JPS6342969A - Production of bulky spun yarn knitted fabric excellent in abrasion resistance - Google Patents

Abstract

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

Description

DETAILED DESCRIPTION OF THE INVENTION (a) Industrial application field The present invention is directed to the use of am yarns, which have a bulky spun system of so-called untwisted yarns on the surface, have a soft feel, and have excellent abrasion resistance. Regarding manufacturing methods.

(b) Conventional technology Spun yarn maintains its shape and strength by twisting short fiber bundles and by the entanglement generated by filament migration and the frictional force generated by the lateral pressure caused by the twisting.

Therefore, it was thought that cloth foil made from spun yarn would be extremely weak if the spun yarn was not twisted. However, in recent years, spun yarns made by hardening short fiber bundles with adhesives have been made, and the properties of the yarns when the adhesives are removed after the fabric is made into pieces have become known. According to the results, the cloth foil made of untwisted spun yarn is stronger than expected.

It has a strength that is close to that of cloth made from ordinary spun yarn, and has enough strength for practical use.It has low air permeability and water permeability, and its texture changes easily depending on the weight density. M-density fabrics are harder than regular spun yarn fabrics, while low-density M- fabrics and knitted fabrics are significantly softer.
It has a softness that cannot be obtained with ordinary spun yarn. The softness of low-density untwisted fabrics is not due to the weak binding force between the fibers, which results in no resistance to elongation, shearing, or bending, but rather due to the large gaps between the fibers, which reduces the compressive resistance. The reason seems to be that it becomes soft to the touch. Therefore, it is difficult to make a woven fabric similar to a low-density non-twisted yarn fabric from conventional spun yarn, and the same is considered to be the same for knitted fabrics.

In response, proposals have been made to create yarns similar to non-twisted spun yarns from conventional spun yarns. It involves aligning spun yarn with water-soluble vinylon yarn, twisting the spun yarn in the direction of untwisting, and creating a yarn with very little twist in the spun yarn and water-soluble vinylon yarn wrapped around it. This is a method in which the water-soluble vinylon thread is removed with warm water after making cloth fabric using the thread.

The problem with this method is the difficulty in dissolving and removing water-soluble vinylon. Water-soluble vinylon dissolves in hot water to produce polyvinyl alcohol (PVA), but since PVA has a strong affinity for various fibers, it is difficult to remove and requires a considerable amount of hot water.

If washing with hot water is insufficient, the fabric will become hard due to adhesion between the fibers, making it impossible to obtain the desired texture, and the disposal of OSE's hot water containing PVA will cause difficult environmental problems.

Another problem is that water-soluble vinylon is generally more difficult to handle than ordinary fiber materials. Water-soluble vinylon expands and contracts significantly depending on the humidity in the air, and at the same time its Young's modulus changes significantly. Therefore, in the thread-making process using water-soluble vinylon, various drawbacks occur unless the temperature and humidity are controlled extremely precisely. In addition, if thread steaming or dry heat treatment is applied to twisted cheese, it may become impossible to unravel it or become difficult to dissolve in water, so as a general rule, such processes should be avoided. In cases where synthetic fibers are mixed in the yarn, the yarn obtained by plying and twisting exhibits strong torque properties, causing problems such as the formation of snarls, which significantly impairs processability.

In order to solve these problems,
No. 6829 discloses a method of producing a non-twisted woven or knitted fabric by using an alkali-ready polyester instead of water-soluble vinylon and subjecting it to alkali treatment. This method has good ease of taking out the alkali easily soluble thread, and is also relatively cheap.
Since the dissolution is hydrolysis, there is no hardening during treatment, and wastewater treatment is generally easy, so it is considered to be superior to the method using water-soluble vinylon, but it still has the following drawbacks.

In order to fully utilize the bulkiness of non-twisted woven and knitted fabrics, loops or piles are often erected on the surface.In this case, there is no binding force between the fibers due to twisting, so they do not come off as fiber bundles, but they do not come off as single fibers. If something gets caught on it, it tends to be pulled out relatively easily, and the fibers tend to fall off often, especially during washing, and the abrasion resistance tends to be poor.

(c) Problems to be Solved by the Invention The present invention aims to improve the common drawback of non-twisted woven or knitted fabrics, which is that single fibers often fall off and the abrasion resistance is poor.

