JPH09119063A - Staple fiber flock for napping and napped structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a napped structure rich in crispiness and natural feeling without causing color fading or whiteness by flocking a substrate with flocks, containing staple fibers having a large diameter and those having a small diameter and having a distribution of cross-sectional area different in the fiber axial direction. SOLUTION: This staple fiber flock for napping is obtained by crimping a polyester thick and thin filament yarn, providing a crimped yarn having <=10% shrinkage factor in boiling water, a change in thick parts and thin parts in the fiber axial direction and a distribution different in cross-sectional area and then cutting or pulverizing the resultant yarn. The prepared fiber flock comprises staple fibers 2 having a birefringence of 15×10<-3> to 80×10<-3> birefringence Δn and a length within the range of 0.1-10mm and a large diameter of 0.13-1.5μm average diameter, staple fibers 3 having 90×10<-3> to 200×10<-3> birefringence and a small diameter of 0.1-1.3μm average diameter and staple fibers 4 having a distribution of cross-sectional area different in the fiber axial direction and the birefringence within the range between those of the staple fibers 2 and 3 and changing in the fiber axial direction. The staple fiber flock comprises >=20wt.% staple fibers, <=10wt.% staple fibers 4 and other staple fibers 3. A base fabric is flocked therewith to afford the napped structure.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a short fiber flock for naps used for flocking and the like, and a napped structure using the short fiber flock for naps. More specifically, the present invention has a short fiber flock for napped hair, which has characteristics of so-called thick and thin yarns having a large and small thickness in the fiber axis direction, and a general clothing cloth, bedding, flocked with it as a base material. The present invention relates to a napped structure such as a rug, a material cloth and the like.

[0002]

2. Description of the Related Art Conventionally, among flocked products, flocked products such as electric flocking products use short fiber flocs obtained by cutting or crushing rayon or polyami fibers as napped fibers. The reason is that these yarns can be easily cut or crushed and have excellent dyeing and coloring properties. However, when rayon is used, the product becomes heavy and wet rubbing occurs. There is a problem that the dyeing fastness is low, and also in the case of polyamide fiber, the wet friction dyeing fastness is low and the heat stability is poor. It has been proposed to use other materials such as polyester fiber. However, up to now, there are few examples in which a flocked product using polyester fiber has been put to practical use. The reason is that polyester fibers cannot be stably cut or crushed into a predetermined length like long hair of 0.5 mm or more in the current equipment.

In addition, since these fiber materials generally have a fiber cross-sectional area, that is, a thickness which is substantially uniform in the axial direction of the fiber, short fiber flocs obtained by cutting and crushing them are used. The flocked product had naps with a uniform thickness, had a monotonous touch texture, had the same color tone and lacked depth, and had defects such as color blur and whiteness depending on the direction of light rays.

On the other hand, as a yarn having a fine structure difference with respect to the fiber axis direction, a polyester yarn having a large and small thickness in the fiber axis direction, a thick portion having a low degree of orientation and a thin portion having a high degree of orientation, and the like. Knitted fabrics using yarns are known.
Similarly, in Japanese Patent Laid-Open No. 52-31144, there is also a thick and thin fiber in the fiber axis direction, and in particular, the thick and thin phases are randomized so that the yarn is visually uniform in thickness. A yarn has been proposed in which a thick and weak portion is then cut and fluffed to obtain an effect substantially similar to that of a staple-like fiber bundle (spun yarn). However, from the viewpoint of a napped structure, it cannot be said that the thick and thin yarn described in Japanese Patent Laid-Open No. 52-31144 also effectively utilizes its characteristics. What is important is that physical properties such as thick and thin shape characteristics and crystal orientation existing in the fiber axis direction with respect to the napped portion are not utilized.

[0005]

DISCLOSURE OF THE INVENTION The present invention avoids the monotonicity of a conventional flockey material having a uniform fineness, improves the stable cuttability and pulverizability of a new flocky material, and improves the fiber in the napped portion. This has been achieved as a result of intensive research aimed at maximizing the utilization of thick and thin shape characteristics in the axial direction.

An object of the present invention is to provide a short fiber flock for napped hair which is rich in crispness and natural feeling, and which can obtain a napped cloth or the like which does not cause color blurring or whitening depending on the direction of light rays. .

