JPH07310205A - Production of clothing product made of nylon 6 yarn - Google Patents

Abstract

PURPOSE:To obtain the subject high-quality product capable of reducing disjointing and selecting operations, recyclable by a closed system, by recovering a prescribed clothing product made of nylon 6 yarn, depolymerizing to give a lactam, polymerizing the lactam and subjecting the lactam to melt spinning. CONSTITUTION:A clothing product (e.g. uniform or rain wear) made of nylon 6 yarn comprising a material of cloth and auxiliary parts of clothing substantially made of nylon 6 uniformly is depolymerized without being disjointed and is purified to recover a lactam, which is polymerized to produce nylon 6. The nylon 6 is subjected to melt spinning and/or molded to produce nylon 6 yarn and/or an auxiliary product (e.g. button) of clothing made of nylon 6 yarn is produced. A clothing product made of nylon 6 yarn comprising a material of cloth and auxiliary parts of clothing substantially made of nylon 6 uniformly is produced by using the nylon 6 yarn and/or the auxiliary product of clothing made of nylon 6 to give the objective product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a textile product for clothing by repeated recycling.

[0002]

2. Description of the Related Art In recent years, in order to protect the global environment, effective use of resources, particularly recovery / reuse, so-called recycling, has been carried out. For example, it is established as a business to collect used glass and paper, sort them, and use them as recycled materials. Further, regarding thermoplastic molded articles such as PET bottles, it has been commercialized that used products are collected, sorted, remelted and molded for reuse.

There are still many problems to be solved in such recycling already carried out. For example, they have the following problems.

A great deal of equipment and labor is required for the collection and sorting work. When the original product is manufactured using the recovered and regenerated raw material, a certain level of purity or higher is required. However, even if the product is relatively easy to sort, such as paper or glass, it takes a lot of effort to sort the items collected from an unspecified number of consumers, which increases the cost of collection and sorting, and the recycling business Becomes a problem.

Furthermore, the quality of products made from recovered raw materials cannot be sufficiently enhanced. As described above, even if a large amount of equipment and labor are applied to the selection, it is extremely difficult to obtain the same purity as the original raw material.

Further, some textile products such as clothing products are reused as second-hand clothes, and are also recycled in the form of reuse of dismantled fabrics, fibers, clothing accessories (buttons, etc.). There is.

[0007]

However, in the case of clothing products, such as paper, glass, and resin molded products, the collected products are returned to the raw materials and reused.

[0008] This is because the clothing product has many main components, such as the body cloth, as well as many sub-components such as lining,
A wide variety of fabrics and clothing accessories made of different materials, such as fiber materials such as interlinings, sewing threads, name plates, and resin and metal members such as buttons, snaps, fasteners, and clasps. This is because it is not possible to dismantle and sort to a recyclable place, because the cloth and clothing accessories are often mixed with various materials. Furthermore, in the case of ordinary clothing products produced in small quantities and in a wide variety of products, it is almost impossible to put together a recyclable amount even if it takes time and effort to disassemble and sort the clothing products.

Since many synthetic fibers made of petroleum such as polyester fibers and polyamide fibers are used in these clothing products, more effective recycling is possible from the viewpoint of effective use of resources for global environment protection. It has been demanded.

[0010] Therefore, the main object of the present invention is to provide a method capable of carrying out repeated recycling in which the recovered clothing product is returned to the raw material monomer and reused.

[0011]

In order to achieve this object, the method of the present invention is a method for recovering a nylon 6 fiber garment product in which the constituent materials of the fabric and the garment accessory are substantially unified with nylon 6. Then, the lactam is recovered by depolymerization and purification, and the recovered lactam is polymerized to produce nylon 6, and the nylon 6 is melt-spun and / or molded to obtain nylon 6 fiber and / or A nylon 6 clothing accessory is manufactured, and the nylon 6 fiber and / or nylon 6 clothing accessory is used to manufacture the nylon 6 fiber clothing product.

[0012] In the present invention, it is important that the constituent materials of the fabric and the clothing accessory are substantially unified with nylon 6 in order to enable repeated recycling. That is,
Nylon 6 is ideal for recycling to return to raw materials from the following points.