(Means for solving the problem of spitting) The present invention is a spun yarn made of poorly alkali-soluble fibers, with continuous yarns made of easily alkali-soluble polyester fibers aligned, and mixed and twisted in the direction in which the spun yarns are untwisted. The fibers protruding from the resulting fabric sheet or the vicinity of the tip of the hanging door are treated with alkali to dissolve and remove the easily alkali-soluble polyester fibers near the tip, and
This is a method for producing a bulky spun yarn woven or knitted material with excellent abrasion resistance, characterized by leaving alkali easily soluble polyester fibers in the vicinity of the base-to-cross point of the fabric foil; The twisted fiber bundle is twisted by the remaining part of the easily alkali-soluble polyester fiber, making it difficult for the single fibers to slip off, and in the part that is lifted from the structure of the fabric, the easily alkali-soluble polyester fiber is twisted. It is dissolved by alkali to develop bulkiness, and a soft texture equivalent to that of conventional non-twisted woven or knitted fabrics can be obtained.

The latent bulky composite yarn obtained by the method of the present invention can be used alone to make bulky fabric foil, or can be used only as a yarn forming loops or pile parts to make bulky fabric foil. . Furthermore, by performing alkali treatment to form a pattern, it is possible to form a pattern based on bulk. Further, by using the composite yarn and ordinary yarn in combination, an uneven pattern can be formed due to the bulk.

There are two methods for removing easily alkali-soluble polyester fibers near the tips by treating the tips of the fibers or tufts protruding from the cloth of the present invention with alkali.

The first method is to leave a highly viscous solution prepared by dissolving a thickener such as polyacrylic acid, water glass, or carboxymethyl cellulose (CMC) in an alkaline aqueous solution, and then apply the alkaline solution uniformly onto a rotating roller. Lightly contact the fabric foil of the present invention with a roller so that the alkaline solution adheres only to the vicinity of the tips of the fibers or tufts protruding from the cloth membrane,
The raw fabric foil is heated by a method such as steaming to dissolve and remove the easily alkali-soluble polyester fibers only near the tips of the tassels, which look like fibers, and are washed with water to dissolve and remove the alkaline solution.
This is a drying method. The second method is to glue the raw fabric foil with an alkali-resistant glue such as polyvinyl alcohol, CMC, etc., dry it, dissolve it in the solvent of the glue for a short time, and remove the fibers protruding from the raw fabric foil. When only the glue adhering to the tip of the tassel is dissolved and removed, dissolving the glue is stopped and dried, and then the original fabric foil is dipped in an alkaline solution to remove any fibers or fibers protruding from the fabric foil. In this method, only the easily alkali-soluble polyester fibers in the part of the tassel from which the glue has been removed are dissolved, the adhering alkali is washed away, and the remaining glue is further dissolved and removed, followed by drying. Regardless of which method is used, the fiber bundles or tufts protruding from the fabric sheet become bulky, and are restrained by the remaining alkali-soluble polyester fibers near the base of the raw fabric sheet, resulting in the formation of single fibers. A fabric foil with excellent abrasion resistance that does not easily fall off is obtained.

The twist remaining in the spun yarn made of poorly alkali-soluble fibers when the spun yarn made of poorly alkali-soluble fibers and the continuous yarn made of easily alkali-soluble polyester fibers are aligned and twisted in the direction of untwisting the spun yarns. The smaller the number of twists, the greater the bulkiness, but since the twists that were present before forming the composite yarn are not uniform, even if the average number of twists is 0, there are many cases where the yarn is not locally untwisted. In some cases, a slight change in the number of twists may cause a significant change in bulkiness. In such cases, it is better to leave a slight twist in the fabric to create a more uniform fabric. In such cases, it may be heated to a slightly over-twisted state; over-untwisted spun yarn tends to have greater torque properties than yarn with some twist remaining, and even though the twist remains, is preferable because it tends to be bulky.The larger the twist remaining in the spun yarn, the smaller the swelling after alkali treatment.If the remaining twist coefficient (cotton count type) is larger than 2.0, it is practically This is not preferable because it becomes difficult to recognize the difference from the spun yarn.

As the slightly alkali-soluble fiber used in the spun yarn used in the present invention, cotton, hemp, rayon (especially polynosic), nylon, polyester (regular type), vinylon, acrylic, etc. can be used. Silk, wool, and acetate cannot be used.

