JPH04361660A - Production of bulky woven and knit fabric - Google Patents

Abstract

PURPOSE:To obtain woven and knit fabric useful for car seats, etc., having bulkiness and soft handle by knitting or weaving using bulky textured yarn comprising multifilament composed of core part and sheath part of different components and dissolving and removing only the core part. CONSTITUTION:In treating two or more multifilaments yarn with a fluid and integrating, copolyester multifilament yarn and regular polyester multifilament yarn are subjected to fluid disturbance treatment while overfeeding the regular polyester multifilament yarn, to give bulky textured yarn comprising sheath part made of the regular polyester and the core part composed of the copolymer polyester. Knit or woven fabric using the bulky textured yarn is treated with a chemical such as caustic soda to selectively dissolve and remove the copolyester of the core part.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The object of the present invention is to provide extremely high-quality fabrics that use bulky textured yarns to improve the aesthetics of woven and knitted fabrics and to enhance the soft feel of the fabrics. For example, the present invention relates to a technology that dramatically improves the hardness of the hand and the lack of bulk, which are the drawbacks of fabrics for car seats made using polyester multifilament bulky yarn.

0002

BACKGROUND OF THE INVENTION Bulky textured yarns, especially taslan textured yarns, mainly made of polyester multifilament, are widely used in fabrics for vehicles such as car seats. This is because Taslan yarn has appropriate bulkiness, elasticity, and sufficient yarn strength, and compared to polyester spun yarn, it has fewer flaws such as fuzz and fluff, and has good process passability in weaving and knitting processes. It can be cited that it is excellent and economical as well. In addition, in terms of fabric properties, woven and knitted fabrics mainly using polyester taslan yarn have superior durability, strength, and abrasion resistance compared to woven and knitted fabrics that use polyester spun yarn of the same specifications, and they have excellent durability, strength, and abrasion resistance even after long-term use. There is also less occurrence of pilling, etc. However, compared to spun yarn, Taslan processed yarn is generally harder to the touch, has a rougher feel, and lacks softness, and the texture of woven and knitted fabrics made mainly from Taslan yarn also lacks bulk and softness. It had the following drawback. As a measure to improve the hardness and bulkiness of Taslan yarn, some of the so-called knit and de-knit yarns, which are made by turning Taslan yarn into tube knitted fabric and unwinding the fabric after dyeing, are used as soft Taslan yarn. However, this type of yarn has a complicated manufacturing process and is not advantageous in terms of cost. Moreover, the quality of fabrics made from this yarn is by no means at a satisfactory level. Furthermore, a method has been proposed in JP-A-61-6370 in which polyester filaments of two or more special shapes with different shrinkage rates are subjected to taslan processing, woven and knitted, and subjected to alkali reduction processing, but the characteristics of this method are as follows. , they claim that the alkali treatment of polyester yarn with a different cross section has a different treatment effect on the cross section, and the effect of combining different shrinkage yarns in the Taslan processing itself. In this case, it is generally considered that the denier is reduced by subjecting the known yarn to alkali weight loss processing and the bulkiness is changed due to changes in the crimp form of the Taslan yarn, but The hardness of the thread itself, which has a form in which the sheath threads are intertwined, cannot be expected to decrease significantly. Moreover, the manufacturing cost of special irregularly shaped yarn is much higher than that of general purpose hollow round cross section yarn, so it is by no means an economical method. In addition, the easiest way to obtain soft Taslan yarn is to make Taslan processed yarn using ultrafine monofilaments, for example, 0.5 d multifilament, in the core yarn and sheath yarn, but Taslan yarn The bulkiness of the woven fabric using the Taslan processed yarn is not necessarily satisfactory.

0003

[Problems to be Solved by the Invention] The object of the present invention is to provide woven and knitted fabrics for vehicles, such as car seats, which have bulkiness and texture that are superior to the conventional level using bulky processed yarns, mainly Taslan processed yarns. It is about providing.

