KR20200038460A - Anti-pilling cloth and its manufacturing method - Google Patents

Abstract

The present invention provides a fabric comprising a short fiber of a thermoplastic synthetic fiber, particularly in a knitted fabric, in which the occurrence of peeling is suppressed, and also a fabric having a reduced strength of fabric and a deterioration of touch is suppressed, and a method for manufacturing the same will be. An anti-pilling fabric comprising short fibers of a thermoplastic synthetic fiber, characterized in that at least one surface of the fabric has a melt bundle at the end of the short fiber and a polishing mark at the melt bundle at the fluff tip of the short fiber. It relates to the anti-pilling cloth and its manufacturing method.

Description

Anti-pilling cloth and its manufacturing method

The present invention relates to an anti-pilling cloth comprising short fibers of a thermoplastic synthetic fiber and its manufacturing method. More specifically, the present invention relates to an anti-pilling knitted fabric comprising a long fiber yarn of thermoplastic synthetic fiber and / or a spun yarn comprising short fibers, and a manufacturing method thereof.

Natural fibers are short fibers (staples) that have been cut into short lengths after removing tulle. For example, the cotton is about 20 to 35 mm long and about 20 µm thick, and the wool (merino species) is about 7.5 to 120 mm long and 13 to 28 µm thick. Therefore, in the natural fiber, a single fiber is unspun, combed, and then the fiber is stretched to form a spinning yarn (hereinafter, also referred to as a spun yarn) by spinning to form a thread. In the spun yarn, there are fluffs, bulkiness, flexibility and heat retention.

On the other hand, synthetic fibers are usually made of filaments through spinning, and for example, many fibers such as polyester or polyamide are made of melt spinning, and acrylic fibers are made of wet spinning. In addition, regenerated cellulose fibers such as rayon and cupra, and semisynthetic fibers such as acetate fibers are also made as filaments. Synthetic fibers are also used as short fibers by cutting what is made of filaments.

Synthetic fibers are generally characterized by being light and sturdy (strong and difficult to cut) compared to natural fibers such as cotton, hemp, silk, and wool, but natural fibers often have a unique fluffy feeling, mainly medical. It is preferably used as a raw material for products. It is known that in order to achieve the fluffy touch of natural fibers with synthetic fibers, it is necessary to weave a knitted fabric with a spun yarn of synthetic fiber, but it is known that in a knitted fabric made from a spun yarn of synthetic fiber, peeling is likely to occur. Peeling means that the surface of the fabric rubs during wear or washing, fluffing occurs on the surface of the fabric, and the lint is entangled, resulting in the formation of small hairs (pills) .In particular, synthetic fibers such as polyester or polyamide are included in the fiber. If present, the fibers are strong and difficult to cut, and thus, brittleness is likely to occur. When the generated hair bundles need to be removed, these synthetic fibers are stretched without being cut when pulled, so once a hair bundle occurs, it is difficult to fall off, thereby damaging the appearance and promoting deterioration of the knitted fabric. Therefore, when a knitted fabric made of a synthetic fiber spinning yarn is manufactured for uses such as medical products or products that repeat washing, countermeasures to suppress the occurrence of peeling (that is, anti-pilling measures) are indispensable.

Conventionally, for example, in the preparation process prior to dyeing, especially in the case of spinning fabrics such as cotton, fluff often occurs on woven fabrics and knitted fabrics. Therefore, in order to remove the fluff, the fiber surface is smoothed by so-called 'singeing', which is cut by burning and fluffing the fluff with a gas burner or electric heater. In line dyeing, the burning of hair is performed after weaving is completed, but it is also carried out in direct yarn.

On the other hand, in textile products, as described below, it is also practiced to brush the knitted fabric to actively make fluff.

In cotton products such as jeans, the lining is soft and rich when it is covered with lint, and the color and pattern appear white and faint, or it changes to a calming feeling, and it has a luxurious feel. What is done is to make the mouth feel.

In woolen fabrics, after weaving, moistening is performed by wetting, knocking, rubbing, etc., and then felting is made by felting to make felt, and, furthermore, brushing, cutting, and making fluff are made to make fluff to make fluff. BACKGROUND ART A so-called brushing brush with a needle having a metal needle is known as a brushed brush that makes a fluff by scratching the surface, or by rubbing the surface with a spine of thistle fruit, so that a brushed effect with a milder feel than a brushed brush is obtained.

In order to obtain a highly sensitive fabric having a smooth, soft texture such as natural cashmere or angora, moisturizing property, and touch, in a knit fabric of a synthetic fiber such as polyester or acrylic, using a single fiber spun yarn, the fabric is fabricated with a raised brush It has been practiced to make a very long fluff called bristle dense.

In addition, emery processing (schamy processing), which is performed on a ground fabric, is polished with a sandpaper called emery paper and finely shortened fluff is known. Sandpaper is different in thickness from sandpaper, but sanding, also known as brushing for polyester fabrics, is brushed with sandpaper, and a plurality of rollers of sandpaper having different degrees of brushing are stacked vertically, rotated at a low speed, and cloth is interposed between them. Friction is caused by passing through, and thin brushing is also performed.

In particular, in the case of performing woolen or brushing, the whole body is cut (shearing) to cut the fluff of the cloth, and the length of the fluff is trimmed or trimmed to reveal the texture, color and pattern, or the appearance is clearly displayed. Trimming is done.

