JPH04370256A - Curtain cloth and production thereof - Google Patents

Abstract

PURPOSE:To obtain a thin curtain cloth not to be seen through in spite of thinness, screening direct sunlight, softly lighting a room, having excellent sound insulating properties and heat insulating properties. CONSTITUTION:A curtain cloth comprising fine yarn obtained by splitting and dividing split type conjugate yarn composed of two or more non-compatible polymers. Production thereof and curtain made of the curtain cloth.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curtain fabric, a method for producing the curtain fabric, and a curtain made from the curtain fabric. In particular, the present invention relates to a curtain fabric that is thin and invisible from the outside, blocks direct sunlight, allows soft sunlight to enter, and has excellent sound insulation and heat retention properties, a method for producing the curtain, and a curtain fabric.

0002

2. Description of the Related Art Thin or lace curtains or thick curtains made of knitted fabric have been widely used for windows and glass doors for purposes such as light shielding, sound insulation, and heat retention. However, conventional curtains made of thin or lace knitted fabrics have the disadvantage that the interior of the room can be seen from outside through the curtains, so privacy cannot be sufficiently protected, and furthermore, heat retention and sound insulation properties are low. On the other hand, curtains made of thick knitted fabric are excellent in terms of heat retention, sound insulation, privacy protection, etc., but when the curtains are closed, sunlight is insufficient or almost completely blocked, making the room dark.

0003

[Contents of the Invention] From the above points, the present inventor has discovered that it is possible to provide gentle lighting that has both the characteristics of conventional thin or lace curtains and the characteristics of thick curtains, and yet We have been conducting research with the aim of developing thin curtains that cannot be seen from the outside and can protect privacy, while also having excellent sound insulation and heat retention properties. As a result, the present invention was completed by discovering that the above object can be achieved by manufacturing curtain fabric from fine fibers obtained by splitting and splitting splittable composite fibers made of two or more types of incompatible polymers. Therefore, the present invention is a curtain fabric made of fine fibers obtained by splitting and splitting splittable composite fibers formed from two or more types of incompatible polymers. Furthermore,
The present invention includes a method of manufacturing the curtain fabric and a curtain made from the curtain fabric.

[0004] In the present invention, "splitable conjugate fiber formed from two or more types of incompatible polymers" means that when cut at right angles to the length direction of the fiber, its cross section is composed of two or more types of incompatible polymers. It has a structure in which multiple mutually incompatible polymers contact each other regularly or irregularly, and by applying an appropriate treatment to the composite fiber, it is possible to prevent splitting or peeling (splitting/splitting) at the joints. ) and can form fine fibers with small fineness made of each polymer.

[0005] In addition, the term "curtain fabric made of fine fibers obtained by splitting and splitting splittable composite fibers" as used in the present invention refers to
It means a curtain fabric made of a nonwoven fabric or a knitted fabric in which at least one or both surface portions or the vicinity thereof are formed from the above-mentioned split/split fine fibers. Therefore, the curtain fabric of the present invention may be one in which only one or both surface portions or the vicinity thereof are formed from the fine fibers obtained by splitting and splitting, or those in which only one or both surface portions or the vicinity thereof are formed from the fine fibers that have been split and split up to a specific thickness of the curtain fabric. The part formed or the entire curtain fabric is divided into
In the case of the first two, the remaining portion not formed by fine fibers may be made of unsplit conjugate fibers or other types. It may be formed from fibers or cloth.

[0006] In the splittable composite fiber used in the present invention, it is rare that all the fine fibers formed by splitting and splitting have a circular cross-section, but may have various non-circular cross-sections depending on the composite form. Fine fibers having a cross-sectional shape, optionally with a circular cross-sectional shape, are formed. In the present invention, it is desirable to use composite fibers in which half or more of the fine fibers formed by splitting and splitting have a non-circular cross-sectional shape. The composite form of the splittable conjugate fiber and the number and type of polymers forming the conjugate fiber may be of any type as long as they are defined above and are not particularly limited.

