JPH08209526A - Production of fiber structure having shape stability - Google Patents

Abstract

PURPOSE: To produce a fiber structure having excellent impact resilience and dimensional stability and improved shape retention. CONSTITUTION: This method for producing a fiber structure having excellent shape stability comprises making yarn composed of a polyester taken off at 2,000-4,000m/minute take-off speed in melt spinning into fabric without providing the yarn with heat history equal to or higher than a secondary transition point, making the fabric into a three-dimensional state and treating it in the state in an atmosphere at a temperature equal to or higher than the secondary transition point. In melt spinning, yarn comprising a polyethylene terephthalate taken off at 2,500-3,500m/minute in melt spinning is made into fabric without providing heat history equal to or higher than the secondary transition point, the fabric is made into a three-dimensional shape and is exposed in the state in an atmosphere of steam heat or dry heat at 90-230 deg.C.

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 fiber structure having excellent shape stability.

[0002]

2. Description of the Related Art Conventionally, synthetic fibers such as nylon and polyester have been widely used in the field of clothing or industrial fields because of their high performance. Fiber sheets made of nylon or polyester are often used as three-dimensional products such as clothing interlinings, bras, and chest and shoulder pads. In addition, recently, the morphological stabilization of a shirt made of a blended yarn of polyester and cotton is often performed.

However, nylon is remarkably inferior in dimensional stability in dry and wet conditions such that it expands when it absorbs moisture and contracts when it is dried, and it is a difficult material to use in fields where dimensional stability is important. Therefore, in recent years, most of textile fibers are being replaced with polyester fibers.

On the other hand, polyester has good dimensional stability when dry and wet, but has a drawback that it has a weak impact resilience and is liable to be set upon repeated bending. Therefore, it is rarely used for toothbrushes, artificial lawns, carpets and the like, although the polymer cost is lower than nylon 6 and nylon 66.

[0005]

However, it is difficult to obtain a fiber structure having good impact resilience and dimensional stability and excellent shape-retaining property from the conventional fibers. Especially, in the fiber structure having a three-dimensional shape, it was even more so.

Taking the interlining of clothes as an example, the interlining is sewn by stacking a number of flatly-manufactured fiber sheets on the curved surface of the interlining in order to beautifully express the shape retention and body lines of the clothes. Although it has a three-dimensional shape with a curved surface, the sewing process is complicated and the fiber remembers the original shape and the one that is forced to deform returns to its original shape with time and is durable. It is difficult to obtain a specific shape.

[0007] Recently, it is often practiced to crosslink or modify cellulose to improve the morphological stability of the shirt, but the chemicals for the shape stabilizing treatment remain (especially formalin is not suitable for those that come into contact with the skin). ), There is a problem that the strength is lowered or the shape stabilizing effect is small.

The present invention solves the above-mentioned drawbacks and provides a fibrous structure having both good impact resilience and dimensional stability and excellent shape retention, and a method for producing the same.

[0009]

In order to achieve the above-mentioned object, the present invention has the following constitution. That is, the method for producing the shape-stable fiber structure of the present invention,
In melt spinning, fibers made of polyester drawn at a take-up speed of 2000 to 4000 m / min are woven into a fabric without giving a thermal history of a second-order transition point or higher, and the fabric is maintained in a three-dimensional shape to form a secondary fabric. It is characterized in that it is treated in an atmosphere of a transition temperature or higher, and in melt spinning, a fiber made of polyethylene terephthalate drawn at a take-up speed of 2500 to 3500 m / min is subjected to a thermal history of a secondary transition point or higher. It is characterized in that it is made into a fabric without being given, and the fabric is exposed to a steam or dry heat atmosphere of 90 to 230 ° C. in a state where the fabric is maintained in a three-dimensional shape.

[0010]

The present invention will be described in more detail below.

The constituent features of the present invention are:
Polyester fibers taken up at a take-up speed of 2000 to 4000 m / min were spun into a fiber without passing through a process to which a heat treatment was applied, then made into a fabric, and then maintained in an arbitrary three-dimensional shape, after which 2 of the fiber polymer was used. It is an important finding that a fiber structure having both good impact resilience and dimensional stability and excellent shape retention can be provided by treating in an atmosphere at a temperature not lower than the next transition point.