In the following Patent Document 1, a letter composed of a blend of polyester single fibers and cotton fibers having a fineness of 1.0 to 2.5 denier, the composition ratio of the cotton fibers in the blend yarn is 75 to 90%, the blend yarn A letter for shirt is disclosed, wherein the twist coefficient is 3.0 to 4.5, and the hair is burned after knitting. In the cited reference 1, when the composition ratio of the cotton fibers is less than 75% (i.e., the composition ratio of the polyester staple fibers is more than 25%), the polyester staple fibers melt upon burning the hair after knitting, and the touch becomes hard, It is described that it becomes easy to be contaminated. In other words, if the burning of hair, which is used as an anti-pilling measure for natural fibers, is adopted as an anti-pilling measure for polyester, which is a synthetic fiber, the lint that causes peeling like natural fibers does not carbonize and fall off, but the lint of polyester is used. Melt bundles are formed at the hairs of the hair, which causes deterioration of the texture such as roughness of the fabric.

In the following patent document 2, when burning synthetic fibers, in order to obtain a soft touch such as cashmere, the raising of a raised cloth having a synthetic fiber made of synthetic fibers such as polyester fiber, polyamide fiber, and acrylic fiber After the tip of the hair is burned to form a melted bundle of synthetic fibers, the hair tip is treated with a solvent or a hydrolyzing agent of the synthetic fiber of a predetermined viscosity, and heat-treated to refine the hair tip to make a beast's fur-like cloth. Methods of manufacturing are disclosed. This is because the melt bundle forming portion becomes non-orientated, and the dissolution rate and hydrolysis rate when treated with a solvent or a hydrolyzing agent are significantly increased, which can significantly shorten the processing time and at the same time very finely refine the tip. It is based on what is. However, in the method of treating with a synthetic fiber solvent or a hydrolysis agent, since the strength of the material is lowered, it is currently only used for limited applications such as women's clothing.

In the following patent document 3, a synthetic fiber-containing spun yarn having a reduced number of fluffs per number of cross-section fibers by a specific spinning method is used for warp and / or weft yarns, such as denim, lumps, etc., which have not been subjected to hair burning and / or alkali reduction. As a fabric of the present invention, an anti-pilling fabric having a class 3 or higher anti-pilling property according to JIS L1076 A method (5 hours for ICI type tester) after washing (JIS L0217 103 method) 10 times is disclosed. In Patent Document 3, when a synthetic fiber spun yarn is used, a hair burning treatment is required to prevent peeling of the synthetic fiber. As a result, the melted bundles of the synthetic fibers are removed by high-temperature alkali reduction or sealing, or shearing. A high cost process is required, and the texture, fastness, and the like are deteriorated, and the burnt melt on the surface of the cloth irritates the skin by burning only the hair. Products that use synthetic fiber-containing spun yarn are popular because they require easy chemical treatment such as strong acid and alkali for a long time under high pressure in denim, chunky, etc. It does not describe what is not.

In the following patent document 4, a spun knitted fabric containing a polyester short fiber having a single fiber fineness of 0.01 to 10 denier and a single fiber strength of 2.5 g / denier or more is impregnated and brushed, and thereafter the surface of the knitted fabric is polished. It is a flexible coarse surface material having a film surface, and by tapping and rubbing it on the support roller surface, the surface lint has an average lint length of at least 1.1 mm or more and 50 mm or less, and an average lint density of 200 / cm or more. A method for producing a polyester spun knitted fabric as finished as possible is disclosed. Then, in such a tapping and abrasion treatment, the long and rough fluff of the brushed and raised brushed cotton is strongly pulled out with a flexible coarse cotton material having a surface of an abrasive film, while cutting and cutting a loop or fiber lump. It has been described to remove, to generate a slightly short and tight fluff. Patent Document 4 describes that in the conventional buffing process using an emery roll, the anti-pilling property in accordance with JIS L1076 was class 1-2, whereas in the processing method using the abrasive film, it was also described as class 5, 4-5. In patent document 4, improvement and commercialization are progressing from the polyester single fiber spun yarn having high physical properties, but the spun cloth composed of such a short fiber wool yarn has a long fluff, so that it is a cloth for a normal short fluff woven fabric. The fluff on the surface is rubbed by wear or washing, and a hair bundle called peeling occurs immediately, and the quality and appearance of the fabric are greatly damaged, which is a problem. Lint existing on the surface, or the lint is pulled out from the fabric, and the lint is entangled. As a countermeasure against the occurrence of defects in peeling, (1) a method for improving the strength and elongation of fibers small, and (2) increasing the tissue binding force of the fabric. Is known, (3) method of embrittlement of surface fluff, (4) method of burning hair, (5) method of resin processing, etc. It has been described that it is very difficult to obtain a polyester spun knitted fabric having excellent peelability.

In patent document 4, in particular, the hair burning process is a method that is applied to a short fluff woven fabric, and is a method of processing the surface fluff of a cloth with a gas burner upon completion of dyeing of the cloth. Although, even if applied, the anti-pilling effect is recognized in its own way, but there are problems such as rough texture, tactile hardening due to heat treatment, poor heat retention, etc., because a melted ball (melt ball) of fluff remains on the surface. It is described. As described above, in the technique disclosed in Patent Document 4, in the woolen knitted fabric of the fluff using synthetic fiber spun yarn, instead of the anti-pilling measures of the prior art, the anti-pilling measures to generate short and tight fluff using a specific polishing method are applied. will be. In the cited document 4, since ordinary buffing and sanding are grinding with an emery roll or an emery belt, a special anti-pilling effect is not obtained, and instead, a metal plate is laminated, and the thickness is reduced across the tip. Rotating a flexible rough surface material having a sharp abrasive film surface, tapping the spun knitted fabric on the support roller surface and completing it by abrasion treatment. The point of this particular abrasive treatment method is to cut the long and rough lint of the raised base surface with strong sharp cotton material, and at the same time, cut and remove the loops or lumps of fibers to generate a slightly shorter and tighter lint, thereby creating a surface. It is described to create, that is, only 'strong hair' by removing the 'loose hair' on the pole surface, thereby increasing the friction resistance to impart anti-pilling properties.