[0007] Examples of the splittable conjugate fiber used in the present invention and the state when the fiber is split and split will be explained in detail with reference to schematic diagrams. Figure 1 shows two types of incompatible polymers A.
This figure shows a splittable composite fiber in which polymer B and polymer B are bonded and arranged in parallel to each other, and when it is split and split, it becomes an aggregate of fine fibers as shown in FIG. Figure 3 is 3
This figure shows a splittable composite fiber in which types of polymer A, polymer B, and polymer C are bonded and arranged in the radial direction. When this composite fiber is divided and split, it becomes approximately triangular fine fibers as shown in Figure 4. become a collection of Moreover, FIG. 5 is a diagram showing a composite fiber in which islands made of polymer A in polymer B are arranged close to each other so that they can be easily divided and split. As shown in FIG. 6, a large number of flat fine fibers are assembled.

Furthermore, the plurality of polymers do not need to be joined in a regular or linear manner, for example, as shown in FIG.
They may be intertwined and irregularly joined to each other, and when this composite fiber is divided or split, an aggregate of irregular fine fibers of various finenesses is obtained as shown in FIG. 8. In the split/split conjugate fiber, it is not necessarily necessary that it is completely split/split into fine fibers along its entire length; for example, as shown in FIGS. 2, 4, and 6 above. , the plurality of polymer parts may remain joined together in an undivided state at the lower part thereof.

The conjugate fibers shown in the figures are examples of splittable conjugate fibers that can be used in the present invention, and as described above, the present invention is not limited thereto. For example, the splittable conjugate fiber may be formed from four or more types of polymers. Furthermore,
The splittable conjugate fiber may be composed of one type of splittable conjugate fiber, or may be a mixture of a plurality of splittable conjugate fibers having different composite forms. For example, use a mixture of the composite fibers shown in Figure 1 and the composite fibers shown in Figure 3, a mixture of the composite fibers shown in Figure 5 and the composite fibers shown in Figure 7, or other mixed fibers. can do.

[0010] The splittable composite fiber is made by selecting and combining two or more types of mutually incompatible polymers from among thermoplastic polymers such as polyester, polyamide, polyolefin, polyvinyl chloride, and other vinyl polymers. It can be manufactured by composite spinning using a joining type spinning method, a special mixed spinning method, etc. Examples of polymer combinations in splittable composite fibers include polyester/modified polyester, polyester/polyamide, and polyester/polyamide.
Examples include polyolefins, polyamides/polyolefins, polyesters/vinyl polymers other than polyolefins, polyamides/vinyl polymers other than polyolefins, polyolefins/vinyl polymers other than polyolefins, and the like. Among these, combinations of polyester/polyamide, polyester/polyolefin, and polyamide/polyolefin are preferred.

The polyester used in the composite fiber of the present invention includes terephthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, phthalic acid, α,β-(4
- Aromatic dicarboxylic acids such as carboxyphenoxy)ethane, 4,4-dicarboxydiphenyl, and 5-sodium sulfoisophthalic acid; aliphatic dicarboxylic acids such as adipic acid and sebacic acid; or acid components of their esters and ethylene glycol, diethylene glycol, 1,
4-butanediol, neopentyl glycol, 1,6
-Fiber-forming polyesters formed from diol compounds such as -hexanediol, cyclohexane-1,4-dimethanol, polyethylene glycol, polytetramethylene glycol, etc. may be mentioned. Among them, polyethylene terephthalate, in which 90 mol% or more of the constituent units of polyester are polyethylene terephthalate units and/or polybutylene terephthalate units;
Polybutylene terephthalate and ethylene terephthalate copolymers are preferred.

[0012] Further, as polyamide, nylon 6,
Nylon 66, metaxylene diamine nylon, nylon 12, and these nylons containing a small amount of a third component can be mentioned, and representative examples of polyolefins include:
Examples include polyethylene, polypropylene, polybutene, ethylene-propylene copolymer, and the like. The polymer that forms the splittable composite fiber contains stabilizers, ultraviolet absorbers,
Additives such as optical brighteners, other modifiers, colorants, and pigments may be contained as necessary.