0004

[Means for Solving the Problems] The present invention involves weaving and weaving a bulky processed yarn composed of multifilament yarns with different components in the core and sheath, and then selectively dissolving the core. The present invention relates to a method for producing a bulky soft woven or knitted material, which is characterized by performing a dissolution treatment using a chemical that removes the material.

[0005] The content of the present invention will be explained in detail below. Bulky yarn is composed of multifilament yarns with different components in the core and sheath parts. Two or more filament yarns are integrated by fluid agitation, and one filament is used as a sheath yarn and the filament is looped on the surface. An example of a bulky yarn in which the other side is a core is a multifilament yarn in which the sheath is made of regular polyester filament yarn and the core is made of polyester copolymer. The manufacturing method is to subject two or more dissimilar filament yarns to a fluid agitation process while overfeeding one filament yarn with respect to the other filament yarn.

[0006]Furthermore, in the fluid disturbance treatment, a pressurized fluid such as air is supplied from the side to the thread guide passage, and the thread and fluid are ejected at the same time to entangle the filament and create many random loops on the surface. The use of known nozzles for so-called taslan processing is common. Generally, the core yarn for Taslan processing nozzles is 0 to 1
The 5% sheath yarn should be overfed by 15-300%, and the difference in overfeed rate between the core yarn and sheath yarn should be 15-285%.
The sheath thread forms a surface loop. In addition, the Taslan processing conditions include a processing speed of 50 to 500 m/min, a disturbance treatment fluid of air, and a pressure of 2 to 7 kg/m2/min.
G level is common.

Next, an example of knitting and weaving using bulky textured yarn will be explained. The greatest innovation of the present invention is to selectively dissolve and remove the core of the above-mentioned bulky textured yarn, so that bulky yarn with virtually no core or with an extremely loose core can be used in fabrics. Because of this, fabrics using 100% bulky processed yarn can be used for very special purposes, such as net-like bulky yarns, but in most cases, fabrics made from 100% regular polyester processed yarn, taslan-processed yarn made of 100% regular polyester, etc. Used by inter-knitting or inter-weaving with twisted yarn or regular polyester spun yarn. If the bulky textured yarn made of multifilament yarn with different core and sheath components using the method of the present invention is denoted by A, and the ordinary taslan yarn processed yarn or spun yarn is denoted by B, then the knitting and weaving of the present invention Most cases include the following combinations.

a. In the case of textiles a) A of 10 to warp
Use 100%, and use B for the rest. The weft is 100% B.
Plain weave, twill weave, satin weave, dobby, and jacquard weave were used. b) Use 100% B for the warp and 10-1% A for the weft.
00% plain weave, knitted weave, satin weave, dobby, and jacquard weave. A), B) The higher the proportion of A used, the softer the fabric will be obtained by decomposing and removing the core yarn component of A in post-processing. However, in the case of fabrics with a small proportion of A, It is also possible to create fabrics with a unique pattern expression and enhanced aesthetics by using bulky threads. c) A pile fabric in which 20 to 100% of A is used as the pile yarn and B is used as the other yarn.

b. In the case of knitted fabrics, as an example of circular double knitting, in a four-way punch rome weave, A yarn is used to knit all needles only on the first feeder dial, all needles are knitted only on the cylinder of the second feeder, and the cylinder and dial short needles of the third feeder. Knits, cylinders of the fourth feeder, and dial long needle knits include fabrics using B yarn. Further, in the case of warp knitted pile fabrics, for example, in the case of three-reed tricot, there is a type in which A is used for the front yarn constituting the pile yarn, and B is used for the middle and back yarns constituting the base yarn. Generally, it is desirable to use a weaving method in which the loops A and B are alternately adjacent, but the method is not necessarily limited to the alternately adjacent type.