In Patent Document 5 below, while running the woven fabric at a predetermined speed using a pasted warp, the fabric is brought into contact with a ceramic roller made of an inorganic powder having a particle size of # 100 to 800, such as thistle brushing or foaming brushing. Instead of pulling out the fibers from the surface, the surface can be fibrillated to give a soft peach-like feel, and the peeling properties are improved, and thin lines such as rope wrinkles, twist-shaped stains, and tissue tangles are unlikely to appear. Disclosed is a method of manufacturing a brushed fabric that can be brushed on a fabric, and furthermore, does not lower the tear strength of the fabric by brushing. In Patent Document 5, compared to the conventional polishing with emery paper (# 200), the polishing with a ceramic roller made of an inorganic powder having a particle size of # 100 to 800 improves the feel and anti-pilling property, and only the fiber surface. Since fibrillation generates fine fluff, it has been described that post-napping does not require post-treatment by physical means such as burning hair or whole hair or by chemical means using chemicals.

Patent Document 6 below discloses that anti-pilling properties and high shrinkability (volume resistance) are provided to modified monomers constituting synthetic fibers by blending and copolymerizing monomers that improve peeling resistance. However, the fiber materials that can be used are limited to polyester, and further, there is a problem in that synthetic fibers lose the properties and texture inherent to synthetic fibers, resulting in a decrease in fiber strength and an increase in cost.

As described above, as anti-pilling measures for knitted fabrics using a spun yarn of synthetic fibers, citations 1 and 2 use hair burning, but in citations 3-6, it is taught that hair burning should not be used. On the other hand, as described above, in Citation 3, there is a description that melt bundles due to the burning of the hair of synthetic fibers can be removed by shearing, but shearing is a method of slicing the raised fibers, so brushing is performed as in the case of polishing. It is practically difficult to apply other than the product, and even if applied, the risk of damaging the cloth material is very high, so it is not actually used.

In addition, in the references 4 and 5, a special polishing method is taught, which is a technique applied to a brushed product. In the spun yarn of synthetic fiber, since the fluff is hard and the fluff (hair tip) flees even when polished, it is difficult to treat only the fluff that causes peeling without damaging the material fabric.

As such, as anti-pilling measures in general textile products, methods such as burning hair, reducing fiber strength, polishing, shearing (whole processing, cutting), and modifying fiber materials are known. As anti-pilling measures for knitted fabrics, all of them are insufficient, so in the review stage of medical product development, there is a tendency to exclude the option of using a synthetic fiber spun yarn.

In addition, surprisingly, as a countermeasure against the anti-pilling of knitted fabrics using a spun yarn of synthetic fiber, a finishing process combining hair burning and polishing is not known, and has not been implemented to this day.

Patent Document 1: Japanese Patent Publication No. Hei 8-144158 Patent Document 2: Japanese Patent Publication No. 61-31234 Patent Document 3: Japanese Patent Publication No. 2004-197243 Patent Document 4: Japanese Patent Publication No. Hei 9-95859 Patent Document 5: Japanese Patent Publication No. Hei 7-97764 Patent Document 6: Japanese Patent Publication No. 2016-108702

In view of the above-described phenomena of the prior art, the problem to be solved by the present invention is that the occurrence of peeling is suppressed in a fabric containing short fibers of a thermoplastic synthetic fiber, for example, a knitted fabric, and the strength of the fabric is reduced. It is to provide a knitted fabric in which the deterioration of touch is suppressed, and a manufacturing method thereof.

The present inventors conducted a series of studies in order to solve the above problems, and as a result, a fabric having a fluff of the short fibers obtained by weaving or knitting using a spun yarn containing short fibers of a thermoplastic synthetic fiber as a yarn. By burning at least one surface of the knitted fabric, a melt bundle is formed at the end of the short fiber, and then the melt bundle of the fluff tip of the short fiber formed is scratched by, for example, polishing using a roll grinding machine or a belt sander grinder. Excessively forming abrasive marks, it was found to unexpectedly obtain a knitted fabric having excellent anti-pilling property and suppressing the deterioration of the strength and the strength of the fabric due to the manufacturing step or repeated use. .

That is, the present invention is as follows.

[1] An anti-pilling fabric comprising short fibers of a thermoplastic synthetic fiber, characterized in that at least one surface of the fabric has a melt bundle at the end of the short fiber and a melt mark at the melt bundle at the fluff tip of the short fiber. Said anti-pilling cloth.

[2] The method of [1], wherein the thermoplastic synthetic fiber is made of polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and polyurethane. An anti-pilling fabric, a fiber selected from the group.

[3] The anti-pilling fabric according to [1] or [2], which is a knitted fabric.

[4] In [3], the anti-pilling grades according to JIS L 1930 C4M method (using tumble) 10 times, and 30 times after JIS L 1076 A method (using an ICI type tester) are all grade 3 Ideal, anti-pilling cloth.

