a gas flow. In addition, fibers with a chrysanthemum-shaped cross section in which one component is interposed radially between other components, multilayer bimetallic fibers,
Multi-layered bimetallic fiber with a doughnut-shaped cross section, mixed spun fiber made by melt-mixing two or more components and spinning, a large number of ultra-fine fibers continuous in the fiber axis direction, which are arranged and aggregated and are wrapped and/or partially wrapped with other components. Ultrafine fibers are produced by applying physical action to a multi-component composite fiber such as a polymeric interlayer fiber that forms a single fiber to cause it to peel off, or by dissolving and removing at least one component (bonding component). be able to. FIG. 3 shows an example of a so-called ultrafine fiber eruption type fiber for obtaining ultrafine fibers. In the figure, 1 and 1' are ultrafine fibers, and 2 and 2' in the figure are binding components.
Of course, the binding component may behave as an ultrafine fiber in some cases. In addition, the ultrafine fibers may be composite fibers made of different or similar polymeric materials, such as crimped fibers, irregular cross-section fibers, hollow fibers,
Lotus root-like fibers may also be used. Furthermore, a mixture of different types of ultrafine fibers may be used. The fineness of the ultrafine fibers is preferably 0.5 denier or less.
It must be 0.2 denier or less. If it is thicker than 0.5 denier, the rigidity of the fibers is too high and the flexibility of the nonwoven fabric is poor, making it difficult to intertwine the fibers closely. When ultrafine fibers of 0.2 denier or less, more preferably 0.05 denier or less, are used, a sewn product with good seam strength, texture, touch, and scorched finish can be obtained. In order to specifically realize the sewn product of the present invention, for example, a bonded fiber bundle obtained by bundling the ultrafine fibers produced by the above method and temporarily adhesively treated with a binding component to maintain the fiber bundle state; Alternatively, a wedge is formed using a filament or a short cut of the multi-component composite fiber, an entangled structure is formed with or without needling, and then a solvent capable of dissolving only the bonded components is used. The bound components are dissolved and removed. Thereafter, a high-speed fluid stream is brought into contact with the ultrafine fibers to branch out the ultrafine fibers and their bundles from the ultrafine fiber bundle and entangle them at the same time. After performing needling to form an entangled structure, a sizing agent such as polyvinyl alcohol is applied to temporarily fix the entire nonwoven fabric, and the sizing agent is removed after dissolving and removing the binding components, or the sizing agent is removed at the same time as the sizing agent is removed. It is also possible to insert a step of performing high-speed fluid treatment to prevent the nonwoven fabric from deforming when the binding components are dissolved and removed. Also, high velocity fluid flow treatment may be performed prior to removal of bound components. In order to obtain a structure in the nonwoven fabric constituting the sewn product of the present invention, it is desirable that the nonwoven fabric has an apparent density of 0.1 to 0.6 g/cm ³ before being treated with high-speed fluid flow. If it is less than 0.1g, the fibers move easily and the fibers pulled by the fluid flow penetrate the nonwoven fabric, and the fibers get stuck in the wire mesh on which the nonwoven fabric is placed, making the surface of the nonwoven fabric extremely uneven. If it is higher than 0.6 g/cm ³ , the fluid flow will be reflected on the surface of the nonwoven fabric and sufficient entanglement will not be achieved, which is not preferable. The fluid referred to here is a liquid or a gas, and in special cases it may contain extremely fine solids, but water is most preferable in terms of ease of handling, cost, and amount of collision energy as a fluid. used. Further, depending on the purpose, various organic solvents capable of dissolving the binding component, or aqueous solutions of alkali or acids such as sodium hydroxide can be used. Pressurize these fluids,
It is injected from a small-diameter nozzle or narrowly spaced slits to form a high-speed columnar flow or curtain-like flow. The pressure applied to the fluid varies depending on the properties of the nonwoven fabric and can range freely from 5 to 300 kg/cm ² . It is also possible to employ methods such as making multiple contacts, changing the pressure each time the contact occurs, vibrating or rocking the nozzle, making contact from an oblique direction, and using intermittent flow. As the binding component used to bundle the ultrafine fibers and temporarily bond them, it is preferable to use a material that can be removed with water due to its industrial cost, such as starch, polyvinyl alcohol, methyl cellulose, carboxymethyl cellulose, etc. Synthetic glues, natural glues, and adhesives such as polyvinyl latex, polybutadiene adhesives, polyurethane adhesives, polyester adhesives, and polyamide adhesives that can be dissolved in other solvents are also used. In addition, the binding components in multicomponent composite fibers include polystyrene,
Polyethylene, polypropylene, polyamide, polyurethane, copolymerized polyethylene terephthalate easily soluble in alkaline solutions, polyvinyl alcohol, copolymerized polyvinyl alcohol, styrene-acrylonitrile copolymer, higher alcohol ester of styrene and acrylic acid and/or higher methacrylic acid Copolymers with alcohol esters are used. In producing the sewn nonwoven product of the present invention, it is not necessary to use 100% ultrafine fibers, and other fibers may be mixed in as long as the purpose of the present invention is not impaired. The nonwoven fabric sewn product of the present invention does not substantially require resin such as a binder, or only requires a very small amount of resin.
When a commonly used elastic polymer such as polyurethane is present in a certain amount or more, rubber-like impact resilience occurs,