First, nylon 6 is almost the only mass-produced polymer that can be easily decomposed into raw material monomers and can be purified to high purity. When nylon 6 is heated in the presence of a depolymerization catalyst, ε-caprolactam, which is a raw material before polymerization, is depolymerized. Further, since this ε-caprolactam has a boiling point of about 140 ° C. under reduced pressure (about 10 mmHg), it can be easily separated and purified by distillation. Therefore,
The ε-caprolactam obtained by depolymerization can be easily purified to the same degree of purity as new lactam by precision distillation or crystallization purification method, and can be reused as a raw material for polymerization.

On the other hand, nylon 66 is difficult to depolymerize into a monomer and is difficult to purify a monomer. Therefore, it is difficult to recycle nylon 66 back to the polymerization raw material. Further, although polyesters can be depolymerized to monomers, it is difficult to industrially carry out purification to a sufficiently high degree of purity, and thus it is difficult to form fibers again and repeatedly recycle them. Acrylic fibers are practically incapable of depolymerizing into monomers. Furthermore, although natural fibers such as wool and cotton can be recovered, they cannot be reduced to the raw materials (for example, protein and cellulose) and fibrillated again.

Secondly, nylon 6 is one of the mass-produced resins having the most excellent function and can be easily formed into fibers and molded, and has strength and beauty as fibers,
It also has toughness as engineering plastics. That is, nylon 6 can be widely manufactured from fibers to resin molded products such as gears and buttons. By using nylon 6, other materials such as fibrous fabrics to clothing accessories such as buttons and fasteners can be practically used. Can be manufactured without using. Therefore, with nylon 6, it is possible to make up a clothing product that is entirely made of the same material.

The garment product comprises fabrics such as body cloth, lining and interlining, and clothing accessories such as sewing threads, name plates, buttons, snaps, fasteners and clasps.

In the nylon garment product of the present invention, substantially all of the fabrics and clothing accessories constituting the nylon garment product are nylon 6
However, other materials may be used as long as the amount is a small amount that does not adversely affect the depolymerization / purification process. However, the amount of other materials is preferably as small as possible, and at most 20% by weight or less, preferably 10% by weight or less, and more preferably 5% by weight or less of the whole clothing product.

Therefore, the clothing product of the present invention includes a sewing thread,
As many constituents as possible, including clothing accessories such as nameplates, buttons, snaps, fasteners and clasps, may be made of nylon 6. Furthermore, the amount of other materials added to those constituent members and the amount of other materials added by processing may be reduced as much as possible.

For example, a woven fabric, a knitted fabric, or a non-woven fabric made of only nylon 6 single fibers is used as a cloth such as a body cloth, a lining or an interlining, and a sewing thread or a name plate is made of nylon 6 single fibers, and buttons, Nylon 6 moldings and nylon 6 fibers for snaps, fasteners and clasps.
A product manufactured from a molded product may be used.

The nylon 6 used in the present invention may be a polymer obtained by polymerizing ε-caprolactam by a conventional method. The degree of polymerization is preferably in the range of 2.0 to 4.0 in terms of relative viscosity of a 98% sulfuric acid solution.
The nylon 6 polymer may contain a small amount of other types of nylon (copolymer) or additives such as titanium oxide and a heat-resistant agent as long as they do not hinder the depolymerization process. However, it is preferable to reduce the amount of these other materials as much as possible, and it is within a range that does not adversely affect the depolymerization / purification process.

This nylon 6 is spun into a nylon 6 fiber having a predetermined thickness by a conventional method. For example, there may be mentioned a method of melt-spinning and stretching to obtain a fiber, and a method of forming a fiber without substantially stretching by high-speed spinning. These fibers may be further processed such as crimping,
It may be staple.

The obtained nylon 6 filaments or staples are formed into filament yarns, spun yarns or the like and knitted or woven by a usual method to obtain a predetermined cloth. This yarn or cloth may be mixed with other fibers, such as polyurethane fiber, nylon 66 fiber, natural fiber, etc., as long as it does not interfere with the depolymerization / refining process. Good.

The cloth is water-repellent / oil-repellent, antistatic, water-absorbent / moisture-absorbent,
Finishing with a processing agent for antibacterial / deodorization may be performed. For example, coating with acrylic resin or polyurethane. In this case also, it should be within the range that does not hinder the depolymerization and purification process.