The following are suitable as the easily alkali-soluble polyester fiber of the present invention. Polyalkylene terephthalate fibers are spun at high speed and have a birefringence of 0.07 or more and a specific gravity of 1.365 or less! # Undrawn yarn with a shrinkage rate of 10% or less in submerged water, 2-25 mol% of a compound having a sulfonic acid group and two or more ester-forming groups, or further a sulfonic acid group other than terephthalic acid. A fiber whose main component is polyethylene terephthalate copolymerized with a dicarboxylic acid that does not have 2 to 5 mol% of a compound having a sulfonic acid group and two or more ester-forming groups, and a sulfonic acid group other than terephthalic acid. A fiber copolymerized with 2 mol% or more of dicarboxylic acid containing no dicarboxylic acid, the main component of which is polyethylene terephthalate, and the content of ethylene terephthalate units is 70 wt. 5-25ffi amount % copolymerized fiber whose main component is polyethylene terephthalate, 2 mol% or more of a compound having a sulfonic acid group and two or more ester-forming groups, molecule ji 200-10.0
Fibers whose main component is polyethylene terephthalate and whose content of ethylene terephthalate units is 70% by weight or more, which are copolymerized with 00 polyether or its derivatives at 2% by weight or more, and which have sulfonic acid groups and ester-forming groups. 2-5 mol% of compounds having two or more of the following, molecular weight 200
A fiber whose main component is polyethylene terephthalate and whose content of ethylene terephthalate units is 70% by weight or more.

As a compound having a sulfonic acid group and having two or more ester-forming groups, an alkali metal salt of sulfoisophthalate is preferable from the viewpoint of cost and reactivity.

As the dicarboxylic acid having no sulfonic acid group other than terephthalic acid to be copolymerized, isophthalic acid and adipic acid are preferred from the viewpoint of cost.

Polyethers or derivatives thereof having a molecular weight of 20o-to, ooo to be copolymerized include polyethylene glycol, polypropylene glycol, polytetramethylene glycol, random or block copolymers of polyethylene glycol and boria-o-pyrene glycol, and ester-forming at the terminals thereof. It is blocked by an ether bond, an imide bond, etc. so that one or more functional groups remain.

Glycol compounds with a molecular weight of less than 200 to be copolymerized include 1.2 propanediol, 1.3 propanediol, 1,3 butanediol, 1.4 butanediol, diethylene glycol, triethylene glycol,
Neopentyl glycol is preferred, and 1°4-butanediol and diethylene glycol are most preferred in view of stability in the polymerization process.

The continuous thread of alkali-soluble polyester fiber used in the present invention may have a structure as a continuous thread of multifilament, monofilament, spun thread, or thread obtained by slitting or splitting a film.
It may also be a crimped thread or a mixture thereof.In order to increase the rate of alkali dissolution, it is preferable that the single fibers be thin, and that the thread should have an irregular cross section rather than a circular cross section. is preferred.

In the present invention, the alkaline solution for dissolving the easily alkali-soluble polyester fiber has a concentration of 0.1-10%, and the solvent is water or a water-based solvent, or an alcohol or an alcohol-based solvent. Additionally, various additives may be added if necessary.The appropriate treatment temperature is 60°C or higher and below the boiling point of the solvent, but in order to promote dissolution, pressurize using a closed container and raise the temperature above the boiling point of the solvent. It can also be processed.

Example 1 Copolymerized polyethylene terephthalate with an intrinsic viscosity of 0.48 measured at 30'C with an equivalent mixture of phenol and tetrachloroethane, which was copolymerized with 3 mol% of sodium sulfoisophthalate and 4.5 mol% of isophthalic acid. was melt spun and wound at 1350 m/min. This fiber was drawn by a conventional method to obtain a 40 denier/24 filament multifilament.

This thread and cotton No. 16 combed thread (twist number 520t/m
Z twist) and S twist of 480t/m were applied and wound up. The remaining twist was in it/in and the twist coefficient was 0.5. The composite yarn and cotton No. 16 single yarn were used alternately as the warp, and the cotton No. 16 single yarn was used as the weft, with a warp density of 38.
A terry cloth was made by weaving at a yarn density of 32 yarns/in and a weft density of 32 yarns/in so that only the composite yarns of the warp formed a pile.

This towel fabric was treated with sodium hydroxide to dissolve the alkaline easily soluble polyester fibers using the following treatment solution.
4% Ethylene Glycol 1% Polyacrylic Acid 20% Water Residual Coat this alkaline solution uniformly on a rotating roll, lightly press the towel fabric onto this roll so that the alkaline solution adheres only to the pile part, and then apply the alkaline solution to a gauge pressure of 1 .2kg/am
The alkali easily soluble polyester fibers in the pile portion were dissolved by heating in saturated steam for 30 minutes, washed with water to remove the adhering alkaline solution, and dried in a tumble dryer.The pile portion of the towel fabric obtained was Extremely bulky
The area near the point of difference was more restrained than the remaining alkali easily soluble polynisder fiber V1 and had good abrasion resistance, and almost no single cotton fibers fell off during washing.

Example 2 A 30'C
A copolymerized polyethylene terephthalate having an intrinsic viscosity of 0.42 was melt-spun and wound at a spinning draft of 1200 times for 5800 m in 7 minutes. This fiber was drawn in a conventional manner to obtain a 75 denier/36 filament fiber.