The texture and appearance of the sewn product will be rubber-like, and the sagging property will be poor, resulting in the formation of a curved surface with many irregularities. Of course, there is no problem with the adhesion of finishing resins, which are essential during the dyeing and finishing processes. In short, it is preferable for the present invention not to actively apply resin as a binder or coating agent. In other words, the amount of resin applied to a sewn product is affected by the type of fiber used, the type of resin, and even the way the resin is applied, and although there are some points that cannot be generalized, there is a substantial It is important that the resin content be zero, with no resin attached, or less than 15% by weight; if it exceeds 15% by weight, the above-mentioned texture, appearance, and sagging resistance will gradually deteriorate, resulting in a poor overall performance. I'm getting old. Preferably the amount of resin is 10% or less, more preferably 5%
The effect of the present invention is greatest when substantially no resin is present. The nonwoven fabric constituting the sewn product of the present invention does not substantially contain resin such as a binder, or even if it does contain it, it is only a small amount, so it is extremely easy to dye, and ordinary dyeing methods can be applied. Although it is a non-woven fabric, it has some extremely dense intertwined portions B, so it can be dyed in exactly the same way as ordinary woven or knitted fabrics. The sewn product of the present invention can be obtained by sewing such a nonwoven fabric using a normal household sewing machine or an industrial sewing machine. Since the sewn products of the present invention do not contain resin such as a binder or contain only a small amount of resin, they are most suitable for use in soft and drapeable clothing, but they are also suitable for use in soft clothing such as hats, gloves, light bags, bags, and shoes. Of course, it can also be used for miscellaneous goods. In particular, the sewn product of the present invention has good curved surface formation properties such as shirring, and is easy to form pleats and gears, so various designs are possible. The examples shown below are for the purpose of clarifying the present invention, and the present invention is not limited thereto. In the examples, parts and percentages are by weight unless otherwise specified. Example 1 95 parts of polystyrene and 5 parts of polyethylene glycol
Figure 3: 16 island components in one filament, with a ratio of 45 parts of a mixture of 50% as a bonding component and 55 parts of polyethylene terephthalate as an ultrafine fiber component, and a large number of ultrafine fiber components in the island component. A 3.8 denier fiber having the following shape was crimped and cut to 38 mm, passed through a card and a cross wrapper to form a web, and then needle punched at 2500 fibers/cm ² . The average thickness of each ultrafine fiber component was 0.0005 denier. Further, the area weight and density of the needle-punched nonwoven fabric were 450 g/m ² and 0.18 g/m ² . After pressing this nonwoven fabric with a hot roll (apparent density became 0.21 g/cm ³ ), it was placed on a 100-mesh wire mesh, and water was applied with a pressure of 100 kg/cm ² through a nozzle with small holes arranged in a row. It was sprayed from the surface of the nonwoven fabric and brought into contact with the surface of the nonwoven fabric. The same treatment was carried out three times on each side, and the fibers were branched and intertwined at the same time as the glue was dissolved. The obtained intertwined nonwoven fabric had a densely intertwined structure consisting of branched ultrafine fibers and bundles thereof at about 1/4 of the thickness from the front and back sides. The distance between the fiber entanglement points was 56 microns. Inside, entanglement consisting of fiber bundles was observed, and the distance between the fiber entanglement points was greater than 1000 microns. Next, this nonwoven fabric was immersed in trichlorethylene, dipping and squeezing were repeated to almost completely extract and remove the bound components, and then dried to evaporate and remove residual trichlorethylene. This sheet was treated with high-temperature dyeing using a disperse dye in the same manner as ordinary polyester products, and was then finished to obtain a nonwoven fabric of the present invention having a thickness of 0.7 mm (product of Example 1 of the present invention). On the other hand, a nonwoven fabric with a thickness of 0.7 mm (comparative example (A)
product) was created. This product consisted only of entangled fiber bundles, and the distance between the entangled points was greater than 1000 microns. In addition, since the nonwoven fabric that is not sprayed with pressurized water (comparative example (A) product) has very low strength, a polyurethane emulsion of 18% by weight was applied instead of sprayed with pressurized water. ,
A comparative nonwoven fabric (comparative example B product) was also produced (thickness: 0.7 mm) using the same process except for the nonwoven fabric. This product had the same fiber structure as Comparative Example (A), but had a structure in which the intertwined points were surrounded by polyurethane resin. Sewn products shown in Table 1 were made using these three types of sheets: Example 1 product, Comparative Example (A) product, and Comparative Example (B) product. In addition, since the sewn product according to the present invention uses a nonwoven fabric whose front and back surfaces are densely intertwined, the densely intertwined side is the front side of the sewn product (the back side is also the same). ). The characteristics of each sewn product are as shown in Table 1, and only the sewn product of the present invention had excellent appearance quality and strength, particularly seam strength, finish feel, and wear durability. Comparative example (A), which consists of a loose entanglement of fiber bundles, lacks practicality in terms of strength and curved surface formation.
Comparative example (B) reinforced with polyurethane does not have high seam strength, has poor texture and curved surface formation, has a rebound and rubbery feel, and is difficult to fit on the body.

