JPS62268860A - Fibrous material and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a fibrous material and a method for producing the same. More specifically, the present invention relates to a fibrous material with excellent abrasion resistance and elasticity, which can be suitably used for automobile interior materials, clothing materials, shoes/shoe materials, etc., and a method for producing the same.

[Conventional technology] Traditionally, fibrous materials used for automobile interior materials, shoes, and footwear materials include dyed needle-punched nonwoven fabrics, dyed fibers, and binders on one side. Needle-punched nonwoven fabrics impregnated with polypropylene, nonwoven fabrics made of spun-dyed high latent crimpable polypropylene fibers, and subjected to shrinkage treatment are used.

[Problems to be Solved by the Invention] However, the dyed needle-punched nonwoven fabric exhibits excellent elongation and has a soft texture, but the fibers are not tightly entangled. Therefore, when this non-woven fabric is stretched, it does not return to its original shape.
It has the disadvantage of poor abrasion resistance, and the needle-punched nonwoven fabric using the above dyed fibers and impregnated with a binder on one side has excellent abrasion resistance, but has a large modulus and poor elasticity. Moreover, it has a hard texture and wrinkles appear when folded. In addition, the shrink-treated nonwoven fabric made of the above-mentioned spun-dyed high latent crimp polypropylene fibers exhibits excellent elongation and has a soft texture, but the fibers are not tightly entangled. ,
It has the disadvantage that punch marks remain on its surface, and furthermore, it has poor abrasion resistance and weather resistance.

The inventors of the present invention have conducted extensive research to solve the above-mentioned problems with the conventional technology. The inventors have discovered a completely new fibrous material that not only does not crease when folded, but also exhibits a suede-like appearance, which is not seen in conventional fibrous materials, and has now completed the present invention. .

[Means for solving the gap point] That is, the present invention uses a web containing at least 70% by weight of highly latent crimpable polyester fibers having a number of crimps of 20 to 60/25 when crimping occurs. The web is coated with a ring, then heated, and then dyed, and the web is shrunk by 10% or more.The abrasion resistance is grade 3 or higher, and the 20% modulus in both the vertical and horizontal directions is 0.1 to 2.0 kg. /
The present invention relates to a fibrous material that is am and a method for producing the same.

[Example] The fibrous material of the present invention is obtained by subjecting a web containing at least 70% by weight of high latent crimp polyester fibers to needling, then heating and shrinking without pressing, and then further shrinking at the same time as dyeing. It can be obtained by letting

The high latent crimp polyester fiber used in the present invention is
A side-by-side product that combines two types of components with different melting points.
Composite fibers are referred to as side-type or eccentric-type fibers, but it is preferable to use fibers in which both of the two components with different melting points do not melt when subjected to heat treatment to develop crimpability. is preferred. Specific examples of such high latent crimp polyester fibers include polyester made of polyethylene terephthalate with a melting point of 265°C;
Either lower the degree of polymerization with the same component, or copolymerize with isophthalic acid, adipic acid, sebacic acid, diethylene glycol, neopentyl gelcol, sulfoisofucuric acid, etc. as a third component during polymerization to reduce the melting point to 235.
Examples include so-called side-pie-side type polyester fibers that are spun in parallel with polyester at a temperature of about °C, but the present invention is not limited to these.
Other materials may also be used as long as they meet the above requirements.

If the fineness of the high latent crimp polyester fiber is less than 0.5 denier, the mechanical properties of the fiber itself will deteriorate and it will be difficult to manufacture; Not only is it difficult to make it dense, but it also becomes impossible to change the suede-like appearance, and furthermore, the horns are likely to appear when folded. Preferably it is 5 denier.

Further, when the crimped shape of the high potential crimpable polyester fiber is a three-dimensional crimped shape such as a spiral shape or a coil shape, the resulting fibrous material exhibits appropriate elasticity. At the same time, it absorbs distortion caused by external forces, for example, when the sheet is folded, no creases occur, and when molded, it easily conforms to the mold, so the three-dimensional crimped shape shown above is suitable. is preferred.

The number of crimps (the number of crimped fiber piles per 25 fiber length) of the high potential crimp polyester fiber when crimping occurs is:
If it is less than 20 threads/25 m+s, it will be difficult to make the sheet denser, and not only will the abrasion resistance and elasticity decrease, but it will become irreplaceable and will have a suede-like appearance.
If the height exceeds 25 mm, the shrinkage of the fibers will become too large and the productivity of the fibrous material will become unstable.
Preferably, the distance is 60 peaks/25 m+s.