The present invention has been discovered and applied to the fact that it can be achieved only in such a constitutional requirement, and the present inventors have conducted a melt spinning using a crystallizable polymer such as polyethylene terephthalate. A fiber (primary specific region) in a controlled range of take-up under the condition of up to 4000 m / min, and without changing the twist (temporary twist) while performing the conventional heat treatment, and further stretching By fixing the fiber in an arbitrary shape and heating it at a temperature at which further crystallization is possible, any certain specific shape is maintained, and then crystallization is promoted,
After that, by forming a fiber (second specific region) which becomes a region of controlled orientation and crystallization, it has both good impact resilience and dimensional stability, which is the object of the present invention, and imparts excellent shape retention. I discovered that I could do it and applied it.

In order to obtain a controlled fiber (primary specific region) which has a history of not being heated and which is drawn at such a specific take-up speed, the fiber polymer is a polyester fiber, and particularly polyethylene terephthalate. Aromatic polyesters such as polybutylene terephthalate or copolymers containing them as a main component are preferably used. In addition, the take-up speed (spinning speed) in melt spinning is 2000 to 4
000 m / min, particularly preferably 2500-3500 m /
It is obtained under the condition of minutes. Whether the speed is lower or higher than the take-up speed, the primary specific region in the present invention cannot be obtained and the effect cannot be obtained. In particular, the former effect is unique and excellent, which is preferable. Needless to say, the effect of the present invention cannot be obtained by using the fiber obtained at the above-mentioned take-up speed, which is further heat-drawn, that is, a conventionally known fiber. Further, the present invention can be realized with polyester fibers, and never with nylon. In particular, it is necessary to pay attention to the fact that this type of fiber has been conventionally used for POY (Pre-Ori
As an ented Yarn, false twisting under heating and additional heat drawing were added, and it was utilized only when heat treatment was already applied. Using a part or all of the fibers in the primary specific region to fabricate a woven fabric, a knitted fabric, a non-woven fabric, a net or the like or fix it to an arbitrary shape, and then treat it in an atmosphere at a secondary transition point or higher. As a result, both good impact resilience and dimensional stability can be provided, and excellent shape retention can be imparted. Especially preferably, instantaneously,
It is to shockly add heat.

By shifting the fibers from the primary specific region to the secondary specific region, the polyester fiber has high elasticity such as nylon and excellent flex resistance against repeated flexing, and is polyester-based. It is possible to combine the dimensional stability in dry and wet, which is an inherent advantage of the fiber. That is, the fiber structure of the present invention has an unprecedented epoch-making effect that it has the advantages of nylon and polyester at the same time.

The treatment for shifting from the primary specific region to the secondary specific region is achieved by treating in an atmosphere at a temperature not lower than the secondary transition point of the fiber polymer, preferably the secondary transition point. More preferably, it is carried out in an atmosphere of 20 ° C or higher, particularly preferably 40 ° C or higher. Since the second-order transition point of polyethylene terephthalate is about 72 ° C., it is preferably treated in an atmosphere of 92 ° C. or higher, particularly preferably 120 ° C. or higher. Therefore, the temperature range of the treatment is preferably 92 to 230 ° C, particularly preferably 120 to 210 ° C. Further, the heating means may be either dry heat or wet heat, and the exposure speed to the atmosphere and the cooling speed may be rapid or gentle, but the former gives a preferable result.

Although the thickness of the fiber is not particularly limited, it is generally preferable to use a single yarn having a denier of 0.1 to 200 and a total fineness of 20 to 1000 denier. The above-mentioned cloth is in the form of ordinary woven fabric, knitted fabric, non-woven fabric, sheets such as nets. Further, the arbitrary shape is a shape of any object and includes, but is not limited to, a clothing shape.
In particular, the present invention exerts a remarkable effect in maintaining a three-dimensional shape such as an interlining for clothes, a brassiere, pads for chest and shoulders, and a collar core, and is preferably applicable. Usually, these are set in a target mold and then exposed to an atmosphere of heat treatment.

The nets are not particularly limited, and conventionally known fishing nets such as frogs and knots, double frogs and knots, trapping nets, laundry nets, duvet cover nets,
Curtains, hat nets, etc. are effective for holding various three-dimensional shapes when applied to them, and are very easy to use and highly effective when the shapes are stably held.