Another object of the present invention is to provide a napped structure such as a general clothing cloth, bedding, rug, etc. using such short fiber flock for napping, which has never been experienced before.

[0008]

SUMMARY OF THE INVENTION The present invention is intended to achieve the above object and has the following structure.

That is, the short fiber flock for napped hair of the present invention is
A short fiber flock for napping in which short fiber A having a large diameter, short fiber B having a small diameter, and short fiber C having a distribution of a different cross-sectional area in the fiber axial direction are mixed, and specifically, the fiber axial direction. It can be obtained by cutting or pulverizing fibers having a large and small change in thickness and different distributions of cross-sectional areas. In the present invention,
A peculiar napped structure can be obtained by implanting such napped short fiber flocs on a yarn, a base cloth or the like.

Further, the present invention includes the following aspects. (1) The length of the short fibers A, B and C of the short fiber flock for napped hair is about 0.1 to about 10 mm. (2) Birefringence Δ of the short fiber A of the short fiber floc for nap
n is 15 × 10 ⁻³ to 80 × 10 ⁻³ , birefringence Δn of the short fiber B is 90 × 10 ⁻³ to 200 × 10 ⁻³ , and the short fiber C is
That the birefringence Δn of is changed in the fiber axis direction within the range of the birefringence of the short fibers A and the short fibers B. (3) The cross-sectional area of the short fiber flock for napped fibers on the large diameter side of the short fibers C is equal to or smaller than the cross-sectional area of the short fibers A, and the cross-sectional area of the short fibers C on the small diameter side is short fibers B. Equal to or larger than the cross-sectional area of (4) Short fibers A and short fibers B of short fibers for flocculation
The cross-sectional area ratio is 1.2 to 3.0. (5) The average diameter of the short fibers A of the short fiber flocs for napped hair is 0.13 to 1.5 microns, and the average diameter of the short fibers B is 0.1 to 1.3 microns. (6) The short fibers C have a diameter at one end larger than that at the other end, that is, the cross-sectional areas at both ends are different. (7) Even if the cross-sectional areas of both ends of the short fiber C are similar, the cross-sectional area of the central part is larger or smaller than the both end parts. (8) The ratio of the short fibers A of the short fiber flock for napped hair is 2
0% by weight or more, the proportion of the short fibers C is 10% by weight or less, and the rest is the short fibers B. (9) The short fiber flocs for napped fibers are formed by cutting or crushing polyester crimped yarn having a change in thickness in the fiber axis direction and a distribution of different cross-sectional areas. (10) The shrinkage rate of boiling water of the polyester crimped yarn is 1
0% or less.

The present invention will be described in more detail below.

[0012]

Among the napped products, a flocked product is, for example, a short fiber flock obtained by cutting a short fiber on a base material coated with an adhesive, by spray pressing, spraying, electrical or mechanical vibration or high voltage. It is fixed as napped hair by using static electricity. In recent years, such a flocky processing is most often made by using direct current electrostatic high voltage, and is also called electrodeposition processing, electrostatic flocking processing, or electric flocking. A water-resistant adhesive or the like is applied to a base fabric, and the short fiber flocs cut into the base fabric are velvet-like or pseudo-fur-like by surface raising by a processing method of vertically or slanting.

In the present invention, the material of the short fiber floc and the fiber material are not particularly limited, but preferably, synthetic fibers represented by polyester, polyamide or polyacrylonitrile are advantageously used.

Up to now, short fiber flocs obtained by cutting or crushing rayon or polyamide fibers have been mainly used for flocking, but in the practice of the present invention, in addition to these, polyester fibers are used. Particularly preferably used. As the polyester fiber, a fiber mainly composed of polyethylene terephthalate and polybutylene terephthalate, in which 10 mol% or less of a third component is copolymerized, or a mixture of 10 wt% or less of an organic or inorganic substance is preferable. Used. In order to increase abrasion resistance, such polyester fibers are usually made from polymers having an intrinsic viscosity of 0.58 or higher, preferably 0.60 or higher. Further, as the polyamide fiber, nylon 6 and nylon 66, which have excellent physical properties, are preferable.

