JPS6156355B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a process for making suede-like fiber sheets having improved melt resistance. More specifically, the present invention relates to improving the properties of a suede-like fiber sheet against cigarette fire.

Conventionally, suede-like fiber sheets are produced by applying a polymeric elastic material such as polyurethane to a woven or knitted fabric with a raised or raised structure, or by buffing it.
Alternatively, it is obtained by applying polyurethane to a nonwoven fabric and buffing it. In particular, there are many combinations of polyester or polyamide and polyurethane. These are widely used in various clothing and furniture. However, these suede-like sheets have the disadvantage that they are easily punctured by cigarette burns. If the piloerection is only damaged, that's okay, but in severe cases, it will completely penetrate. It has been desired for a long time to improve this defect and make it difficult for holes to form. Generally, there are various post-processing methods for improving this type of melt resistance. That is, after the suede has been formed, it is treated with chemicals to improve it.

Up until now, post-processing methods have used very small amounts of chemicals to maintain the texture and surface texture, but the effect is small. If treated sufficiently, the texture and surface texture will be completely lost. This tendency is particularly strong in the case of suede. Especially with suede, the key point is the surface touch, and this can be damaged. In particular, in the case of suede-like sheets made of ultra-fine fibers, the anti-melt effect of the chemical (the hard film that forms on the surface and the rubbery film that forms between the fibers has the effect of deteriorating the texture). Because of the coating that causes this, the ultra-fine nape that tends to fall down becomes stiff and the touch and feel are significantly impaired.

From this point of view, the present invention reduces the perforation of the cigarette and increases the time it takes for the cigarette to penetrate, without deteriorating the texture and texture of the raised pile.
It is an object of the present invention to provide an improved method for manufacturing a suede-like fiber sheet that allows time for tobacco to be removed before the holes are completely opened.

In order to achieve such an objective, the present inventors
As a result of intensive research, we finally arrived at the present invention as described below.

That is, the present invention proposes that ``a fiber sheet capable of forming napped fibers mainly composed of fibers from which ultrafine fibers of less than 0.9 denier consisting of other components can be generated by removing at least one component is subjected to a combination of the following steps ~, and then A method for manufacturing a suede-like fiber sheet with improved melting resistance, which is characterized in that a process is performed after passing through a process.

A step of applying and curing a curable organosilicon compound having poor adhesion to the ultrafine fiber component, or applying an organosilicon resin or rubber.

A process of imparting a polymer elastic body.

A step of generating ultrafine fibers by removing at least one component of the fibers that can generate ultrafine fibers.

A step of releasing the binding of the raised nap by the organosilicon compound resin or rubber by applying mechanical action.

It provides:

Through the present invention, for the first time, it has become possible to obtain a suede-like fiber sheet in which the pores are opened for a longer period of time when lit by a cigarette, etc., without deteriorating the texture or ultra-fine naps.

The configuration of the present invention and the accompanying effects thereof will be further described.

In general, in order to produce a suede effect, the nape tends to be thinner to a certain extent. That is, at least less than 0.9 denier (some companies call suede using fibers of 1.5 to 1.0 denier, but they use other materials to achieve this effect, such as polyurethane). It is preferably 0.3 denier or less, particularly preferably. On the other hand, the thinner the nape is, the more easily it falls down and absorbs liquid, so when it is treated with chemicals as in the past, it gives the strong impression that it becomes rough and hard.

Fiber sheets include woven fabrics, knitted fabrics, non-woven fabrics, and combination fabrics of woven and non-woven fabrics. Woven and knitted fabrics can be made to have raised naps by various means such as raising, pile cutting, or cutting and weaving like double velvet weaving.

In addition, non-woven fabrics are buffed to form raised fluff after applying a binder. Of course, there are also combinations like this, such as those in which polyurethane is applied to an ultra-fine napped product made from knitted fabrics and then buffed.

In any case, in such fiber sheets such as napped fabrics, knitted fabrics, nonwoven fabrics, etc., organosilicon resin, rubber (hereinafter referred to as silicone), and polymeric elastic material are added to other base parts.
On the other hand, the raised part has a structure that is not bound or hardened by these rubbers or resins. Due to this structure, the nap has a suede-like appearance, and the base portion constitutes at least a ternary composite of fibers, silicone, and polymeric elastic material. The silicone preferably has a polydialkylsiloxane skeleton, and after being applied to the sheet, it is cured by a chemical reaction to form a resin, particularly preferably a rubber. Alternatively, a method may be used in which the agent is applied in the form of an emulsion or dispersion and the medium is removed. The following methods of curing by reaction are known. For example, there are an I-liquid type and a two-liquid type, and both condensation reaction types and addition reaction types are known, and these are effectively used. The chemical formula of only the main reaction part is shown below. These often react even at relatively low temperatures such as room temperature.