In addition, it is preferable that the fiber used for the fibrous material contains at least 70% by weight of the high latent crimp polyester fiber in terms of densification, abrasion resistance, and elasticity of the sheet. Fibers other than the high potential crimpability polyester fibers include synthetic fibers such as polyester fibers, polyamide fibers, acrylic fibers, and rayon fibers that do not melt when heat treated to develop crimpability. Examples include semi-synthetic fibers, natural fibers such as cotton and wool, and these fibers are used in an amount not exceeding 30% by weight.

Next, after a web containing at least 70% of the high latent crimp polyester fibers is formed, needling is performed, but if the needle density is less than 150/clr, durability such as tensile strength etc. There is a shortage of 500
If it exceeds 150 to 150 cd, the elasticity will decrease.
500 needles/c+f, and the needle depth is 3-15m+
Preferably it is s.

Note that in order to give the surface a suede-like appearance, needling is preferably performed from one side.

By heating the needled web, the high latent crimp polyester fibers are crimped and the web is shrunk, but such heating is usually done in order to avoid applying tension or pressing force to the web as much as possible, for example. This is done using a heat shrinking machine or the like. The heating temperature of the web is preferably high in order to sufficiently develop the crimp of the high latent crimp polyester fibers, but if it is too high, the low melting point components of the high latent crimp polyester fibers may be heated. Since it is melted, the temperature is 160-200℃, and <170-19
Preferably it is 0''C.

The shrinkage rate of the web due to heating is preferably 5% or more, preferably 10% or more in order to sufficiently densify the sheet and improve abrasion resistance and elasticity.

The web heat-treated as described above is dyed by the method detailed below.

That is, the web is immersed for about 60 minutes in a dye bath containing a disperse dye, a dispersant, and a pH adjuster at a liquid temperature of 120 to 130°C, then washed with water, reduced in a reducing bath, then washed with water again, and then dried. , dyeing is applied.

Examples of the disperse dyes include monoazo, disazo, anthraquinone, nitro, styryl, methine, quinonaphthalene, aminonaphthylimide, naphthoquinone imine, and coumarin derivatives, and examples of the dispersant include dodecylbenzene sulfonate, dodecyl sulfate ester salt, and polyoxyethylene dodecyl. Ethers and their sulfate salts, etc., pH
Examples of the adjusting agent include those commonly used such as acetic acid, acetic acid/sodium acetate, ammonium sulfate/acetic acid, and ammonium sulfate/formic acid. Since it varies depending on the type of disperse dye, etc., it cannot be determined generally, but usually 1 to 10% by weight of disperse dye, 0.5 to 4% by weight of dispersant, and 0.01% of pH adjuster are added to the dye bath. The content is preferably adjusted to 0.1% by weight.

The reducing bath used to reduce the dye impregnated into the web immersed in the dye bath is a commonly used reducing bath containing, for example, 1-3 g of sodium hydroxide. , a solution containing 0.1 to 2 glo of a nonionic surfactant, etc. can be used.

The present invention is not limited to the dyeing methods described above, and carrier dyeing, thermosol dyeing, pad dyeing, etc., which are usually methods for dyeing polyester fibers, can be employed; however, according to the dyeing method described above, This method is particularly suitable for use in the dye bath, as it allows the development of crimp in the latent crimpable fibers in the web over a long period of time in the dye bath, thereby allowing the web to re-shrink.

The shrinkage rate of the web in the dye bath is preferably 3% or more, preferably 5% or more in order to sufficiently densify the sheet and improve abrasion resistance and elasticity. The shrinkage rate of the web is 10% or more, preferably 15% during the entire manufacturing process, including shrinkage during heating and dyeing.
% or more.

The fibrous material obtained as described above has a 20% duress of 0.1 to 2.0 kg/c in the vertical and horizontal directions.
m, and satisfies abrasion resistance of grade 3 or higher.

The 20% modulus refers to the stress required to elongate the base fabric by 20%, and is determined by the method detailed below. The 20% modulus of fibrous material is 0.1 kg
If it is less than 2.0kg/cm, the strength will be poor, and if it is less than 2.0kg/cm.
If it exceeds cm, the extensibility decreases.

The abrasion resistance is evaluated by conducting a test according to JIS L 10215.12 and based on the criteria detailed below. If the abrasion resistance is less than grade 3, it will not be practical when the fibrous material is used, for example, as an interior material for an automobile, so it is preferably grade 3 or higher.