The staple fiber flocs for napped hair of the present invention include three types of staple fibers, a staple fiber A having a large diameter, a staple fiber B having a small diameter, and a staple fiber C having a different cross-sectional area distribution in the fiber axial direction. Are mixed. The schematic diagram is shown in FIG. 2 and 3 in FIG. 1 exemplify a short fiber A having a large diameter and a short fiber B having a small diameter, respectively, and 4 in FIG. 1 exemplifies a short fiber C having a change in thickness in the length direction. The present invention is not limited to these.

The short fibers A of the present invention are relatively thicker than the short fibers B, and the cross-sectional area ratio between the short fibers A and the short fibers B is preferably 1.2 to 3.0. . If the cross-sectional area ratio is close to 1, the denier mixing effect cannot be expected monotonously when napped, and if it is too large, the natural feel tends to be impaired. The thickness of the short fibers A is preferably 0.5d to 60d in terms of fineness, and that of the short fibers B is preferably 0.3d to 40d. Alternatively, it is preferable that the short fibers A have an average diameter of 0.13 to 1.5 microns and the short fibers B have an average diameter of 0.1 to 1.3 microns.

The short fiber C of the present invention may have any thickness,
It is preferable that the fibers are similar to the short fibers A and the short fibers B because they have a natural feeling as a napped product. In this relationship, the cross-sectional area of the short fibers C on the large diameter side is equal to or smaller than the cross-sectional area of the short fibers A, and the cross-sectional area of the short fibers C on the small diameter side is equal to the cross-sectional area of the short fibers B. It is desired to be large.

The length of the short fiber floc of the present invention varies depending on the use, but it can be preferably used in the range of 0.1 mm to 10 mm. For example, about 0.5 to about 1 mm for clothes, about 0.5 to about 2 mm for materials, and about 3 to about 8 for rugs.
Flocks of each fiber length of mm are used. The lengths of the respective short fibers A, B and C may be different from each other, but in order to give a more natural feeling, the short fibers can be transplanted with substantially the same length. If the fiber length is too large, it is difficult to enhance the napping property such as the uprightness of the hair transplant, and hair fall occurs. On the contrary, if the fiber length is too small, the soft texture and feel cannot be obtained.

The short fiber flocs for napped hair of the present invention are composed of short fibers A, B and C, but because of the relationship with the method for producing the short fiber flocs described later and because of the entanglement with dyeing property such as dyeing with a dye. The internal crystal orientation is one of the important factors. In terms of birefringence, in the present invention, the birefringence Δn of the short fibers A is 15 × 10 ⁻³ to 80 × 10 ⁻³ , and the birefringence Δn of the short fibers B is 90 × 10 ⁻³ to 200 × 10 ^{−. 3} , and the birefringence of the short fibers C is preferably changed in the fiber axis direction within the range of the birefringence of the short fibers A and the short fibers B.

When cutting into short fiber flocs, several to tens of thousands are bundled and cut, and the birefringence Δn is 90 × 10 ^−3.
When ~ 200 × 10 ^-3 is 100%, the cutting blade has a higher damage rate and birefringence Δ than rayon and nylon.
When n is 15 × 10 ⁻³ to 80 × 10 ⁻³ is 100%,
Elongation at the time of cutting is likely to occur, which may cause problems in industrial production. It is desirable that these are randomly bundled, which makes it possible to more stably produce polyester short fiber flocs.

Next, the method for producing the short fiber flocs for napped hair of the present invention will be described.

In the present invention, as described above, it is possible to use fibers having a change in thickness in the fiber axis direction and a distribution of different cross-sectional areas. Artificial fibers are generally produced by spinning and drawing and usually become fibers with substantially no thickness unevenness, but the discharge amount of the polymer in the spinning process, the take-up speed, the spinning length and the spinning atmosphere are varied, and the stretching process is performed. By changing the stretching ratio, the stretching length, the stretching atmosphere, etc., it is possible to obtain fibers that change in the axial direction, and this is already known.