Next, a description will be given of the part of the present invention in which the core is subjected to dissolution treatment using a chemical that selectively dissolves and removes the core. First, the most common combination of the easily soluble component in the core and the hardly soluble component in the sheath is the core: modified polyester fiber and the sheath: regular polyester (polyethylene terephthalate) fiber. Modified polyester fibers include, for example, in a copolymerized polyester obtained from a dicarboxylic acid component and a glycol component, 80 mol% or more of the dicarboxylic acid component is terephthalic acid or its ester-forming derivative, and 0.8 to 8.0 mol%, It is preferably a multifilament yarn obtained by spinning and drawing a copolyester in which 2.0 to 3.0 mol% is 5-metal sulfoisophthalic acid or its ester-forming derivative, and its composition and monofilament fineness are as follows: 0.5-5.0
Denier is preferred. In general, if 2 moles or more of the isophthalic acid component (S component) containing a metal sulfonate group is copolymerized, polymerization and spinning become difficult due to the polymer thickening effect of the S component. must be lowered until it is possible, and the resulting force becomes less powerful. Normally, in the case of general-purpose thread, the "force" of the thread is DT x DE1/
2≧25 is desirable, but since the bulky yarn core yarn of the present invention is dissolved and removed by chemical treatment after fabric weaving and knitting, it is sufficient that it has yarn characteristics that allow stable industrial production as a bulky yarn core yarn. The “force” of the fiber is DT×DE1/2 ≧1
A value of 2.5 is sufficient, and a higher S component content of 2.0 mol % is preferable for chemical treatment, ie, alkali weight loss and dissolution. It should be noted that the denier of the multifilament and monofilament of the core yarn is the same as that of the sheath yarn, or a fine denier is preferable for chemical treatment. Other examples of modified polyesters include alkylene terephthalate-based PET in which 15 mol% or less, especially 5 to 12 mol% of copolymer components such as isophthalic acid and aliphatic dicarboxylic acids are copolymerized with the S component, based on the total acid content. May be used.

[0011] For the selective dissolution and removal of the core component in the above-mentioned core-sheath combination, heat treatment with a solution of an alkali metal salt such as caustic soda is generally used, but the method is not necessarily limited to this method. For example, a method is also adopted in which the 6-nylon component of the core is dissolved and removed using a 35 wt% sulfuric acid solution or a 60 wt% formic acid solution for a bulky processed yarn that uses 6-nylon for the core and regular polyester thread for the sheath. You may. Note that dissolution and removal of the core yarn with chemicals is not necessarily 100%.
Depending on the type of product, it is sufficient not only to completely dissolve the yarn, but also to selectively dissolve the core yarn, which is the axis of the sheath yarn of the bulky yarn, and the removal rate of one component is 2.
The range is generally from 0 to 100%, preferably from 45 to 100%, and after the treatment of the present invention, the surface layer of the fabric is subjected to cutting, brushing, etc. In the case of fabrics, it is generally sufficient for the dissolution removal rate of the core yarn to be in the range of 20 to 50%.

0012

[Example] Example 1 Polyethylene terephthalate fiber yarn (150d/48f) A, 5-sodium sulfoisophthalate 2.5 mol%, isophthalate 8 based on the total acid content
Using ethylene terephthalate-based modified polyester (75d/36f) B containing mol %, a taslan processed yarn was prepared using the former as a sheath yarn and the latter as a core yarn. The conditions for Taslan processing are: 2 yarns A are pulled together and overfeed is 40%, 2 yarns B are also pulled together and overfeed is 7%, the air fluid injection nozzle is Heberline T-311, and the air pressure is 6kg/cm2.
Pressure was applied under the conditions of /G to obtain Taslan Yarn C of 590 denier. Next, regular taslan yarn D was obtained using 100% polyethylene terephthalate yarn in the same combination as C and under the same air-fluid injection conditions. C is warp, D
A diagonal fabric with a 6/5 structure was created using a dobby specification rapier loom using the material as the weft. Next, the fabric was subjected to alkali weight loss treatment at 130° C. using an aqueous solution of 10 g/l of 38° Be caustic soda, and after washing with water, high-pressure dyeing was performed using a disperse dye with excellent light fastness. The weight of the finished fabric is 310g/m2
showed that.