[5] The following steps:

A process of weaving or knitting a fluff of a cut end of the long fiber yarn or a fabric having a fluff of the short fiber using a spun yarn containing long fiber yarns and / or short fibers of a thermoplastic synthetic fiber as a yarn;

A step of burning at least one surface of the obtained fabric to form a melt bundle at the cut end of the long fiber yarn or the end of the short fiber; And

A step of forming abrasive marks by rubbing the cut ends of the long fiber yarns formed on one surface of the obtained fabric or the melted bundles of the fluff tips of the short fibers by polishing;

Method of manufacturing an anti-pilling cloth comprising a.

[6] The method of [5], wherein the thermoplastic synthetic fiber is made of polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and polyurethane. A method, which is a fiber selected from the group.

[7] The method of [5] or [6], wherein the anti-pilling cloth is a knitted fabric.

[8] The anti-pilling according to [7], wherein the anti-pilling cloth is washed in accordance with JIS L 1930 C4M method (using tumble) 10 times, and after 30 times in accordance with JIS L 1076 A method (using an ICI type tester). Method with all grades 3 or higher.

Since the anti-pilling cloth comprising the short fibers of the thermoplastic synthetic fiber according to the present invention, a melt bundle by burning hair remains inside the fabric, and only the polishing marks of the melt bundle of the short ends of the fluff of the short fibers exist on the cloth surface. It is a fabric with very good peeling properties, and also has a significant decrease in strength even after the manufacturing step or repeated use, but the deterioration of touch is suppressed, for example, a knitted fabric. For this reason, the present invention enables the application of knitted fabrics using spun yarns of synthetic fibers, which have been difficult to commercialize, for various medical products or other textile products having a desired touch and appearance. The type of synthetic fiber used as the yarn is thermoplastic and can be freely selected without any limitation. In addition, the present invention can also be applied to knitted fabrics or the like subjected to brushing treatment. Moreover, in the weaving, knitting, etc. of knitted fabrics of long fibers, the long fibers are cut, and it is also applicable to knitted fabrics having fibers having end portions on their surfaces. For this reason, the anti-pilling fabric comprising the short fibers of the thermoplastic synthetic fiber according to the present invention provides, for example, a lighter and more durable medical product than natural fibers while having a soft touch like natural fibers, and is durable and deteriorated even after repeated use. It can be applied to various textile products such as difficult-to-wear shirts and bedding covers.

1 is an electron microscope photograph of the surface of the cloth after washing 10 times of the finished product (regular processed product) of the spun polyester plain fabric prepared in Comparative Example 1.
Fig. 2 is an electron microscope photograph of the surface of the fabric after washing 30 times of the finished product (regular processed product) of the spun polyester plain fabric prepared in Comparative Example 1.
FIG. 3 is an electron microscope photograph of the surface of the cloth after washing 10 times of the finished product (hair burning + polishing) of the spun polyester plain fabric prepared in Example 1.
4 is an electron micrograph of the surface of the cloth after 30 washes of the finished product (hair burning + polishing) of the spun polyester plain fabric prepared in Example 1.
FIG. 5 is an electron micrograph of the surface of the fabric (hair burning only) immediately after the hair burning process after refining by subtracting loosening of dough during the production of the spun polyester plain fabric prepared in Example 1. FIG.
6 is an electron microscope photograph of the surface of the fabric immediately after completion of the finished product (hair burning + polishing) of the spun polyester plain fabric prepared in Example 1.
Fig. 7 is an electron microscope photograph of the surface (regular processed product) of the finished product (regular processed product) of the spun nylon plain fabric of Comparative Example 3.
Fig. 8 is an electron microscope photograph of the surface of the cloth immediately after completion of the finished product (hair burning + polishing) of the spun nylon plain fabric of Example 2.
FIG. 9 is an electron micrograph of the surface of the fabric (hair burning only) immediately after the hair burning process after refining by subtracting loosening of the dough during the production of the spun nylon plain fabric of Example 2. FIG.
10 is a schematic view showing an example of a device of a belt sander grinder for forming abrasive marks by rubbing a lump of melt on the tip of a fluff after burning hair.

Hereinafter, embodiments of the present invention will be described in detail.

A first embodiment of the present invention is an anti-pilling fabric comprising short fibers of a thermoplastic synthetic fiber, wherein at least one surface of the fabric is melted at the ends of the short fibers and melted at the fluff tip of the short fibers. It is characterized by having an abrasive mark, the anti-pilling cloth.

The term 'thermoplastic synthetic fiber' in the present specification is not particularly limited as long as a melt bundle is formed by melting by gas burning or the like, but is not particularly limited, but a chemical fiber composed of a chemically synthesized polymer, for example, polyester-based, poly And synthetic fibers such as amide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and polyurethane. For example, the melting point of the short fibers of the polyester fiber is 255 to 260 ° C, the melting point of the short fibers of the polyamide fiber nylon is 215 to 220 ° C, and the melting point of the polyacrylic fiber is not clear, but the softening point is 190 to 240 ° C, and the melting point of short fibers of polypropylene, a polyolefin-based fiber, is 165 to 173 ° C. In contrast, cotton (upland), a natural fiber, decomposes at 235 ° C, burns at 275 to 456 ° C, and wool (merino) thermally decomposes at 130 ° C, burns at 205 ° C, and carbonizes at 300 ° C. In addition, rayon and cupra, which are regenerated cellulose fibers, do not soften or melt, but are colored at 160 to 300 ° C and begin to decompose. The thermoplastic synthetic fiber in the present embodiment is selected from the group consisting of polyester-based, polyamide-based, polyacrylic-based, polyvinyl chloride-based, polyvinylidene chloride-based, polyvinyl alcohol-based, polyolefin-based, and polyurethane-based. Fibers are preferred, and polyester, polyamide or polyacrylic fibers are more preferred.