Of the members constituting the garment, the members made of fibers, for example, the body cloth, the lining, the interlining, the sewing thread, the name plate and the like are preferably made of the above nylon 6 fiber, but depolymerized. -Other fiber products may be included as long as they do not interfere with the refining process.

It is preferable that the members other than the fibers constituting the garment, such as fasteners, snaps, buttons, and clasps, are also made of nylon 6, but depolymerization
Other materials may be included as long as they do not interfere with the purification process.

Accessories such as snaps, buttons, and clasps made of nylon 6 may be manufactured by the same method as for ordinary nylon 6 molded products. Further, the fastener may be manufactured from nylon 6 fiber and nylon 6 resin by an ordinary method.

Among the materials constituting the garment, the total weight of the materials other than nylon 6 which are introduced in the above-mentioned steps is at most 20% by weight or less, preferably 10% by weight or less. The materials should be limited to substances that do not adversely affect the decomposition and recovery process.

For example, inorganic pigments, metals, chemically stable organic compounds, etc. which do not change in the depolymerization process from recovered nylon 6 to ε-caprolactam remain as reaction residues and can be removed by a separate treatment. Is. In addition, volatile organic substances by-produced in this depolymerization step can be separated and removed from ε-caprolactam by means such as purification.

However, a volatile compound (especially ε-caprolactam) generated during the depolymerization reaction of nylon 6
Substances which have a boiling point close to, or which generate a compound that flows out by azeotropic distillation, or substances which corrode the material of the apparatus are not preferable because the depolymerization / purification process becomes complicated. Specifically, polyester is not preferable because it generates a large amount of low-boiling compounds such as ethylene glycol and acetaldehyde at the decomposition temperature of nylon, and is preferably not included as much as possible. In addition, substances such as vinylidene chloride and vinyl chloride that generate corrosive hydrochloric acid gas when decomposed are not preferable and may be contained as little as possible.

Most ideally, nylon 6 is used as all the constituent members from the front material to the lining, interlining, sewing thread, fasteners, snaps, buttons, clasps and other clothing accessories.

Thus, 80% by weight or more of the constituent materials,
Preferably, 90% by weight or more, and more preferably substantially all of nylon 6 is unified with nylon 6 to reduce the load of the recovery step and the depolymerization step, and to separate and collect ε. -Caprolactam can be easily purified, and high-purity ε-caprolactam can be obtained.

The nylon-made clothing product thus recovered is not substantially disassembled, and if necessary after removing stains,
Buttons that are supplied to the depolymerization process as they are in the state of clothing products, but are relatively easy to remove after collection if necessary,
Dismantling to the extent that snaps, clasps, etc. are removed may be performed.

The depolymerization may be carried out by a usual method in which a depolymerization catalyst is added while being melted by heating to effect depolymerization. For example, in the presence of a depolymerization catalyst represented by phosphoric acid catalyst, 200
It may be heated to a high temperature of about 350 ° C., and the produced ε-caprolactam may be distilled and cooled to be collected.

For this depolymerization, along with the above-mentioned clothing products,
Oligomers and nylon 6-based scraps, which are by-produced in the steps from lactam polymerization to the manufacture of clothing products, may be simultaneously supplied and depolymerized, or only the clothing product may be depolymerized.

The ε-caprolactam recovered by depolymerization is purified by a conventional purification method such as precision distillation or crystallization purification method to increase its purity. For example, crystallization purification methods such as crystallization with an organic solvent, crystallization with a water solvent, and melt crystallization may be used.

The obtained high-purity ε-caprolactam is mixed with new ε-caprolactam, if necessary, and then nylon 6 is prepared by solution polymerization or melt polymerization by a usual polymerization method.
To manufacture.

The nylon 6 from the recovered lactam produced in this manner is again melt-spun into nylon 6 fibers, and substances such as reinforcing materials and additives are added to the nylon 6 fibers in the usual manner. Molded into parts such as fasteners and fasteners.

Using the obtained nylon 6 fiber or nylon 6 molded product, a nylon 6 fiber clothing product may be manufactured in the same manner as described above.

The nylon 6 fiber clothing product thus recycled is preferably manufactured and distributed as a recyclable clothing product, and may be repeatedly recycled.