Comparative Example 1 A 6/5 diagonal fabric was fabricated using the Taslan processed yarn D made of 100% normal polyester yarn shown in Example 1 for the warp and weft, and with the same specifications as Example 1. Obtained. Next, the fabric was subjected to alkali weight reduction processing and dyeing processing using the same recipe as in Example 1. The weight of the finished fabric is 340g/m2
showed that.

Comparative Example 2 A diagonal fabric having exactly the same specifications as Comparative Example 1 was subjected to the same dyeing process without being subjected to the alkali weight loss treatment. The weight of the finished fabric was 357 g/m2.

Example 2 5-sodium sulfoisophthalate 2.
1 ethylene terephthalate-based modified polyester yarn (75-36) B and polyethylene terephthalate yarn (100-36) E containing 5 mol% and 8 mol% isophthalate.
Taslan yarn 29 was prepared using a nozzle with the same specifications as in Example 1 under the conditions of 10% overfeed for B yarn, 100% overfeed for E yarn, and a supply air pressure of 4.5 kg/m2.
5dF was obtained. Taslan yarn, which also does not contain modified polyester, i.e., polyethylene terephthalate yarn (75
d-36f) G1 core thread, (100d-36f) E1
Taslan yarn H300d was obtained using a book sheath yarn, and F and H Taslan yarns were alternately fed to an 18 gauge double knit circular knitting machine to obtain an interlock knitted fabric. This knitted fabric is 38
°Be Caustic soda 10g/l aqueous solution at 130°C for alkaline weight loss treatment, washed with water, dried, then 510g/m2
A knitted fabric was obtained.

Comparative Example 3 The interlock gray knitted fabric obtained in Example 2 was
After soaping at 5°C, washing with water, and drying, a knitted fabric weighing 600 g/m2 was obtained. Evaluations of the processed fiber fabrics of Examples 1 and 2 and Comparative Examples 1, 2, and 3 are summarized in Table 1.

[0017]

[Table 1]

[0018] The greatest aim of the present invention is to improve the texture of fabrics, that is, to improve the softness of the texture of the parts of woven and knitted fabrics using Taslan yarn, which are utilized in the present invention, and a very clear effect has been obtained. Furthermore, a significant improvement in bulkiness was also observed. The reason for this is largely due to the difference in the thread shape of the fabric using the method of the present invention, that is, the core yarn of the Taslan yarn is reduced in chemical content and decomposed and removed, and the yarn shape of the fabric using the conventional Taslan yarn. FIG. 1 is a schematic diagram of the fabric of the present invention viewed under 40x magnification, and FIG. 2 is a similar schematic diagram of a conventional Taslan fabric. It is clear that the effect of selectively dissolving and removing the core yarn and unraveling the restraint of the sheath yarn is significant, and the corresponding part a of the fabric in FIG. It has been unwound and has an extremely bulky shape. On the other hand, b shows the traditional Taslan thread shape as it is,
The difference between the two is clearly visible.

[0019]

[Effects of the Invention] According to the present invention, it is possible to provide a woven or knitted fabric useful for car seats, etc., which has unprecedented bulk and soft texture.

[0020]

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of the fabric in the present invention.

[Fig. 2] A cross-sectional view of a conventional Taslan processed yarn fabric.

[Explanation of symbols]

a: warp (bulky textured yarn in the present invention), b: warp (conventional Taslan textured yarn), c: weft

Claims (1)

[Claims] Claim 1: Weaving and weaving using a bulky textured yarn composed of multifilament yarns in which the core and sheath have different components, and then subjecting the core to dissolution treatment using a chemical that selectively dissolves and removes the core. A method for producing a bulky woven or knitted fabric.