[0013] The splittable composite fiber before splitting and splitting is performed by spinning,
It is desirable that the single yarn denier has a fineness of about 1 to 8 denier after undergoing treatments such as drawing, heat treatment, and crimping.
In addition, the fine fibers obtained by splitting and splitting are approximately 0.05~
It is desirable that the fineness is 0.5 denier. In the curtain fabric of the present invention, the splittable composite fibers can also be used in the form of continuous filaments. However, from splittable composite fiber filaments, the fiber length is about 20~
It is desirable to form short fibers of 120 mm and use these short fibers to produce curtain fabric made of non-woven fabric or knitted fabric.

[0014] Curtain fabric made of non-woven fabric is produced by producing dry webs such as random webs, parallel webs, cross webs, etc. using short fibers of splittable composite fibers by a conventional method, or by producing wet webs by papermaking methods etc. Then, the web is processed by a needle punch method, a high-pressure water jet method, etc. to entangle the fibers and split/split them into fine fibers. The intertwining of the fibers and the division and splitting into fine fibers are preferably carried out by a high-pressure water jet method in terms of promoting splitting and splitting and increasing the strength of the fabric. In that case, depending on the type of composite fiber used, the water temperature of the jet water stream may be adjusted from room temperature to 80°C.
℃ temperature range, and water pressure 10~200kg/cm2
It is advisable to select an appropriate value from the range of . This treatment with high-pressure water jets is preferably carried out in multiple stages (usually 2 to 12 steps), whereby the composite fibers located at least on the surface of the nonwoven fabric are split and split into fine fibers with a non-circular cross section. A nonwoven fabric in which fibers account for more than half of the fibers and fine fibers are densely intertwined with each other can be obtained. In order to facilitate entanglement and division/splitting into fine fibers, a surfactant and a swelling agent are added to one of the multiple polymers forming the composite fibers in a high-pressure water jet. You can leave it there.

[0015] The splitting/splitting of fine fibers and the entangling of the fibers by needle punching, high-pressure water jets, etc. may be performed uniformly over the entire surface of the nonwoven fabric, or only on specific parts, or may be performed to create differences in strength or weakness. It is also possible to provide a non-uniform method. When the process is carried out partially or non-uniformly, the patterning on the nonwoven fabric can be carried out at the same time as the splitting and splitting into fine fibers and the entangling process.

[0016] Furthermore, in order to increase the strength of the nonwoven fabric, it is preferable to bond the fine fibers and/or the fine fibers and the undivided composite fibers in the nonwoven fabric. Methods for performing such bonding include a method in which the above-mentioned nonwoven fabric is divided into fine fibers, split, and entangled, and then a suitable binder is applied to the nonwoven fabric for bonding treatment; A method is adopted in which short fibers made of composite fibers are mixed with short polymer fibers having a lower melting point than the short fibers, and after splitting, splitting, and entangling, the low melting point fibers are melted to bond the fibers. be able to. As the binder in the former method, acrylic resin liquid, urethane resin liquid, etc. can be used. In addition, as the low melting point short fibers in the latter method,
Fibers of thermoplastic polymers having a melting point approximately 30 to 130°C lower than the melting point of fine fibers formed from splittable conjugate fibers are desirable, and such low melting point fibers may vary depending on the type of splittable conjugate fibers used. It is better to select the appropriate one. The amount of the binder and the low melting point fibers to be used can be appropriately selected depending on the intended texture of the curtain fabric, but is usually about 10 to 200% by weight of the base fiber.

Furthermore, in order to increase the strength of the nonwoven fabric, a woven fabric may be laminated and integrated on the middle or one side of the nonwoven fabric. The nonwoven fabric produced as described above is then further heat-treated to fix the bonds between the fibers, ironed to smooth the surface, heat-embossed to create a pattern, dyed or printed to be colored, and flame-retardant. chemical treatment, resin processing,
It is made into curtain fabric by applying a softening process. Furthermore, the curtain fabric of the present invention is produced by producing spun yarn from short fibers of the above-mentioned splittable composite fibers, knitting and weaving the spun yarn to produce knitted fabrics and napped knitted fabrics, and applying high-pressure water jets to this knitted fabric. It can also be produced by dividing and splitting the conjugate fibers present at least on the surface of the textile fabric into fine fibers by subjecting them to splitting and splitting treatment using a processing method or the like.