The term 'single fiber' in the present specification refers to a short fiber (staple) cut into a short length, and in the case of a short fiber of a thermoplastic synthetic fiber, generally made of a long fiber (filament). The length of the short fibers is preferably 20 to 70 mm, more preferably 30 to 60 mm, further preferably 38 to 51 mm from the viewpoint of spinning processability. The fineness (single-fiber fineness) of the short fibers is preferably from 0.01 to 10 denier, more preferably from 0.8 to 5 denier, and even more preferably from 1.0 to 2.5 denier, from the viewpoint of spinning and maintaining the strength of the fabric. If the single yarn fineness is less than 0.01 denier, it is easy to be contaminated, and fluff occurs, so that the tip is concentrated to make the hair easily. On the other hand, when it exceeds 10 denier, the occurrence of fluff is less, but the strength increases, so once the hair is generated It becomes difficult to fall off, and the touch feels worse. The cross-sectional shape of the short fiber may be a round cross-section or a cross-section.

On the other hand, the term 'short fiber' in the present specification is a result of cutting the long fiber by weaving, knitting, brushing, etc. on the surface of the dough obtained by weaving, knitting, etc., using long fiber of thermoplastic synthetic fiber as the yarn. Also includes fibers with cut ends.

The term 'spun yarn (spun yarn)' in the present specification refers to a thread in which a single fiber is untwisted and combed, and the fiber is stretched and twisted. From the viewpoint of forming a melt bundle, the spun yarn is preferably made of only short fibers of a kind of thermoplastic synthetic fiber, and may be mixed yarns of short fibers of two or more kinds of thermoplastic synthetic fibers. In addition, a blended yarn of a thermoplastic synthetic fiber with a short fiber and other natural fibers may be used, or a composite fiber yarn, a twisted yarn with a filament yarn, or a square yarn. The number of spun yarns is preferably 7 to 120 (760 to 44 denier). If the number is less than 7, the fabric is thick, and if it is greater than 120, the strength decreases. In addition, the soft water (撚 數) is preferably 60 to 1500 times / m.

The term 'cloth' in the present specification may be any of woven fabric, knitted fabric (round knitted fabric, light knitted fabric, upper knitted fabric) and non-woven fabric. From the viewpoint of exerting a desired effect as a garment product, a fabric or a knitted fabric is preferable as the cloth. The fabric is preferably composed of 100% of the spun yarn, and it is preferable because a soft fabric with a soft and resilient feel is obtained with a long fiber for warp yarn and a fabric using spun yarn for weft yarn. The fabric and knitted fabrics are not particularly limited. Moreover, the term 'knitted fabric' in the present specification refers to a fabric or knitted fabric.

The term 'fluff' in the present specification refers to an end portion of a short fiber that has grown from the surface of the fabric, and an end portion of the short fiber existing in the fabric or in the interior of the yarn is not called fluff. 1 and 2 show an example of polyester fluff, and Fig. 7 shows an example of nylon fluff.

The term 'melt bunch' in the present specification means that the fluff of the thermoplastic synthetic fiber is melted and transformed into a substantially spherical shape by burning hair. In the present embodiment, the melt bundle existing on the surface of the cloth is converted into abrasive marks by abrasion caused by polishing. 5 shows an example of a melt bundle of polyester, and FIG. 9 shows an example of a melt bundle of nylon.

The term 'abrasive marks' in the present specification refers to the ends of short fibers having a shape in which a bundle of melts on the surface of the fabric has a trace of abrasion. 3, 4 and 6 show an example of polyester polishing marks, and Fig. 8 shows an example of nylon polishing marks.

Another embodiment of the present invention, the following steps:

A process of weaving or knitting a cloth having fluff of the short fibers by using a spun yarn containing short fibers of the thermoplastic synthetic fibers as the yarn;

A step of burning at least one surface of the obtained knitted fabric to form a melt bundle at the end of the short fiber; And

A step of forming abrasive marks by rubbing a bundle of melt of the fluff tip of the short fibers formed on one surface of the obtained knitted fabric by polishing;

It is a method of manufacturing an anti-pilling cloth comprising a.

Hereinafter, an example of manufacture of the anti-pilling cloth of the present embodiment will be described.

The short fibers of the thermoplastic synthetic fiber are used as the spun yarn. In this case, a mixture of two or more types of thermoplastic synthetic fibers may be used, or a mixture of one or more types of thermoplastic synthetic fibers and one or more types of natural fibers may be used.

Subsequently, the spun yarn is woven and used as warp and / or weft yarns to make a dough.

Subsequently, refining is performed on the dough.

Next, the following hair burning is performed.

(Burning hair)

A melt bundle is formed at the tip of the fluff present on the surface of the fabric. At this time, although it is buried inside the fabric, there may be a case where melt bundles are formed even at the ends of the short fibers outside the spun yarn, and the melt bundles present in these areas do not appear on the surface of the fabric, so there is no fear that the texture of the fabric is deteriorated. Hair burning can be carried out, for example, by direct hair burning (flame burning) by flame from a gas burner and / or indirect hair burning (contact burning) by contact with a heating roller. Since polyester and nylon have a melting point of 210 to 260 ° C, it is preferable to burn the hair directly. For a material having a higher melting point, it is preferable to burn the indirect hair in which heat is transferred in a short time when the temperature of the heating roller is made higher. The conditions for burning the hair are not particularly limited, but it is sufficient to form a melt bundle at the end of the fluff present on the surface of the fabric, which causes peeling. The passing speed of the fabric provided for the hair burning process (hair burning processing speed) is preferably 60 to 120 m / min, and more preferably 80 to 100 m / min. On the other hand, when the spun yarn contains natural fibers, it is preferable to burn the gas hair because the peeling is suppressed by burning and cutting the fluff of the natural fiber by burning the hair.