(1) Deacetic acid condensation type (2) Oxime decondensation type (3) Dealcoholization condensation type (4) Deamine condensation type (5) Deamidation condensation type 1 Liquid addition reaction type (1) Vinyl addition reaction type (2) Peroxide type Two-liquid condensation reaction type (1) Dealcoholization condensation type Example Cat.; Fatty acid metal salt (2) Deoxyalamine condensed type (3) Dehydrogenated condensation type 2 Liquid reaction type (1) Vinyl addition reaction type Examples Cat.: Platinum compounds, etc. Others The main skeleton is polysiloxane, and polydimethylsiloxane is the most typical example.In addition, polysiloxane is the most typical example, and in addition, polysiloxane is used as a polysiloxane, and polydimethylsiloxane is the most typical example. Things are also well known. In addition, the terminal is -OH, -CH=CH ₂ ,
-OR-CH ₃ and the like are common, and they react with themselves or with various silanes. Water including steam, various platinum compounds such as chloroplatinic acid, peroxides, organometallic compounds such as fatty acid metal salts, radical releasing compounds, aminosilane compounds, etc. are used in the reaction.

The molecular weight of the main skeleton is 10,000 to several hundreds of thousands, which is most commonly used.

The most commonly used methods for improving the physical properties of cured products are:
Silicon oxides such as fumed silica. In addition, titanium oxide, carbon black, calcium carbonate,
These include diatomaceous earth, quartz powder, asbestos, zinc oxide, and zirconium silicate.

These are preferably treated with linear and cyclic silanes, silanols, siloxanes, and silazane. Needless to say, various additives such as coloring pigments and extractants for forming pores may be used. In addition to many patents of the Dow Corning Company in the United States, you can learn about these in various technical materials for sale by Toray Silicon, Toshiba Silicon, Shin-Etsu Chemical, and more recently. −27704, 51−27705, 51−
27706 (Dow Corning), JP 50-94295 (Dow Corning, UK), JP 51-27703 (Kuraray), JP 51-24303 (Toshiba Silicon), JP JP
51-24301, 51-24302, 51-23977, 51-23979,
51-25069, 51-28308, 51-28309, 51-28310
(Shin-Etsu Chemical Co., Ltd.), JP-A-51-34291, 51-39773,
51-49995 (same), etc., which have been shown to be made into resins for various purposes, and these knowledge and techniques can be effectively and preferably used in the present invention.

It should be noted that the silicone used in the present invention is not a lubricant such as silicone oil for the purpose of mold releasability and smoothness.

Next, the application of various polymer elastic bodies such as polyurethane will be explained. The polymeric elastomer is preferably applied in the form of a solution or emulsion. After application, it goes without saying that post-processes such as coagulation, desolvation, and heat drying may be carried out as necessary.

Silicone and fibers generally have poor adhesion, but in the present invention, this poor adhesion is actually an advantage, so silicones with relatively good adhesion are selected and used, and silicones are used to improve adhesion. It is better to avoid adding silane coupling agents. As will be described later, there is a method in which the sea component is first removed when using polymeric mutual array fibers;
There is a method for removing it later, but the former method is particularly undesirable because the silicone becomes difficult to peel off from the fibers during buffing.

The total amount of silicon and polymeric elastomer added to the fiber sheet is preferably about 15 to 70 parts by weight based on 100 parts by weight of the sheet. In addition, the ratio of silicon to polymer elastic material is 0.5 to 50% by weight, especially 0.5 to 20% by weight of silicon to 100% of polymer elastic material.
degree is preferred.

The suede-like fiber sheet of the present invention is manufactured, for example, by the following method.

That is, if at least one component is removed, ultrafine fibers of less than 0.9 denier consisting of other components can be generated, and a curable fiber sheet that is capable of forming napped fibers is combined with a curable fiber sheet that has poor adhesion with the ultrafine fiber component. Applying an organosilicon compound and curing it, or performing a combination of the steps of applying an organosilicon resin or rubber and applying a polymeric elastic body, and then removing at least one component of the fibers that can generate ultrafine fibers. After passing through a step of generating ultrafine fibers, a step of releasing the binding of the organosilicon compound resin or rubber adhering to the napped fibers by applying mechanical action is performed. The mechanical action is preferably applied by buffing and, if necessary, further dyeing treatment.

Buffing can be done using sandpaper, sand cloth, sand net, sand brush, whetstone, wire brush, sand honing, etc.