[Table] The stability was also poor. Examples 2 and 3 A ratio of 60 parts of a vinyl polymer (hereinafter referred to as AS resin) copolymerized with 20 parts of 2-ethylhexyl acrylate and 80 parts of styrene as a binding component, and 40 parts of nylon 6 as an ultrafine fiber component. Mixed spun fibers of the form shown in Figure 3
Using 4.0 denier, 51 mm staples, a web with a fabric weight of 480 g/m ² was formed through a card and a cross wrapper. Although the thickness of the ultrafine fiber component varied, it was 0.002 denier on average. This web was subjected to needle punching, pressing, water treatment, and removal of bound components in the same manner as in Example 1, and then dyed at 95°C using a metal-containing dye and subjected to finishing treatment. A nonwoven fabric having a thickness of 0.85 mm was obtained (Example 2). The distance between fiber entanglement points near the surface layer on both the front and back sides was 90 microns. The inside was even larger than 1000 microns. On the other hand, about nylon 6 was
After spinning 0.005 denier ultra-fine fibers and cutting them into 51mm pieces, they are processed using a random webber to produce approximately 410g/m ²
A web was formed and needle punched at 2500 webs/cm ² . After shrinking this needle-punched nonwoven fabric with hot water, it was subjected to high-speed water jet treatment under the same conditions as in Example 1 and dried.
The distance between the fiber entanglement points was microns, and inside, continuous fibers from the surface were loosely and randomly entangled, and the distance between the fiber entanglement points was over 1000 microns. Since this nonwoven fabric had a rather large distance between fiber entanglement points, it was impregnated with about 2% by weight of polyurethane emulsion. This nonwoven fabric was dyed at 95° C. using a metal-containing dye and then a conventional finishing agent was applied thereto to obtain a nonwoven fabric with a thickness of 0.85 mm according to the present invention (Example 3). When these two types of nonwoven fabrics according to the present invention were used to sew men's jackets with the densely intertwined side facing up, the sewn product of Example 2 was found to be in good condition as shown in Table 2. Strong seams,
It showed good appearance, tailoring quality, curved surface formation, and wear durability. The sewn product of Example 3 also achieved the purpose of the present invention, but compared to the sewn product of Example 2,

[Table] It was found that the seam strength and curved surface forming properties were slightly inferior.

[Brief explanation of drawings]

FIGS. 1A and 1B are examples of cross-sectional views of nonwoven fabrics used in sewn products according to the present invention. 2A to 2D show examples of combinations of portions such as A and B in FIG. 1. Figure 3 A to Y are typical examples of ultrafine fiber generation type fibers. FIG. 4 is an enlarged schematic view of the constituent fibers of part B of the sewn product according to the present invention, when observed from the surface side.

Claims (1)

[Claims] 1 Part A in which ultrafine fibers of 0.5 denier or less and/or bundles thereof are intertwined relatively loosely with a distance between fiber entanglement points of more than 200 microns, and continuous or branched from the ultrafine fibers and/or bundles thereof in part A The ultrafine fibers and/or bundles thereof are
A nonwoven fabric is used which has a fiber structure in which a portion B is densely intertwined with a distance between fiber entanglement points of 200 microns or less, and both portions A and B are unevenly distributed in the thickness direction, and the B portion side is A sewn nonwoven product characterized by being sewn with the front side facing out.