JPS6144991B2 - - Google Patents

Description

[Detailed description of the invention] The present invention has appropriate air permeability and water repellency, and
The present invention relates to a method for producing a high-density fabric with excellent down-proof properties and surface smoothness.

Feather (down) is a filler material with extremely excellent lightness, heat retention, moisture absorption, and moisture permeability.Recently, down-filled clothing is gradually penetrating the market in Japan as well, focusing on these characteristics.

Conventionally, materials suitable for filling such down have generally been made by weaving fine-count cotton threads in high density in the warp and weft, and then undergoing finishing treatments such as resin treatment and surface pressing. However, such woven fabrics have difficulty in weaving efficiency because fine-count cotton threads are inserted at an ultra-high density.
Not only is this deterioration inevitable, but the resulting fabric itself has a thick feel and cannot necessarily be said to be satisfactory in terms of texture.Furthermore, it is expensive due to the use of a large amount of high-quality yarn, making it difficult to spread to the general public. It also had the disadvantage of being hindered.

Therefore, in order to overcome the above-mentioned drawbacks while penetrating the market of down-filled clothing, efforts have been made to develop materials suitable for filling down with synthetic filament yarns, one of which is nylon filament yarn. Products made from ultra-high-density taffeta were provided.

However, the weaving technology for ultra-high density taffeta made from synthetic filament yarns is extremely difficult, resulting in extremely low weaving efficiency, making it unsuitable for commercial production. Because the material is coated, the texture is hard and the gloss lacks quality, and the down-proof property, which prevents the down filler from falling out due to impact during use, was not fully satisfactory. .

There is a method of coating the surface as a means of improving down proof properties, but if you coat it, you will not lose breathability and you will not be able to take advantage of the excellent moisture absorption and moisture permeability of down. As a result, the value of the product will decline.

Thus, in view of the above-mentioned circumstances, the inventors of the present invention have conducted extensive research in order to obtain a fabric with excellent down-proof properties using long fiber yarns, and as a result, they have developed a fabric that can be crimped and has a specific cross-sectional shape. Using a fibrillated composite filament that is not strained, and without requiring special densification on the weaving surface, it shrinks and densifies to the required degree at the processing stage and specifies the single yarn arrangement inside the fabric. By doing so, we have discovered a method for obtaining a woven fabric with appropriate air permeability and water repellency, as well as excellent down-proof performance, and have arrived at the present invention.

That is, the main purpose of the present invention is to use long fiber yarn,
The object of the present invention is to provide a method for producing a smooth surface high-density fabric having appropriate air permeability, water repellency, and excellent down-proofing properties without requiring particularly high density on the weaving surface.

In addition, the present invention uses long fiber yarn to produce a high-density fabric with good down-proof properties that is sufficient for practical use and has no inferiority in texture and gloss even when it is shrunk and densified in the processing stage. It is another object to provide a method for obtaining.

Accordingly, the present invention achieves the above object, in which polyamide and polyester are bonded along the longitudinal direction, and the cross section is composed of at least one of the above-mentioned components.
A fibrillated composite filament that is not crimped and is composed of a segment that extends radially in the direction of the weft and a segment that is made of the other component and has a shape that complements the segment is inserted into the weft. The gist of the method is to weave a woven fabric using at least 20% by weight, then treat the woven fabric with an agent that swells polyamide to cause it to shrink, and then smooth the surface of the woven fabric by heating and pressing.

Hereinafter, the present invention will be further explained in detail,
The warp constituting the high-density fabric of the present invention is not particularly limited, and any suitable synthetic filament yarn can be used, but polyester yarn is particularly suitable, with a single yarn fineness of 1.5 denier or less, preferably 1.0 Polyester yarns of denier or less are most preferred.

On the other hand, the warp and the weft to be woven account for an important element in achieving the object of the present invention, and are preferably 20% by weight or more, especially 50% by weight or more, and more preferably 50% by weight or more.
80% by weight or more of the fibrillated composite filament is composed of uncrimped polyamide and polyester having a specific cross-sectional shape as illustrated.

That is, such a fibrillated composite filament is first a composite filament in which polyamide and polyester components indicated by A and B are joined along the longitudinal direction as illustrated in FIG. Although the desired effect can be sufficiently achieved even if either A or B in each illustrated example is a polyamide or polyester component, it is usually preferable that component (A) is a polyamide component. In this case, the bonding ratio of both polyamide/polyester components is usually in the range of 0.05 to 0.95.

The composite filament seen in each of these illustrated examples usually has a feature that it can be easily fibrillated by some subsequent processing due to the difference in the properties of the two components, and in particular, the composite filament has a shape that extends radially in at least two directions. A and a segment B having a shape that complements the segment A (see FIG. 1 Ro to Ho) are deformed during fibrillation, and as shown in FIG. 2, the radial segment A is The high-density fabric unique to the present invention can be constructed by exhibiting a flattened state.