Further, the interlining material for clothes can be given a shape-retaining property by being subjected to a heat treatment after being made into an interlining material called a construction core or after being sewn as clothes. Conventionally, the interlining is made into a three-dimensional curved shape by sewing many fiber sheets in order to retain the shape of clothes and to express the body line beautifully, but if the present invention is applied, it is not a multilayer structure. Even though it retains its shape, it can be made lighter and cooler. Although the structure or structure of the interlining is not questioned, a coarse knitted fabric called mesh knitting or open stitch knitting is preferably applied to make the effect of the present invention more effective. In addition, various three-dimensional objects such as brassieres and pads for chest and shoulders are not particularly limited.

Further, in a napped cloth such as carpet, artificial lawn, and moquette, or a brush molded product such as a toothbrush and a cleaning brush, remarkable shape retention and durable bending property are obtained, and a napped product which is hard to be worn can be obtained. .

Further, the polyester fiber is singly or mixed with or mixed with rayon, cotton or hemp to form a non-woven fabric, a woven fabric or a knitted fabric, and a part or all of the non-woven fabric is used to form a shirt. A shirt having a preferable shape-retaining property can be obtained by performing a rapid heat treatment such that the temperature gradient is 0.5 to 10 ° C./sec at the second-order transition point of the fiber or higher. Compared to the conventional shape stabilization processing by VP processing and various resin processing, there are no problems such as toxic chemicals such as formalin remaining and fiber strength reduction.

[0021] Usually, the morphological processing of a polyester fiber / cotton blended product is to crosslink or modify the cellulose component of cotton, but the present invention is to retain the shape of the polyester fiber itself, and its effect. Is high and has the advantage of not requiring fiber upholstery or complicated processing. Further, it goes without saying that the polyester fiber / cotton can be subjected to a conventionally known form stabilizing treatment on the cotton side as well to achieve higher-performance shape stabilization.

Naturally, it is more effective and preferable to subject the fibrous structure obtained in the present invention to various finishing processes such as dyeing, water repellent treatment, laminating and coating.

[0023]

EXAMPLES The present invention will be described in more detail by way of examples, which should not be construed as limiting the present invention, but rather for those who are familiar with the constitution of the present invention. It will be easy to apply and develop the technology.

Example 1, Comparative Example 1, Comparative Example 2 Polyethylene terephthalate (IV = 0.7) was used as a raw material.
2), spinning temperature 285 ° C., take-up speed 3100 m /
Melt-spun in minutes to obtain a 160-denier, 48-filament raw yarn. The strength of the raw yarn is 3.0 g / d, and the elongation is 16
5%. A tubular knitted product was produced by using a tubular knitting machine using such a raw yarn, mounted and fixed on the outer periphery of a rectangular form frame, and subjected to dry heat treatment at 180 ° C. for 60 seconds to produce a formwork-shaped fiber structure.

As Comparative Example 1, the above raw materials were melt-spun at a spinning temperature of 285 ° C. and a take-up speed of 1200 m / min.
As a comparative example 2, nylon 0 was used as a raw material and a take-up speed of 3000 m /
200 denier, 24 filaments melt-spun in minutes
The same treatment as in the example was performed using a strength of 3.2 g / d and an elongation of 175%.

As a result, in Example 1, one having the same shape as the rectangular form was obtained. Moreover, the rectangular parallelepiped shape did not collapse even after washing with water and dry washing five times. Also,
No settling was observed after 20 buckling tests. On the other hand, both Comparative Example 1 and Comparative Example 2 were in a state of being cluttered and could not have a rectangular shape.

Examples 2, 3, 4, Comparative Example 3, Comparative Example 4 Polyethylene terephthalate (IV = 0.6) was used as a raw material.
8), spinning temperature 285 ° C., take-up speed 3000 m /
Melt spinning was carried out for a minute to obtain a raw yarn of 200 denier and 24 filaments. The strength of the raw yarn is 2.8 g / d and the elongation is 17
5%. Using such a raw yarn, a mesh knitted fabric having a 4-course double atlas with a front design of 1/1 and a 4-course double atlas with a back design of 1/3 was knitted by an 18 gauge, 4-blade Russell knitting machine. Using this knitted fabric, (1) foreground interlining of clothes (Example 2), (2) brassiere (Example 3), (3) breast pad of swimwear (Example 4) were produced, and each was three-dimensional. The mold was fixed to each shape mold and subjected to a dry heat treatment at 180 ° C. for 30 seconds to produce a fiber structure of each shape.