In the present invention, polymer interlayer fibers are most preferably used to make the ultrafine fibers that form the nap. This is a typical example of a fiber that consists of at least two components, and if one component (sea component) is removed, a bundle of ultrafine fibers consisting of the other component (island component) can be obtained in good yield, but it is not limited to this. Naturally, from the purpose of the present invention, this is not the case.

These ultrafine fibers are used as all or part (raised portion) of fibers such as woven, knitted, and nonwoven fabrics, but in woven and knitted fabrics, they are preferably used together with other thicker fibers. That is, it is preferable to configure the fabric so that the thick fibers serve as the "ground" and the ultra-fine fibers serve as the nap. When a nonwoven fabric is used, a sandwich structure corresponds to such a structure.

In woven and knitted fabrics, it is common that napped fabrics are first formed, then a binder is applied, and then buffed. In non-woven fabrics, the napped fabric is usually not pre-napped and is buffed after applying a binder. Do the following.

In the present invention, the term "poor adhesion" refers to adhesion to the extent that the binding of the raised naps caused by silicone can be completely released by applying mechanical action, such as buffing, and dyeing if necessary, in accordance with this method. It is. Whether the piloerection is tied together can be easily determined using a microscope.

According to the present invention, surprisingly, the tobacco puncture resistance is improved, the feel is good, and the nap has a good appearance and touch as suede.
In addition, silicone's properties of heat resistance, weather resistance, gas resistance, and chemical resistance (sweat, hair conditioner, perfume) are added, so it is highly durable and has many surprising additional effects in addition to its direct purpose. I found out.

Examples will be shown next, but the effectiveness of the present invention is not limited or restricted by these in any way, but rather brings about the following applications, expansions, and developments.

Example 1 A sea-island type fiber in which the sea component is polystyrene and the island component is polyethylene terephthalate, the island component is dispersed in the sea component, and the island component is continuous in the fiber axis direction, with a sea-island ratio of 40/60 and an island component. This fiber has a denier of 3.2 d, a crimp number of 12 threads/inch, and a cut length of 51 mm. A web is formed using the cross slapping method, and the fabric weight is 530 g/m ² by needle punching at 3000 strands/cm ² . An entangled nonwoven fabric having an apparent density of 0.18 g/cm ³ was obtained. This non-woven fabric was then washed with hot water (97-100
°C), the basis weight and apparent density were 862 g/m ² and 0.375 g/cm ³ in the dry state, respectively.

Next, a room-temperature water-resistant polyvinyl alcohol solution with a saponification degree of approximately 99% is applied to this nonwoven fabric based on the fiber weight.
23 parts of solid content was impregnated. After drying, it was impregnated with an emulsion solution containing 7% (purity equivalent) of condensation reaction type silicon (Toray Silicon SH-8240) and a small amount of catalyst (SH-8200K), and then dried at 100 to 105°C. Further heat treatment was performed at 120°C for 7 minutes. At this time, the amount of silicon applied is based on the solid content for the entire sheet.
It was 12.6%.

The silicone-treated fabric was then quickly impregnated with a solution of polyurethane in dimethylformamide to approximately 24 parts of polyurethane solids per sheet (at this time, the sea component began to be dissolved by the dimethylformamide, but it quickly disappeared). After completion of impregnation, dissolution was small), followed by water bath coagulation and removal of polyvinyl alcohol (simultaneously removal of dimethylformamide).

After the polyurethane-impregnated cloth was dried, the sea component was removed using trichlorethylene to obtain an intermediate product having a basis weight and an apparent density of 770 g/m ² and 0.350 g/cm ³ , respectively.

The thickness of this intermediate product was divided into two using a slicing machine to obtain two intermediate products, and the non-sliced surface was mainly subjected to a buffing machine to obtain a nonwoven fabric having a raised surface. Finally, pressure dyeing was carried out at 125°C using a disperse dye.

The obtained product has a fire melting resistance of the cigarette (the time it takes for a hole to form in the product when a product with a diameter of 3 cm is placed on a lit cigarette) to be approximately A two-fold improvement was observed, and the result was a very soft suede preparation.

Claims (1)

[Scope of Claims] 1 A combination of the following steps is applied to a fiber sheet that can form naps mainly composed of fibers that can generate ultrafine fibers of less than 0.9 denier made of other components by removing at least one component, A method for manufacturing a suede-like fiber sheet with improved melting resistance, which is characterized in that a process is performed after passing through a process. A step of applying and curing a curable organosilicon compound having poor adhesion to the ultrafine fiber component, or applying an organosilicon resin or rubber. A process of imparting a polymer elastic body. A step of generating ultrafine fibers by removing at least one component of the fibers that can generate ultrafine fibers. A step of releasing the binding of the raised nap by the organosilicon compound resin or rubber by applying mechanical action.