Therefore, it is extremely effective to include at least a portion of the weft yarns with composite filaments having such radially extending segments.

Of course, the cross-sectional shape of the composite filament is circular in each example shown in FIG. 1, but it is not limited to a circular shape, and may have various irregular cross-sectional shapes.

The thus produced composite filament having a specific configuration is used in a predetermined proportion or more with respect to the weft yarn, and after weaving in combination with the warp yarn, the composite filament is subjected to various treatments described below to form a high-density woven fabric that is a feature of the present invention. . When the weft yarn is composed of a plurality of composite filaments or a composite filament and a normal filament, the filaments may be subjected to interlacing treatment (for example, interlace processing) or twisting, if necessary.

It should be noted that the weaving is not particularly different from conventional conventional weaving operations, that is, it is carried out in a conventional manner without requiring particularly high density. At this time,
The amount of the fibrillated composite filament used for the weft has a delicate relationship with the texture of the fabric.
It is important to use it in an amount of at least 20% by weight since it will affect the subsequent fibrillation and flattening. As the weave structure, plain weave, twill weave, satin weave, etc., or modified structures thereof are used.

The fabric woven as described above is then treated as a polyamide swelling treatment with an agent that swells the polyamide (hereinafter referred to as a fibrillating agent) to shrink and densify the fabric. Specifically, the fibrillating agent here includes benzyl alcohol, β
-Phenylethyl alcohol, phenol, m-
Examples include cresol, formic acid, acetic acid, and the like. It is also suitable for use as an aqueous solution or emulsion thereof. Particularly, among the above methods, the method using an aqueous emulsion of benzyl alcohol is most suitable for the method of the present invention in terms of the shrinkability of the fabric and the fibrillation effect, and also because it is relatively easy to handle.

In order to make an aqueous emulsion of the above fibrillating agent, a surfactant may be added to the fibrillating agent and emulsified and dispersed. The active agent may be an amphoteric active agent, an amphoteric active agent, or a mixture thereof.

The concentration of the fibrillating agent should be at least 1.5% by weight to obtain sufficient shrinkage and fibrillating effect, and if it exceeds 50% by weight, it will become unstable in the case of aqueous emulsions, and the subsequent fibrillating agent It becomes very difficult to remove. Furthermore, if it exceeds 50% by weight, there is a risk of adversely affecting components other than the polyamide component. From this point of view, the concentration is preferably 3 to 30% by weight.

In the method of the present invention, it is preferable to leave the fabric to be treated immersed in a treatment liquid containing the fibrillating agent as described above, or to squeeze the fabric using a mangle or the like after dipping.

The temperature of the treatment liquid is preferably 5 to 80°C, particularly 10 to 50°C, and when the fabric is immersed and squeezed, the amount of fibrillating agent retained by the fabric is preferably 1 to 50% by weight (based on the weight of the fabric). .

The woven fabric subjected to the polyamide swelling treatment is then subjected to a smooth finish using a thermal calender to smooth the surface.

Smoothing treatment is usually carried out by heating and pressing using a thermal calendar maintained at 130 to 190°C, but if the degree of pressing is too strong, it will not only impair the texture of the fabric, but also reduce its air permeability. On the other hand, if it is too weak, it will be difficult to obtain sufficient smoothness, so it is preferably about 150 to 350 kg/cm.

Through these treatments, the fibrillated composite filaments in the weft yarns constituting the fabric undergo a substantial fibrillation phenomenon, and the cross-sectional area of the fibrillated composite filaments present in the surface layer of the fabric The filaments of the radial segments are deformed and flattened, and at the same time, the surface sides of the single yarns constituting the fabric are flattened and arranged in surface contact with each other to form a smooth fabric surface. (See Figure 2) At this time, spaces are formed inside the weft yarns that spread randomly and in a three-dimensional direction, and spaces inside the warp yarns that expand in a direction horizontal to the surface of the fabric are created, unlike the conventional It is possible to obtain a completely new woven fabric that eliminates the runner-up problem of high-density woven fabrics.

Such a high-density fabric has excellent down-proof properties due to its smooth surface, and in particular, exhibits excellent water repellency because the radial segment filaments on the surface of the weft are flattened.

In addition, because of the space-retaining structure with special internal voids, it has a suitable amount of breathability, and therefore, while taking advantage of the moisture absorption and moisture permeability of down, it can still ensure sufficient heat retention. .

In addition, it has a densified structure due to the mixture of polyamide and polyester yarns with irregular cross-sections derived from a special composite filament, and the swelling treatment of only polyamide, so it has a soft texture and an elegant luster without glare.

Furthermore, since the fibrillated composite filament used for the weft yarn is not crimped, it is possible to produce products with a strong metallic luster compared to those using crimped yarn. While products using processed yarn have a "fluffy" texture, the products obtained by the present invention do not have "fluffiness" and are more dense.
In addition, since the filament does not need to be crimped, a low-cost high-density woven fabric can be obtained.