Taking polyester fibers as an example, in the present invention, the polyester is melt-spun by such an existing method, and the obtained semi-drawn yarn having a thickness in the axial direction of the fiber is heat-treated with a hot plate or the like to be crystallized. The degree of orientation is controlled to reduce shrinkage. In the present invention, it is preferable that the shrinkage rate of boiling water is 10% or less due to the low shrinkage. For the purpose of the light treatment, in the case of polyester fiber, heat treatment at about 150 ° C to 230 ° C is performed.
The stabilized polyester fibers thus obtained are then subjected to a fluid treatment, preferably by air or the like such as turbulence or entanglement treatment, to give the fibrous material for the short fiber flocs of the present invention. In the practice of the present invention, apart from the above, crimped yarn such as false twisted yarn may be used. The processed yarn is usually wound around cheese, dyed with a cheese dyeing machine, and then cut or crushed into a predetermined length with a cutter or the like.

The fiber material prepared in this manner is a fiber having a change in thickness in the fiber axis direction and a distribution of different cross-sectional areas. In the present invention, the fiber material is cut or crushed to be made into short fibers. To do. In the production of this short fiber in the conventional fiber material, the diameter of the fiber end cut by a cutter or the like becomes thick due to elastic recovery, or due to poor cutting,
When the so-called burr becomes large and the cut end swells, it becomes difficult to firmly bond the short fibers to the substrate surface in an upright state, but in the case of the fiber material of the present invention, There is no problem. For example, the fiber material is cut in the state of a fiber bundle having a total denier of about 5 million D, and the cut portion corresponds to a thick portion, a thin portion of the fiber and an intermediate portion thereof along the fiber length. Either one of the parts, the thick part has a relatively small degree of crystal orientation, the thin part has advanced crystallization but the fineness is small, and the remaining part is characterized by both of the above. Both can be cut easily and sharply. A guillotine type cutter or the like is used for the cutting.

In the practice of the present invention, the short fiber flocs for napped hair use various combinations of the short fibers A, B and C. Usually, these are in the form of a mixture of the three, for example, the proportion of short fibers A is 20% by weight or more, the proportion of short fibers C having different cross-sectional areas is 10% by weight or less, and the rest are short fibers B. It is in good condition. In the practice of the invention,
As described above, the thick short fibers A account for 20% by weight or more, which is half, and the ratio of the short fibers C having different cross-sectional areas is 10% by weight.
When the napped product is made to be a napped product, the short fiber B occupies a large amount so as to give a bathochromic property and to firmly fix the napped hair to give a sense of stability. A mixture of B and short fibers C can give a natural feeling.

The flocking process can be performed on any substrate such as yarn, cloth and base cloth, and any adhesive such as solvent type, aqueous solution type and emulsion type can be used. Specific examples include polyurethane resins, polyacrylic acid ester resins, epoxy resins, polyvinyl acetate resins, and natural rubber-based and synthetic rubber-based adhesives.

In the present invention, the short fiber flocs preferably have a bristle density of at least 0.06 g / cm ³ with respect to the substrate. The napped hair may be vertical or may be slanted and may be transplanted.

As shown in FIG. 2, the napped structure of the present invention has short fibers A (2) having a large diameter, short fibers B (3) having a small diameter, and short fibers C with respect to the base fabric (1). (4) is flocked with the adhesive layer (5). There are two types of short fiber C (4) flocking forms: naps with a thin tip and a thick root, and naps with a thick tip and a thin root, so in the present invention, four types of naps are mixed together. Will be there. According to the present invention, which can be configured in this manner, a flocked product having an unprecedented crispness and natural feel can be obtained in which the mixing and dispersing effect is effectively exhibited.

The short fiber flock for napped hair of the present invention comprises a yarn,
It can be used for general clothing cloth, bedding, rugs and material cloth and the like.

[0030]

【Example】

(Example 1) Polyester semi-drawn yarn having a birefringence Δn of 50 × 10 ⁻³ , 150 denier, and 36 filaments were used.
Yarn speed 500 m / min, draw ratio 1.55 times, hot plate temperature 80
After processing with uneven thickness in the fiber axis direction at ℃, 1
Thermal processing was performed at a hot plate temperature of 50 ° C.