The recycled nylon 6 fiber garment product of the present invention is applicable to any clothing product in which nylon 6 fiber can be used. For example, uniforms (uniforms for infants, children and students, work clothes) can be used. In addition, white coat, explosion-proof garment, dust-free garment, sports trainer, garments that are worn like uniforms in special work such as hats and gloves accompanying them), rainwear, sportswear, outerwear, innerwear , Stockings, swimwear, leotards, etc.

Among these clothing products, rental wear and uniforms lent to employees are relatively easy to collect and sort. Therefore, it is effective to apply the present invention to recycle them. .

A uniform is often composed of a combination of parts such as outerwear, pants, middlewear, and underwear, and the present invention may be applied to all of them. May be applied to some parts of.

[0043]

【Example】

Example A new ε-caprolactam containing 0.4% by weight of titanium oxide was polymerized by a conventional method to obtain nylon 6 having 98% sulfuric acid relative viscosity of 2.70. This nylon 6 is melt spun in the usual way to give 70
Nylon 6 fibers of denier 24 filaments or 70 denier 40 filaments were used. The strength and elongation of the obtained nylon 6 fiber are as shown in Table 1.

As the outer material of the uniform woven fabric, nylon 6 fibers of 70 denier 24 filaments are used as warp yarns and 70
A plain weave fabric was woven by using two weft-supplied Taslan-processed yarns of nylon 6 fibers of denier 24 filaments and nylon 6 fibers of 70 denier 40 filaments as weft yarns. After dyeing the surface material with a normal acid dye, a fluororesin (“Asahi Guard” AG-710 (Asahi Glass Co., Ltd.)
Manufactured)). The total amount of the dye and water repellent applied was 1.5% by weight (vs. fiber).

For lining, plain weave taffeta was woven using 70 denier 24 filament nylon 6 fiber as warp and weft, and dyed and finished by a usual method.

As the interlining, a nylon 6 knit interlining produced by a usual method was used.

Nylon 6 resin not containing titanium oxide
A button having a diameter of 1 cm was molded by a usual molding method using a resin composition in which glass fiber was mixed in a weight percentage. Also, nylon 6 fiber woven fabric, nylon 6 monofilament, glass fiber reinforced nylon 6 molded part, and nylon 6
Fasteners were manufactured in the usual way using sutures.

Using these nylon 6 cloth and accessories, sewing was carried out in the usual manner to produce a work jacket. 98% by weight of the constituent materials of the obtained outerwear is nylon 6
However, 620 g of nylon 6 was used per piece.

The obtained outerwear was worn as rental wear for 6 months and then collected.

The recovered outerwear was put into a nylon depolymerization facility without being disassembled, and was decomposed by adding a phosphoric acid catalyst while melting at 290 ° C., and the produced ε-caprolactam was distilled and cooled to be collected. Almost 90% of the charged raw material could be recovered as ε-caprolactam. The unrecovered residue was an additive other than nylon 6, a treating agent, a carbide generated in the depolymerization step, a gel, and the like.

The recovered ε-caprolactam further comprises
Purified by ordinary rectification and crystallization refining methods, it has substantially the same high purity ε-caprolactam as new ε-caprolactam from petroleum raw materials.
-Caprolactam is obtained.

When the characteristics of the obtained recovered / purified ε-caprolactam were analyzed, as shown in Table 1, it was almost the same as the characteristics of the new ε-caprolactam, and it was an excellent quality that could be used as if it was new. Each characteristic of ε-caprolactam was measured by the following methods.

Permanganic acid value (PMV): Potassium permanganate was added to a 3 wt% aqueous solution of ε-caprolactam, and the time (seconds) until the purple color of the mixed solution coincided with the standard color tone was measured. The longer this time, the less impurities.

Color tone (APHA): JIS-K-41
In accordance with No. 01, the color tone of a 50 wt% aqueous solution of ε-caprolactam is measured by a method of comparing with the color tone of a standard solution.

Water content: ε-caprolactam is dissolved in methanol to prepare a sample, and the amount of water contained in this sample is determined by a titration method using Karl Fischer reagent.