Next, the following polishing is performed.

(grinding)

By the burning of the hair, the melted bundles of the fluff tip portions of the short fibers formed on at least one surface of the knitted fabric are rubbed by, for example, polishing using an abrasive or abrasive paper to form abrasive marks. In the case where a melt bundle is formed on both sides of the cloth, it is preferable to perform polishing on both sides. The polishing method may be manual or various polishing machines may be used. As a polishing machine, a roll polishing machine provided with abrasives on a roll, a roll polishing machine wound with abrasive paper on a roll, or a belt sander polishing machine using a belt-shaped abrasive paper can be used. 10 shows an example of a polishing apparatus using a belt sander polishing machine. When both surfaces of the cloth are polished using a belt sander grinder, the polishing surface may be changed twice. As shown in Fig. 10, the cloth after burning the hair is preheated by the heat cylinders 3 to 5 through the reversing rollers 1 and 2, and through the reversing rollers 6 to 8 to the rotating belt sander 10. , It is pressed while adjusting the pressing strength by the movable push valve (9), the melt bundle on the surface of the cloth is abrasive, and abrasive marks are formed. The powder generated by grinding is removed by removing the powder from the paper (11) and removing the powder from the dough (12, 14), and finally the cloth from which the abrasive powder has been removed is overlaid and recovered by a dropping device (19). do.

Conventional anti-pilling measures by polishing, for example, as described in Patent Document 5, was to be divided (fibrillated), the polishing in the present embodiment, a bundle of melt generated by burning hair It is carried out to cut. As shown in Figs. 5 and 9, since the melt bundle has a substantially spherical shape of a predetermined size, when the abrasive or abrasive paper is brought into contact with the surface of the fabric, and when rubbed, the melt bundle cannot enter the inside of the fabric. It is preferentially polished and abrasive to minimize damage to the fabric's paper texture. Therefore, by such polishing, problems such as roughness of the fabric, deterioration of touch, and appearance due to the remainder of the molten bundle, which was the largest problem in the burning of the hair of the thermoplastic synthetic fiber, are solved, and furthermore, a decrease in the strength of the fabric is suppressed. do. As described above, in the references 4 and 5, a special polishing method is taught, and such a polishing method is a technique applied to a brushed product, and in the spun yarn of synthetic fiber, the fluff is hard and fluff (hair tip) even when polished. ), It is difficult to treat only the fluff that causes peeling without damaging the fabric. However, the present inventors are able to polish the melted bundle by abrasion without damaging the material cloth, because it is difficult to escape if the fluff is formed with a melted bundle at the tip thereof by burning the hair, so that the anti-pilling property is very high. It has been discovered that an excellent fabric can be produced, and the present invention has been completed. In addition, as described above, in Citation 3, there is a description that the melted bundle due to the burning of the hair of the synthetic fiber can be removed by shearing, but shearing is a method of cutting conventionally brushed fibers, as in the case of polishing. It is practically difficult to apply other than brushed products, and even if applied, the risk of damaging the fabric material is very high, so it is not actually used.

(Raising treatment)

The manufacturing method of the anti-pilling cloth of this embodiment is applicable also to knitted fabrics etc. which have the surface subjected to brushing. As a method of making the surface of the dough, which has been woven and knitted, by using a spun yarn containing a short fiber of a thermoplastic synthetic fiber as a yarn, is used for example, a processing method such as a brushed brushing treatment, an emery brushing treatment, or a pile fabric. The method according to the knitting, and the method according to the knitting such as the fabric by the center cutting of the double raschel letter can be mentioned. By burning at least one surface, such as a knitted fabric having a brushed surface, to form a melted bundle at the end of the short fiber, and polishing the melted bundle of the shortened fluff tip formed on one surface of the obtained knitted fabric, etc. Abrasion marks can be formed by abrasion.

In addition, the manufacturing method of the anti-pilling fabric of the present embodiment is a result of cutting long fibers by weaving, knitting, brushing, etc. on the surface of the dough, which is woven, knitted, etc., using long fibers of thermoplastic synthetic fibers as yarn. It is also applicable to knitted fabrics, etc., where short fibers exist. Because, if the end of the fiber is present on one surface of the dough, the melt bundle is formed at the end of the fiber by burning hair, and the melt bundle of the fluff tip formed on one surface of the obtained knitted fabric is scratched and opened by polishing. It is because it can form a forty and exhibit a desired effect.

(Heat setting)

Subsequently, heat treatment is performed to eliminate the influence of the uneven thermal history of the synthetic fiber. It is preferable to perform heat setting in order to achieve dimensional stability and uniform dyeing of the fabric. In the case of polyester fiber or nylon fiber, heat treatment is performed at 180 ° C for about 30 seconds to 1 minute.

(dyeing)

There are no particular restrictions on dyeing. Dyeing includes dyeing (staining and dyeing) and continuous dyeing, and dyeing is common. Some continuous dyeing is performed on the polyester, but the touch is hardened and the flexibility is impaired. In dyeing, when the hair is burned before dyeing, dyeing stains are generated due to different dyeing properties of the melt bundle and the base. In the present embodiment, since the melt bundle on the surface of the fabric is removed by polishing, there is no problem of dye staining. If hair burning is non-uniform, dyeing streaks occur. If the dyeing stripes due to hair burning cannot be solved in any way, after direct dyeing, the fabric may be burned and polished, that is, any of dyeing before hair burning and dyeing after hair burning may be used.