As a result, the birefringence Δn of the thick part is 50 to 50.
70 × 10 ⁻³ , birefringence Δn of the thin portion is 120 to 130
× is 10 ^-3, the shrinkage rate after 20 min treatment with boiling water of 100 ° C. 3.5% of the yarn is obtained. Create a fiber bundle by bundling 30,000 of these yarns, and use a guillotine cutter
Cut into pieces. Cut the flock with polyester fiber 10
When electric flocking was performed on 0% woven base fabric, it had excellent color development,
An excellent electric flocking product with excellent touch and no directional blurring or whitening was obtained.

[0032]

According to the present invention, since three different types of short fiber flocs are mixed, there is the first excellent denier mixing effect. Specifically, since the surface and cross section of the flock has changed, the touch feeling is not uniform and the light is irregularly reflected, resulting in a non-uniform and gentle natural feeling, and the falling and bending of the napped hair also differ from each other. Since this is not the case, the mixing and dispersing effect is effectively exhibited.

Secondly, since other short fibers are mixed on the basis of thick short fibers, it is strong and has a good texture. In addition, since the color is not the same color and the color has no directionality and is not uniform, there is bathochromicity and there is no color blur or whiteness.

Thirdly, according to the use and purpose, the fineness and the number of the short fibers A, B and C can be freely set, and a flocked product with a super soft texture to a hard texture is provided. The manufacturing process can be handled very easily, and the cost can be greatly reduced.

Fourthly, according to the present invention, the flocking process using the polyester fiber, which has been difficult to apply in the past, can be performed, so that the soft and lightweight flocking process can be performed by the alkali weight reduction treatment. It is extremely epoch-making that it is possible to enter the bedding field, which was not possible to apply and develop because of the heavy weight of conventional products and low fastness to wet friction dyeing.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram showing a staple fiber flock for napped hair of the present invention.

FIG. 2 is a conceptual diagram showing a state of planting short fiber flock for napping in the napped structure of the present invention.

[Explanation of symbols]

 1 ... Base fabric 2 ... Large diameter short fiber A 3 ... Small diameter short fiber B 4 ..Adhesive layers

Claims (11)

[Claims] 1. A short-fiber floc for napping, which is obtained by cutting or crushing fibers having a change in thickness in the fiber axis direction and a distribution of different cross-sectional areas. 2. A short fiber A having a large diameter and a short fiber B having a small diameter,
A short fiber flock for napped hair, characterized in that short fibers C having different cross-sectional area distributions are mixed in the fiber axis direction. 3. The short fiber flocs for napped hair according to claim 2, wherein the length of the short fibers A, B and C is about 0.1 to about 10 mm. 4. The birefringence Δn of the short fibers A is 15 × 10.
⁻³ to 80 × 10 ⁻³ , the birefringence Δn of the short fiber B is 90 ×
10 ⁻³ to 200 × 10 ⁻³ , wherein the birefringence Δn of the short fibers C changes in the fiber axis direction within the birefringence range of the short fibers A and the short fibers B. Short fiber flock for nap according to 3. 5. The cross-sectional area of the short fiber C on the large diameter side is equal to or smaller than the cross-sectional area of the short fiber A, and the cross-sectional area of the short fiber C on the small diameter side is the same as the cross-sectional area of the short fiber B. The short fiber flock for napped hair according to claim 2, 3 or 4, which is equal or larger. 6. The cross-sectional area ratio of the short fibers A and the short fibers B is 1.2 to 3.0, 2.
The short fiber flock for nap according to 4 or 5. 7. The average diameter of the short fibers A is from 0.13 to
1.5 microns, the average diameter of the short fibers B is 0.1 to
The short fiber flocs for napped hair according to claims 2 to 6, characterized in that it is 1.3 microns. 8. The proportion of the short fibers A is 20% by weight or more,
The staple fiber flocs for napped hair according to claims 2 to 7, wherein the proportion of the staple fibers C is 10% by weight or less and the rest is staple fibers B. 9. A staple fiber floc for napped hair, which is obtained by cutting or crushing polyester crimped yarn having a change in thickness in the fiber axis direction and a distribution of different cross-sectional areas. 10. The short fiber flock for napped hair according to claim 9, wherein the polyester crimped yarn has a boiling water shrinkage of 10% or less. 11. A napped structure obtained by planting the short fiber flocs according to claim 1 on a base material.