This fiber and cotton number 30 single yarn (twist number 680t/m).

A composite yarn was made by applying S twist of 650 t/m while aligning the yarns (Zm). Using the composite yarn and a No. 30 cotton single yarn alternately as the warp, and using a No. 30 cotton single yarn as the weft,
A terry cloth with a warp density of 65 yarns/in and a weft yarn density of 35 yarns/in was prepared so that only the composite yarns of the warp form a pile, and an alkali easily soluble polyester was applied only to the pile portion using the same alkaline treatment solution as in Example 1. A dissolution treatment was performed. After 30 minutes of steam treatment, the alkali-soluble polyester fibers in the pile part are completely dissolved and removed, resulting in a pile made of diametrically twisted cotton threads, a solid structure near the telegram difference point, extremely bulky, and soft to the touch. A non-twisted yarn fabric was obtained. This fabric had good abrasion resistance, and almost no single cotton fibers fell off during washing.

Example 3 A mixture of equivalent amounts of phenol and tetrachloroethane copolymerized with 10 mol% of sthorium sulfoisophthalate.
A copolymerized polyethylene terephthalate having an intrinsic viscosity of 0.47 measured at 0°C was melt-spun and wound to 1300 m in 7 minutes. This fiber was drawn in a conventional manner to obtain a 40 denier/24 filament multifilament.

This yarn and cotton No. 16 combed yarn (twist number 520t/m, Z
fi) and twisted together with S twist of 480t/m to make a composite yarn. The composite yarn and No. 18 cotton single yarn were used alternately as the warp, and the cotton No. 16 single yarn was used as the weft, with a warp density of 36/in and a weft density of 30/in, so that only the composite yarn of the warp was used. I made towels that can be piled up.

This towel cloth was dipped in a 7% polyvinyl alcohol aqueous solution, and the sludge was removed with a nip roll so that the sludge ratio was 150%.After drying, the towel cloth was immersed in hot water at 90°C for 1 minute. The polyvinyl alcohol only in the pile portion was dissolved and dried.

Next, the easily alkali-soluble polyester fibers were subjected to dissolution treatment using the following alkaline treatment solution. The alkali easily soluble polyester fibers were completely dissolved and removed at a bath ratio of 200:1, a temperature of 90''C1, and a treatment time of 10 minutes.

Sodium hydroxide 4% Ethylene glycol 1% Sodium terephthalate Saturated water Residual Next, the towel fabric was washed with water to remove the alkaline solution adhering to it, and then immersed in hot water at 98°C to remove the remaining polyvinyl alcohol. was dissolved and removed and dried. The resulting towel fabric was extremely bulky and was bound by the easily alkali-soluble polyester fibers remaining near the In#1 point, so it had good abrasion resistance and almost no single cotton fibers fell off during washing.

Example 4 Copolymerized polyethylene terephthalate with an intrinsic viscosity of 0.66 measured at 30°C was melted with a mixture of equivalent amounts of phenol and tetrachloroethane, which was copolymerized with 8% by weight of methoxypolyethylene glycol having a molecular weight of 2200 and 1.0% of pentaerythritol. The yarn was spun and wound at 1350 m in 7 minutes. This fiber was stretched in a conventional manner to obtain a 40 denier/24 filament multifilament.

This fiber and cotton No. 30 single yarn (680t/mZ twist)
A composite yarn was made by aligning the fibers and applying an S twist of 650 t/m. Using this composite yarn, a towel fabric was made under the same conditions as in Example 1 and treated with alkali. As in Example 1, a fabric with excellent bulk and good abrasion resistance was obtained.

(f) Effects of the Invention The bulky spun yarn woven material produced by the present invention, especially the woven or knitted material having a looped pile, is suitable for toweling, underwear, and knitted shirts, and the tips of the loops are bulky and soft to the touch, and absorb water. It has excellent durability and is tightly packed inside the woven structure, resulting in poor abrasion resistance and washing resistance.

Claims (1)

[Claims] A spun yarn consisting of poorly alkali-soluble fibers and a continuous yarn consisting of easily alkali-soluble polyester fibers are aligned, and the fabric is woven or knitted using yarns twisted in the direction of untwisting the spun yarns. The fabric is characterized by alkali treatment near the tips of the fibers or tassels protruding from the fabric to remove the easily alkali-soluble polyester fibers near the tips, and to leave the easily alkali-soluble polyester fibers in the vicinity of the thread intersections of the fabric. Manufacturing method for bulky spun yarn woven and knitted fabrics with excellent abrasion resistance