Note that the fibrous material may be subjected to water repellent treatment and antistatic treatment to improve functions such as water repellency and antistatic property.

Next, the fibrous material of the present invention and its manufacturing method will be explained in more detail based on Examples, but the present invention is not limited to these Examples.

Example 1 High latent crimpability polyester fiber (Unitika ■) with a fineness of 2.5 denier and a fiber length of 51 am, which has an average number of crimps of 50 crimps/25 crimps when heat treated at 180°C for 3 minutes in a single fiber state. Made of polyester C-81, initial crimp number lO/2
5) Web 200r/nf consisting of 100% by weight
Needling was performed from one side (needle density 280/cd, needle depth 10 mm). Next, this web is treated with a heat shrinking machine at a temperature of 180°C to develop latent crimp in the fibers, and at the same time, the warp and width lengths of the web are reduced to approximately 13
% shrinkage. After this, disperse dye (ND manufactured by Nagase Sangyo Co., Ltd.)
Out.

Blue E502 1.2% by weight and ND Auto
Red E3025% by weight), anionic dispersant (Sunsolt RM-40) 1 g/Ω, acetic acid 0.2 g #!
The web was immersed in a dye bath containing 2 g/D of ammonium sulfate, the temperature was raised to 130°C for 40 minutes, and the web was further immersed at 130°C for 60 minutes. During this time, the web shrunk an additional approximately 8%.

Next, this web was washed with water, and 2 g/N of sodium hydroxide was added.
The web was reduced by immersing it in a reducing bath consisting of a solution containing 2 g/R of hydrosulfide and 2 g of a nonionic surfactant, and was further washed with water and dried to obtain a fibrous material.

The physical properties of the obtained fibrous material, such as tensile strength, tensile elongation, 20% modulus, abrasion resistance, weather resistance, and appearance, were examined according to the following methods. The results are shown in Table 1.

(Tensile strength and tensile elongation) Five test pieces of 5 am in length and 20 Cffi in width were taken and tensile tested at a tensile speed of 20 cm/min in accordance with JIS L 1068 using a tensile tester to determine the strength at break (kg).
and elongation (%), and find the average value.

(20% modulus) 5 test pieces of length 54 cm and width 20 cm were taken, and JIS
Tensile speed 2 using a tensile tester according to L 1068
It is pulled at 0 cm/min, and the stress (kg) when the elongation becomes 20% is measured, and its average value is determined.

(Abrasion resistance) According to JIS L 10215.12, the diameter is approximately 13 (2
) was mounted on the rubber mat of the test holder of the tapered abrasion tester, and 500 g was attached to the abrasion wheel C9-10.
A weight was placed on the test piece, and the test piece was rotated at a speed of approximately 80 rpm.
After rotational abrasion, the surface condition of the test piece is evaluated. The judgment criteria are as follows.

(Grade) (Judgment Criteria) Grade 5 Grade 4 with no visible wear Grade 3 with slight wear Grade 2 with obvious wear Grade 1 with rather significant changes Significant changes (weather resistance) Suga Test Machine■ Standard knee buoy long life fade meter (5 standard UV lon
Temperature: 83℃ (Glife Fade meter)
After 200 hours of irradiation, gray scale (JIS L 10
453.12)).

(Appearance) Observe the surface condition of the test piece, and judge those that exhibit a suede-like appearance as good, and those that do not exhibit a suede-like appearance as poor.

Example 2 Consisting of 70% by weight of the high latent crimpable polyester fiber used in Example 1 and 30% by weight of ordinary polyester fiber (15 crimps/25m5+) with a fineness of 2.5 denier and a fiber length of 51 am. A fibrous material was obtained in the same manner as in Example 1 except that a web of 20 Gg/rrr was used.

The shrinkage rate of the obtained fibrous material using a heat shrinkage machine is approximately 9%.
The shrinkage rate due to the dyeing process was about 6%.

Next, the physical properties of the obtained fibrous material were investigated in the same manner as in Example 1. The results are shown in Table 1.

Example 3 A high latent crimp polyester fiber with a fineness of 6 denier and a fiber length of 51 am (initial crimp number lO 200g/rr of web consisting of 100% by weight (mountain/25mm)? A fibrous material was obtained in the same manner as in Example 1 except that . The shrinkage rate of the obtained fibrous material by heat shrinkage machine is about 10%, and the shrinkage rate by dyeing process is about 6%.
Met.

Next, the physical properties of the obtained fibrous material were investigated in the same manner as in Example 1. The results are shown in Table 1.