[0018] In addition to the above-mentioned splittable composite fibers, other natural fibers or synthetic fibers may be used as necessary during the production of curtain fabrics, whether made of non-woven fabrics or knitted fabrics. Fibers can be mixed up to about 50% by weight. The weight (thickness) of the curtain fabric can be selected as appropriate depending on the purpose of use, but normally, a weight (thickness) of approximately 50 to 500 g/m2 is thin, yet gives a sense of volume, and is suitable for direct sunlight. A curtain material that blocks sunlight and allows gentle sunlight to be obtained can be obtained. When the weight per square meter is the same, non-woven fabric curtain fabric is superior to knitted fabric curtain fabric in the above points.

[0019]

【Example】

Example 1 Polyethylene terephthalate (intrinsic viscosity [η] = 0.7
2) and 6-nylon (intrinsic viscosity [η] = 1.16) are melted in separate melting devices, and the molten polymers are combined at a volume ratio of 1:1 at the spinning head to perform bonding and separation. After repeating the process several times, it was spun at 290°C to produce a bonded composite fiber having the cross-sectional shape shown in FIG. This composite fiber was drawn, heat-set, crimped, and cut by conventional methods to obtain short fibers having a single yarn denier of 2 deniers and a fiber length of 38 mm. The short fibers were passed through a card and a random web with an average weight of 35 g/m.
A fibrous web of No. 2 was produced. These three webs were stacked and needle-punched at 30/cm2 with a #40 needle, and then placed on a moving wire mesh support.
A high-pressure water jet nozzle with 5 mm nozzles arranged in a row produces a final output of 150 kg at an initial water pressure of 70 kg/m2.
/m2 in three stages while increasing the water pressure.
The treatment was carried out by spraying a columnar water stream at a temperature of 20°C.

As a result, the average fineness of the fine fibers formed by splitting and splitting was 0.34 denier, and the depth of the splitting and splitting varied in the thickness direction of the nonwoven fabric.
An intertwined nonwoven fabric having an average weight of 114 g/m 2 and an apparent density of 0.18 g/cm 3 was obtained, consisting of fine fibers having a flat cross-sectional shape as shown in FIG. In this intertwined nonwoven fabric, fine fibers with a flat cross-sectional shape are densely intertwined on the surface, and a slight undivided portion exists on the back surface, and the undivided portion and the divided fine fiber portion are also densely intertwined. It was confounding. This non-woven fabric was treated with an acrylic resin liquid (manufactured by Dainippon Ink Co., Ltd.: Dicknaar E-8310) to give a 12 g/m
2, and a cationic surfactant (Saphanol 503-D, manufactured by Sanyo Kasei Co., Ltd.) was further applied to soften the surface. Next, the surface was smoothed by calendering, and a nonwoven fabric with soft drape properties was obtained. When this non-woven fabric was made into a curtain and used, it was found that the light seen through the curtain was not harsh compared to a woven fabric curtain made of rayon spun yarn of the same weight, and it had excellent shielding properties against direct sunlight, allowing it to remain calm under gentle conditions. It was well-lit and had excellent sound insulation.

Example 2 Polyethylene terephthalate copolymer (intrinsic viscosity [η
] = 0.64: melting point 246°C) and 6-nylon (intrinsic viscosity [η] = 1.16) were combined at a volume ratio of 1:1 at the spinning head in the same manner as in Example 1, and bonding and separation were performed. After repeating this process twice, it was spun at 290°C to produce a bonded composite fiber having the cross-sectional shape shown in FIG. Stretch this using a conventional method.
After heat setting, crimping and cutting, short fibers of a splittable composite fiber having a single yarn denier of 2.5 denier and a fiber length of 38 mm were obtained. In addition, the core component is polyethylene terephthalate (intrinsic viscosity [
η] = 0.66), and the sheath component is made of a polyethylene terephthalate copolymer (melting point 136°C) copolymerized with 50 mol% hexamethylene terephthalate. Fiber length 38
Short fibers for thermal binder of mm were prepared. 85 parts by weight of the short fibers of the splittable composite fibers obtained above and 15 parts by weight of short fibers for thermal binder were mixed and passed through a card and a random web to produce a fiber web having an average weight of 50 g/m2. Three of these webs were stacked and subjected to needle punching and high pressure water jet treatment in the same manner as in Example 1. As a result, an intertwined nonwoven fabric having an average weight of 164 g/m 2 and an apparent density of 0.17 g/cm 3 was obtained, which was made of fine fibers having a flat cross-sectional shape formed by splitting and splitting. In this intertwined nonwoven fabric, fibers mainly composed of fine fibers having a flat cross-sectional shape are densely intertwined on the surface, and a few unsplit fibers are present on the back surface, and the unsplit fibers and the split fine fibers are present on the back surface. and thermal binder fibers were tightly entangled.