As Comparative Example 3, a stretched yarn obtained by further stretching the melt-spun raw yarn through a heating roll of 150 ° C. for 1.7-fold drawing was used. As Comparative Example 4, nylon was used as a raw material and a take-up speed was used. 200 denier melt-spun at 3000 m / min, 24 filaments, strength 3.2 g / d, elongation 1
Using 75%, the same process was performed using the same mold as in Example 2, Example 3 and Example 4.

As a result, all of the fiber structures of the present invention had very good shape retention, and the clothes of (1) had a three-dimensional shape capable of expressing a beautiful curved surface along the line of the body. Further, such clothes are lighter in weight, more breathable and more comfortable than conventional ones. Also, 5
The shape did not collapse even after repeated washing with water and dry washing. Regarding (2) and (3), the three-dimensional shape retention was good, and no problems occurred in terms of dimensional change even when sweat or water was included.

On the other hand, both Comparative Example 1 and Comparative Example 2 had insufficient shape-retaining properties, and could not have the desired shape.

Example 5 Polyethylene terephthalate (IV = 0.6) was used as a raw material.
8), spinning temperature 285 ° C., take-up speed 3000 m /
Melt-spun for 5 minutes to obtain a yarn of 75 denier and 36 filaments. This raw yarn is combined into about 100,000 denier, crimped through a crimper, and then the fiber length 51
Cut into mm and polyethylene terephthalate raw cotton (T)
Was produced. T / C the raw cotton (T) and cotton raw cotton (C)
= 65/35 was mixed with a mixing machine. A short fiber was spun using the mixed raw cotton as described above to obtain a spun yarn, and a plain woven fabric was sewn on a shirt. Then, it was mounted and fixed on the body and treated at 170 ° C. for 60 seconds in a hot air dryer.
The shirt thus obtained was less likely to wrinkle, and had a three-dimensional shape conforming to the shape of the body, which was extremely good in shape retention. No ironing was required after washing. The shirt was comparable to a commercially available shape-stabilized shirt treated with formalin and was good.

[0032]

The present invention has the following effects.

(1) It is possible to provide a fibrous structure having both good impact resilience and dimensional stability and excellent shape retention.

(2) In particular, it is easy to obtain a fiber structure having a three-dimensional shape, and its shape durability is good.

(3) Since no chemicals are used as compared with the conventional shape-retaining process, no toxic chemicals remain, and
The strength does not decrease.

(4) In a napped fabric or brush, the napped hair has good bending resistance and is difficult to set.

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Claims (9)

[Claims] 1. In melt spinning, the take-up speed is 2000-4.
Fibers made of polyester taken up at 000 m / min are made into a fabric without giving a thermal history of the second transition point or higher, and the fabric is treated in an atmosphere of the second transition point or higher while maintaining the three-dimensional shape. A method for producing a shape-stable fiber structure, comprising: 2. In melt spinning, the take-up speed 2500-3
Fibers made of polyethylene terephthalate taken up at 500 m / min were made into a fabric without giving a thermal history of a secondary transition point or higher, and the fabric was maintained in a three-dimensional shape,
A method for producing a shape-stable fiber structure, which comprises exposing to a steam or dry heat atmosphere of 90 to 230 ° C. 3. The shape-stable fiber structure according to claim 1 or 2, wherein the cloth is selected from a non-woven fabric, a woven fabric or a knitted fabric, and the shape-stable fiber structure is an interlining material or an outer material. Production method. 4. A shirt using the interlining material or surface material according to claim 3. 5. A brassiere using the interlining material or the surface material according to claim 3. 6. A pad using the interlining material or the outer material according to claim 3. 7. The method for producing a shape-stable fiber structure according to claim 1, wherein the fibers are mixed or mixed-spun with at least one selected from rayon, cotton and hemp. 8. The method for producing a shape-stable fiber structure according to claim 1, wherein the cloth is a net. 9. The method for producing a shape-stable fiber structure according to claim 1, wherein the cloth is a napped cloth.