Comparative Example 1 A web 200+r/rr made of 100% by weight of normal polyester fibers (15 crimps/25 crimps) with a fineness of 265 denier and a fiber length of 51 rhymes. Needling was performed from one side (needle density 280/cd, needle depth 1011111). Next, this web was immersed and dyed in the same dye bath as in Example 1 under the same conditions to obtain a fibrous material.

The physical properties of the obtained fibrous material were investigated in the same manner as in Example 1. The results are shown in Table 1.

Comparative Example 2 Spun-dyed polyester fiber with fineness of 2.5 denier and fiber length of 511I+ (number of crimps: 15/25us) 100% by weight
Web consisting of 180g/rr? Needling was performed from one side (needle density 280/C, needle depth 10am).

Next, apply acrylic resin emulsion 2 on one side of this web.
0g/rr? After impregnation with (amount of solid content attached), backing treatment and processing were performed to obtain a fibrous material.

The physical properties of the obtained fibrous material were investigated in the same manner as in Example 1. The results are shown in Table 1.

Comparative Example 3 A fiber with a fineness of 2.5 denier, which has an average number of crimps of 30 crimps/25 m+a when heat treated at 130°C for 3 minutes in a single fiber state.
Latent crimp spun-dyed polypropylene composite fiber with fiber length of 51 m+g (side-by-side type, polypropylene-
Web 2 consisting of polyethylene fiber>100% by weight
oog/rd was subjected to needling (needle density 280/cd, needle depth 10 mm) from one side. Next, this web was treated with a heat shrinking machine at a temperature of 130° C. to develop latent crimp of the fibers and at the same time shrink the warp and length of the web by about 15% to obtain a fibrous material.

The physical properties of the obtained fibrous material were investigated in the same manner as in Example 1. The results are shown in Table 1.

The fibrous material obtained in Example 1 exhibited excellent elongation and abrasion resistance, had a soft texture, and had a rich suede-like surface.

The fibrous materials obtained in Examples 2 and 3 are slightly inferior in abrasion resistance and fiber density compared to the fibrous materials obtained in Example 1, but have a suede-like appearance and are suitable for practical use. There were no problems at all.

The fibrous material obtained in Comparative Example 1 is a dyed needle-punched nonwoven fabric and exhibits excellent elongation, but this elongation is caused by so-called fiber displacement, and the recovery of its shape is difficult. It also lacked any wear resistance, making it impractical.

The fibrous material obtained in Comparative Example 2 is a needle-punched nonwoven fabric using spun-dyed fibers and impregnated with a binder on one side, and satisfies grade 3 abrasion resistance, but has a large 20% modulus. However, it was not a stretchy material, had a hard texture, and had horns when bent.

The fibrous material obtained in Comparative Example 3 is a shrink-treated nonwoven fabric made of spun-dyed, highly latent crimpable polypropylene fibers, exhibits excellent elongation, and has a soft texture. The fibers were not tightly intertwined, punch marks remained, the appearance was not suede-like, and furthermore, the abrasion resistance was poor. Moreover, this fibrous material has poor weather resistance and is prone to discoloration and deterioration, making it unsuitable for practical use.

[Effects of the Invention] The fibrous material of the present invention has a suede-like appearance and has high elongation, which is completely new and which is not seen in conventional fibrous materials. However, it has excellent surface resistance.

Furthermore, the fibrous material of the present invention has a soft and supple feel, and does not exhibit any creases (horns) when folded.

Furthermore, even when used as a molding material, it conforms well to the mold, and furthermore, it contains components with a lower melting point than ordinary polyester fibers, and the fibers are spiral or coiled. , good heat setting properties,
It also has excellent shape retention.

Patent applicant: Japan Vilene Co., Ltd.;

Claims (1)

[Claims] 1. A web containing at least 70% by weight of highly latent crimpable polyester fibers with a number of crimps of 20 to 60/25 mm at the time of crimp development is subjected to needling, then heated, and then dyed. and the web is shrunk by 10% or more and has a wear resistance of grade 3 or higher, 20% in the vertical and horizontal directions.
A fibrous material having a modulus of 0.1 to 2.0 kg/cm. 2 A web containing at least 70% by weight of high latent crimp polyester fibers with a needle density of 150 to 400 needles/c.
A method for producing a fibrous material, which comprises needling the material to a diameter of m^2, then shrinking it by heating at 160 to 200° C. without pressing, and further shrinking it at the same time as dyeing.