This non-woven fabric is heat treated at 150°C to fix the fibers with the sheath of the thermal binder fibers, further dyed with a cationic dye (Kayacryl ED manufactured by Nippon Kayaku Co., Ltd.), and after soaping, a cationic surfactant ( Sansoflon TK-07 (manufactured by NICCA CHEMICAL CO., LTD.) was added to soften the material. Next, the surface was smoothed by calendering, and a nonwoven fabric with soft drape properties was obtained. When this non-woven fabric was made into a curtain and used, compared to a woven fabric curtain made of polyester spun yarn of the same weight, when viewed from the outside, the indoor scene could not be seen through, allowing privacy to be maintained. The light that entered the room through the curtains was not harsh, and the curtains had excellent shielding properties against direct sunlight, allowing for gentle sunlight, and had excellent sound insulation and heat retention properties.

[0023]

[Effects of the Invention] Although the curtain fabric of the present invention is thin, it is not visible from the outside and is effective in protecting privacy. Moreover, the curtain material of the present invention can block strong direct sunlight and allow soft and gentle lighting into the room. Further, the curtain material of the present invention has excellent sound insulation properties and heat retention properties. Furthermore, the curtain fabric of the present invention is
Even if it is thin, it has a sense of volume and drape. The above-mentioned excellent effects are particularly remarkable in the curtain fabric of the present invention made into a non-woven fabric, and such effects of the present invention cannot be expected from conventional curtain fabrics made of knitted or woven fabric.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing an example of the cross-sectional shape of splittable conjugate fibers used in manufacturing the curtain fabric of the present invention.

FIG. 2 is a diagram showing a state in which the splittable conjugate fiber having the cross-sectional shape of FIG. 1 is split and split into fine fibers.

FIG. 3 is a diagram showing another example of the cross-sectional shape of the splittable conjugate fiber used in manufacturing the curtain fabric of the present invention.

FIG. 4 is a diagram showing a state in which the splittable conjugate fiber having the cross-sectional shape of FIG. 3 is split and split into fine fibers.

FIG. 5 is a diagram showing still another example of the cross-sectional shape of the splittable conjugate fiber used in manufacturing the curtain fabric of the present invention.

FIG. 6 is a diagram showing a state in which the splittable conjugate fiber having the cross-sectional shape of FIG. 5 is split and split into fine fibers.

FIG. 7 is a diagram showing still another example of the cross-sectional shape of the splittable conjugate fiber used in manufacturing the curtain fabric of the present invention.

8 is a diagram showing a state in which the splittable conjugate fiber having the cross-sectional shape of FIG. 7 is split and split into fine fibers; FIG.

[Explanation of symbols]

A Polymer A B Polymer B C Polymer C

Claims (5)

[Claims] 1. A curtain fabric made of fine fibers obtained by splitting and splitting splittable composite fibers formed from two or more types of incompatible polymers. 2. The curtain fabric according to claim 1, which is in the form of a woven fabric or a non-woven fabric. 3. The curtain fabric according to claim 2, which is in the form of a nonwoven fabric. 4. After producing a nonwoven fabric or a knitted fabric using a splittable conjugate fiber formed from two or more types of incompatible polymers, the splittable conjugate fiber is divided into fine fibers by performing a splitting/splitting process. - The method for manufacturing curtain fabric according to claim 2 or 3, characterized in that the curtain fabric is split into pieces. 5. A curtain manufactured using the curtain fabric according to any one of claims 1 to 3.