As described above, the method of the present invention for obtaining a high-density fabric by improving the performance of the conventional down-filled material is extremely industrially advantageous, and there are great expectations for its practical application, and its effectiveness is remarkable.

Examples of the present invention will be further described below in comparison with comparative examples.

Example 1 Having the cross-sectional structure shown in FIG.
The component is nylon 6, the B component is polyethylene terephthalate, and the area ratio is 100d/50f, which is a fibrillated composite fiber of 100d/50f.
Filament 1 is a filament that has not been crimped.

Filament 1 is used as a weft in a warp group consisting of two 75d/72f, 200T/M twisted polyester yarns aligned at 73 threads/inch (however, the dimensions are whale scale), with a density of 82 threads/inch. The material was pounded into a flat weave and woven into a fabric.

Next, an aqueous emulsion containing 15% benzyl alcohol at 30°C (using 1.5% Sunmol BK manufactured by NICCA Chemical Co., Ltd. as an emulsifier) was applied, and then heated at 60°C.
It was washed with warm water for about 5 minutes and dried.

Next, this fabric is dyed and treated with a water repellent agent, and after that, the fabric is dyed at a temperature of 180℃ and a pressure of 230℃.
A plain woven product was obtained by cylinder calendering of kg/cm.

The obtained product has a longitudinal density of 140 pieces/inch and a latitudinal density of 90 pieces/inch.
book/inch, water repellency 90 points, air permeability 0.31~0.46cc/ ^cm2 /
sec, and had a strong metallic luster and a dense, soft texture.

Next, a down jacket was created using this product as a down filling material, and a jacket that fully utilized the lightness and softness of down was obtained.

Furthermore, as a result of a try-on test, it was found that although it has excellent heat retention, there was no stuffiness inside at all, and even after wearing it for a long period of time, the down did not fly out at all.

Example 2 Filament 1 used in Example 1 was added to a warp group consisting of two 75d/72f polyester yarns twisted to 200T/M arranged at 78 threads/dimension (however, the dimensions are whale scale).
A twill weave was woven by using the yarns as weft yarns and driving them into a 2/1 twill structure at a density of 90 yarns/inch. Next, it was padded with an aqueous emulsion containing 20% benzyl alcohol at 30°C (using 2% emulsifier), and then washed with warm water at 70°C for about 2 minutes and dried.

Next, this fabric is dyed and treated with a water repellent finishing agent, and after that, the fabric is dyed at a temperature of 160℃ and a pressure of 230℃.
Pass through a kg/cm cylinder calender at a speed of 20 m/min, then in a tenter at 130°C.
A twill fabric product was obtained by heat setting for 30 seconds.

The obtained product has a longitudinal density of 153 pieces/inch and a latitudinal density of 99 pieces.
It has a water repellency of 90 points and an air permeability of 0.4 cc/cm ² /sec.It has a unique strong luster and a dense yet soft texture, making it an excellent material for shirts, blousons, and coats. It was warm.

(Comparative example) (1) Weaving: Both warp and weft use nylon 6 threads of 70d/36f.
The warp threads were set at 73 threads per inch, and the weft threads were set at 93 threads per inch.

(2) Textile treatment First, after scouring, the fabric was treated with benzyl alcohol in the same manner as in the above example, washed with hot water at 98°C for about 5 seconds, and then dried.

Then, after setting with dry heat at 180°C, it was dyed, a water repellent was applied, and then it was set again with dry heat at 180°C.

Next, the cylinder is calendered at a temperature of 160℃ and a pressure of 50Kg/cm ² to achieve a warp density of 125 cylinders/cm2.
Obtained two plain woven fabrics.

This plain fabric has a water repellency of 70 points and an air permeability of 1.5 to 1.5 points.
It is 1.6cc/cm ² /sec, lacks bulge, is paper-like and hard, has a glossy shine, and lacks quality.The down-proof property is low at grade 3, and it is not satisfactory as a material for down-proofing. Ta.

[Brief explanation of the drawing]

FIGS. 1A to 1E are cross-sectional views showing examples of fibrillated composite filaments used for the weft of the plain woven fabric of the present invention, and FIG. 2 is a partially enlarged view of a cross section in the warp direction of the plain woven fabric of the present invention.

Claims (1)

[Scope of Claims] 1. Polyamide and polyester are bonded along the longitudinal direction, and the cross section is made of one of the components and has a shape extending radially in at least two directions, and the segment is made of the other component. After weaving a fabric using at least 20% by weight of the weft yarn, an uncrimped fibrillated composite filament consisting of segments with complementary shapes, the fabric is swollen with polyamide. 1. A method for producing a high-density fabric, which comprises shrinking the fabric by treating it with a chemical at 5 to 80°C, and then smoothing the fabric surface by heating and pressing. 2. The method for producing a high-density woven fabric according to claim 1, wherein the components extending radially in at least two directions in the cross section of the composite filament are made of polyamide.