(Finish drying)

Then, it is dried to finish.

Since the knitted fabric, which has been subjected to anti-pilling measures according to the above-described manufacturing method, undergoes a hair burning process and a polishing process, as shown in FIGS. 3, 4, 6, and 8, when checked with an electron microscope, the inside of the cloth There are abrasive marks that are buried but outside the spun yarn, resulting from the melting bundle of short fiber ends and the melting bundle of the fluff tip on the fabric surface.

By implementing the anti-pilling measures including the above-mentioned hair burning process and the polishing process, even if the anti-pilling grade comprising short fibers of the thermoplastic synthetic fiber is a knit fabric of class 1 or 2, it has an anti-pilling class of class 3 or higher, preferably It can be made into a 4th grade or more, more preferably a 5th grade, and can also be made into a knitted fabric in which a decrease in strength and a deterioration in feel are suppressed. The knitted fabric which carried out the anti-pilling measure of the present embodiment is excellent in durability since the anti-pilling performance is maintained even after washing, as shown in the following examples.

Example

[Example 1] Preparation of spun polyester product (hair burning + polishing product)

The spun polyester fiber (short fiber of polyester fiber, 1.6 denier, 38 mm cutting) was spun according to a conventional method, and a polyester spun yarn (number 30) was obtained.

The obtained polyester spun yarn is canned as a warp, and this canned warp is coated with a foam mainly made of foam, and the obtained polyester spun yarn is used for the weft, and the warp density is 90 / inch. (2.54 cm), weft density of 70 pieces / inch weaved plain weave.

After refining the obtained dough, the both sides of the fabric were burned by gas burning (80 m / min) to form a melt bundle on the fabric. Subsequently, polishing was performed on both sides of the fabric with a belt sander (mesh # 1000), and the melt bundles generated on the fabric surface were removed. Thereafter, a plain weave test panel composed of spun polyester fibers was obtained through a 180 ° C., 1 minute heat setting process, a dip dyeing process according to dipping, and a drying process.

[Comparative Example 1] Preparation of spun polyester products (regular processed products)

A test panel was obtained in the same manner as in Example 1, except that the hair burning step and the polishing step were omitted.

[Comparative Example 2] Preparation of spun polyester products (hair burning + weight loss products)

After the hair burning step of Example 1, a test panel was obtained in the same manner as in Example 1, except that an alkali reduction treatment (10%) was performed instead of the polishing step.

[Comparative Example 3] Preparation of spun polyester products (hair burning + weight loss products)

After the hair burning step of Example 1, a test panel was obtained in the same manner as in Example 1, except that an alkali reduction treatment (20%) was performed instead of the polishing step.

[Comparative Example 4] Preparation of spun polyester products (hair burning + weight loss products)

After the hair burning step of Example 1, a test panel was obtained in the same manner as in Example 1, except that an alkali reduction treatment (30%) was performed instead of the polishing step.

[Example 2] Preparation of spun nylon products (hair burning + polishing products)

Spun nylon fibers (short fibers of nylon 66 fibers, 1.7 denier, 38 mm cut) were spun according to a conventional method to obtain nylon spun yarn (number 30).

The obtained nylon spun yarn is defined as a warp yarn, and the warp yarn mainly made of foam is applied to the warp yarn, and the obtained nylon spun yarn is used for the weft yarn, and the warp density is 90 / inch and the weft density is 70 / inch. Weaving dough.

After refining the obtained dough, the both sides of the fabric were burned with a gas whisk (80 m / min), and a melt bundle was formed on the fabric. Subsequently, polishing was performed on both surfaces of the cloth with a belt sander (mesh # 1000), and a melt bundle generated on the surface of the cloth was removed. Thereafter, a test panel composed of spun nylon fibers was obtained through a 180 ° C., 1 minute heat setting process, immersion dyeing by immersion, and drying.

[Comparative Example 5] Preparation of spun nylon products (regular processed products)

A test panel was obtained by the same method as in Example 2 except that the hair burning process and the polishing process were omitted.

[Example 3] Preparation of blended brushed material product (burning hair + polished product)

Twisted yarn composed of two blended yarns (40 times) and one polyurethane filament yarn (40 deniers) spun with a polyester fiber (38 mm cut, saw dyed) and rayon fiber (38 mm cut) with a 65:35 blend ratio (final blend ratio of 61:33) : 6) was used for the warp and weft yarns to prepare a woven salt dye cloth (96 warp yarns × 90 weft yarns), and further raised and raised. Gas burning was performed on the fabric (80 m / min) to form a melt bundle, followed by polishing on both sides of the fabric with a belt sander (mesh # 1000) to remove the melt bundle generated on the fabric surface. After that, a 180 °, 1 minute heat setting process was performed to obtain a plain weave test panel composed of a blend material.

[Comparative Example 6] Preparation of a blended brushed material product (hair burning processed product)

A test panel was obtained by the same method as in Example 3 except that the polishing step was omitted.

[Comparative Example 7] Production of blended brushed material products (regular processed products)

A test panel was obtained by the same method as in Example 3 except that the hair burning process and the polishing process were omitted.

Using the test panels obtained in Examples 1 to 3 and Comparative Examples 1 to 7, an anti-pilling test and a tear strength test were performed on samples without washing, after washing 10 times, and after washing 30 times. However, for the test panels obtained in Examples 2, 5, and 3, the tear strength test was omitted, and for the test panels obtained in Comparative Examples 6 and 7, anti-pilling test after 10 washes and 30 washes Omitted. The results are shown in Table 1 below.