The ε-caprolactam obtained by the recovery and purification was supplied to a nylon 6 polymerization facility and polymerized by a usual method, and as a result, a high quality nylon 6 obtained from the new ε-caprolactam was obtained. .

The nylon 6 thus obtained from the recovered lactam was melt-spun in the same manner as described above to produce nylon 6 fiber. The physical properties of the obtained nylon 6 fiber are as shown in Table 1.

[0058]

[Table 1]

Using this nylon 6 fiber, a surface material and a lining material were manufactured by the same method as described above.

Further, nylon 6 from the recovered lactam was used to produce a nylon 6 button by molding in the usual manner, and a nylon 6 fastener component was used to produce a fastener.

Using these nylon 6 fiber outer material, lining, lining, button, and fastener, a work jacket composed of 98% by weight of nylon 6 was prepared in the same manner as described above.

In this way, the work jacket is recycled by the recycling method of depolymerizing the work jacket and once returning it to the raw material monomer. 88% by weight of nylon 6 could be recycled as a work jacket.

[0063]

EFFECTS OF THE INVENTION The present invention substantially unifies the raw materials of clothing products with nylon 6 which can be easily purified by returning it to the raw material monomer and can be reused as the raw material monomer. After returning the clothing product thus obtained to the raw material monomer, it is polymerized again, melt-spun and / or molded, and the original clothing product can be produced for repeated recycling.

Furthermore, since the nylon 6 is substantially unified, it can be subjected to the depolymerization step without being disassembled and sorted, which is a big problem when recycling clothing products. -The sorting work can be significantly reduced.

Moreover, since the raw material monomer is returned, it is possible to recycle a clothing product having the same quality as a clothing product manufactured from a new monomer.

Therefore, according to the present invention, it is possible to recycle by a closed system of raw material-product-raw material-product by only generating a small amount of waste, which contributes to effective utilization of resources.

The present invention is particularly effective when applied to clothing products such as rental wear and uniforms, which are renewed after a large amount of similar products have been manufactured and used and in which used products can be collected relatively easily. is there.

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Claims (9)

[Claims] 1. Polymerization using a lactam recovered by depolymerizing and purifying a constituent polymer of a nylon 6 fiber garment product in which the constituent fabrics and the materials for clothing accessories are substantially unified with nylon 6. To produce nylon 6, and melt-spin and / or mold using the nylon 6 to produce nylon 6 fiber and / or nylon 6 clothing accessory, and the nylon 6 fiber and / or nylon 6 clothing accessory A method for producing a nylon 6 fiber garment product, characterized in that a nylon 6 fiber garment product in which the constituent materials of the fabric and the clothing accessory are substantially unified with nylon 6 is produced using the product. 2. The method for producing a nylon 6 fiber garment product according to claim 1, wherein the nylon 6 fiber garment product is subjected to depolymerization without being substantially disassembled. 3. When depolymerizing the constituent polymer of the nylon 6 fiber garment product, oligomers and nylon 6 wastes by-produced in the steps from lactam polymerization to manufacturing of the garment product are simultaneously depolymerized. The method for producing a nylon 6 fiber garment product according to claim 1 or 2. 4. The nylon according to claim 1, 2 or 3, wherein 80% by weight or more of all materials of the cloth and the clothing accessories constituting the nylon 6 fiber clothing product is nylon 6. 6 Manufacturing method for textile products. 5. The nylon 6 according to claim 1, 2, 3 or 4, wherein substantially all the materials of the cloth and the clothing accessories constituting the nylon 6 fiber clothing product are nylon 6. A method of manufacturing a textile garment product. 6. The method for producing a nylon 6 fiber garment product according to claim 1, 2, 3, 4 or 5, wherein the nylon 6 fiber garment product is a uniform or rainwear. 7. The method for manufacturing a nylon 6 fiber garment product according to claim 6, wherein the uniform is a work uniform. 8. The nylon 6 fiber garment product is rental clothing, 1, 2, 3,
A method for manufacturing a nylon 6 fiber clothing product according to 4, 5, 6 or 7. 9. The nylon 6 fiber garment product to be subjected to depolymerization and / or the nylon 6 fiber garment product obtained by the production is a product manufactured as a recyclable clothing product. 1, 2, 3, 4, 5,
A method for producing a nylon 6 fiber clothing product according to 6, 7, or 8.