The anti-pilling test was performed for 10 hours in accordance with JIS L 1076 A method (method using ICI type tester). The test result was taken as the average value of the four test pieces.

The tear strength test was performed according to JIS L 1096 D (pendulum method).

Washing was performed 10 times and 30 times according to JIS L 1930 C4M method (using tumble).

Test group Washing frequency (times) Anti-pilling grade Tear strength (N) (hard) Tear strength (N) (above)
Example 1 (PE) 0 5 38.9 30.0 10 5 33.5 26.7 30 5 31.3 24.1
Comparative Example 1 (PE) 0 One 39.8 31.4 10 One 33.6 29.7 30 One 31.3 23.6
Comparative Example 2 (PE) 0 5 16.7 15.1 10 5 15.9 14.2 30 5 16.2 13.6
Comparative Example 3 (PE) 0 5 13.6 8.3 10 5 13.2 11.1 30 5 13.3 11.1
Comparative Example 4 (PE) 0 5 7.5 7.1 10 5 7.8 6.6 30 5 8.1 7.2
Example 2 (NY) 0 5 -* - 10 5 - - 30 5 - -
Comparative Example 5 (NY) 0 1.5 - - 10 1.5 - - 30 1.5 - -
Example 3 (PE + R) 0 4.5 - - 10 4.5 - - 30 5 - -
Comparative Example 6 (PE + R) 0 3.5 - - 10 - - - 30 - - -
Comparative Example 7 (PE + R) 0 One - - 10 - - - 30 - - -

*-: Not implemented

From Table 1, the test panels of Examples 1 to 3 were subjected to hair burning and polishing, so that the anti-pilling grade was the highest level after washing 30 times, the highest level of 5, the anti-pilling property was very excellent, the touch was good, and the strength of There was no degradation. On the other hand, the anti-pilling grade of the test panel of Comparative Example 1 prepared without burning and polishing the hair was grade 1, the anti-pilling grade of the test panel of Comparative Example 5 was class 1.5, and the anti-pilling grade of the test panel of Comparative Example 7 was class 1. , A number of peeling occurred in the manufacturing stage.

In addition, in Comparative Examples 2 to 4 showing the results of alkali weight loss treatment, which is known as an anti-pilling measure for conventional spun polyester fibers, the anti-pilling grade, as in Examples 1 and 2, has a desirable result of class 5 However, in the result of the strength test, it fell to about 50% or less of Example 1, and a significant strength deterioration of the fabric was recognized. Therefore, it was difficult to maintain the strength and feel of the original fabric. Moreover, anti-pilling measures by weight loss processing were not preferable from the viewpoint of stable anti-pilling measures because variations in tactile feel and strength tend to occur due to the difference in the reduction ratio. In Comparative Example 6, the anti-pilling grade was 3.5, and the anti-pilling property was improved compared to Comparative Example 7. However, the number of melt bundles generated by burning the hair was present on the surface of the fabric, resulting in poor fabric feel and product value. Damaged.

The anti-pilling fabric of the present invention is excellent in anti-pilling properties, has a good touch, and has no significant decrease in strength, and thus is a variety of medical products or other textile products having a desired tactile feel or appearance, and is a synthetic fiber spinning yarn that has been difficult to commercialize. It can be suitably used as a knitted fabric used.

1: Reverse roller
2: Reverse roller
3: Heat cylinder
4: Heat cylinder
5: Heat cylinder
6: Reverse roller
7: Reverse roller
8: Reverse roller
9: movable push valve
10: belt sander
11: Paper powder removal
12: Removal of raw powder
13: reverse roller
14: Remove powder from raw dough
15: reverse roller
16: Guide roller
17: Guide roller
18: reverse roller
19: screening device

Claims (8)

An anti-pilling fabric comprising short fibers of a thermoplastic synthetic fiber, characterized in that at least one surface of the fabric has a melt bundle at the end of the short fiber and a polishing mark at the melt bundle at the fluff tip of the short fiber. Anti-pilling cloth. According to claim 1,
The thermoplastic synthetic fiber is a fiber selected from the group consisting of polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and polyurethane. cloth. The method of claim 1 or 2,
Direct product, anti-pilling cloth. The method of claim 3,
An anti-pilling cloth having anti-pilling grades of class 3 or higher according to JIS L 1930 C4M method (using tumble) 10 times and 30 times after JIS L 1076 A method (using an ICI type tester). The following process:
A process of weaving or knitting or fabricating a fabric having a fluff or short fiber fluff at the cut end of the long fiber yarn by using a spun yarn comprising long fiber yarns and / or short fibers of a thermoplastic synthetic fiber as a yarn;
A step of burning at least one surface of the obtained fabric to form a melt bundle at the cut end or the short fiber end of the long fiber yarn; And
A step of forming abrasive marks by rubbing the cut ends of the long fiber yarns formed on one surface of the obtained fabric or the melted bundles of the fluff tips of the short fibers by polishing;
Method of manufacturing an anti-pilling cloth comprising a. The method of claim 5,
The thermoplastic synthetic fiber is a fiber selected from the group consisting of polyester, polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, and polyurethane. The method of claim 5 or 6,
The method, wherein the anti-pilling cloth is a knitted fabric. The method of claim 7,
The anti-pilling grade of the anti-pilling cloth according to JIS L 1930 C4M method (using tumble), and the anti-pilling grade according to JIS L 1076 A method (method using ICI type tester) after 30 times are all three or more.

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