TWI617432B - Method for preparing foamed fabric - Google Patents

Method for preparing foamed fabric Download PDF

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Publication number
TWI617432B
TWI617432B TW106112004A TW106112004A TWI617432B TW I617432 B TWI617432 B TW I617432B TW 106112004 A TW106112004 A TW 106112004A TW 106112004 A TW106112004 A TW 106112004A TW I617432 B TWI617432 B TW I617432B
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Taiwan
Prior art keywords
fabric
foamed
supercritical fluid
foamable
yarn
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TW106112004A
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English (en)
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TW201836832A (zh
Inventor
yi-song Su
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Li Cheng Enterprise Co Ltd
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Priority to TW106112004A priority Critical patent/TWI617432B/zh
Priority to US15/646,670 priority patent/US20180290348A1/en
Application granted granted Critical
Publication of TWI617432B publication Critical patent/TWI617432B/zh
Publication of TW201836832A publication Critical patent/TW201836832A/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3403—Foaming under special conditions, e.g. in sub-atmospheric pressure, in or on a liquid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/35—Component parts; Details or accessories
    • B29C44/355—Characteristics of the foam, e.g. having particular surface properties or structure
    • B29C44/358—Foamed of foamable fibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/08—Addition of substances to the spinning solution or to the melt for forming hollow filaments
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
    • D06M11/76—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon oxides or carbonates
    • D—TEXTILES; PAPER
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    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M7/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made of other substances with subsequent freeing of the treated goods from the treating medium, e.g. swelling, e.g. polyolefins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8214—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing ester and amide groups
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/20—Physical treatments affecting dyeing, e.g. ultrasonic or electric
    • D06P5/2044—Textile treatments at a pression higher than 1 atm
    • D06P5/2055—Textile treatments at a pression higher than 1 atm during dyeing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P7/00—Dyeing or printing processes combined with mechanical treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C44/3446—Feeding the blowing agent
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2025/00—Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
    • B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
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    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/04—Polyesters derived from hydroxycarboxylic acids
    • B29K2067/046—PLA, i.e. polylactic acid or polylactide
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    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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    • B29K2081/06—PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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    • B29K2105/25—Solid
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/10—Processes in which the treating agent is dissolved or dispersed in organic solvents; Processes for the recovery of organic solvents thereof
    • D06M23/105—Processes in which the solvent is in a supercritical state
    • D—TEXTILES; PAPER
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    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/0004—General aspects of dyeing
    • D06P1/0016—Dye baths containing a dyeing agent in a special form such as for instance in melted or solid form, as a floating film or gel, spray or aerosol, or atomised dyes
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Abstract

一種發泡織物的製備方法，包含：(a)提供包括至少一編織層的織物，該至少一編織層含有多數條由第一可發泡高分子材料所製成之第一可發泡紗線；(b)使該超臨界流體注入該織物中，獲得經處理織物；(c)使該經處理織物於減壓環境下，以讓該至少一編織層進行預發泡並獲得預發泡織物；(d)將該預發泡織物放置於模具內；及(e)加熱該模具而獲得經塑型發泡織物。本發明方法利用特殊設計的織物及超臨界流體進行發泡塑型，所獲得的經塑型的發泡織物具有立體結構，且可具有多種形狀或顏色變化，更能滿足後續的加工及其他各項應用。

Description

發泡織物的製備方法
本發明是有關於一種發泡織物的製備方法，特別是指一種利用超臨界流體及特殊織物設計的發泡織物的製備方法。
高分子材料於製備及加工期間需要使用大量溶劑或塑化劑，為了符合環保需求，多數運用高分子材料的製程都朝向無溶劑或減少塑化劑用量的方式進行開發，例如，利用超臨界流體來取代溶劑或塑化劑。超臨界流體可運用於高分子聚合、改性、摻合、發泡及染色等製程。
目前超臨界流體最廣泛被使用的製程為鞋材製程，例如美國專利公開案US 2014/0259753 A1就揭示一種發泡一含有熱塑性彈性體之物件的方法，包含：(1) 以一超臨界流體浸漬該物件；(2) 由該超臨界流體移出該物件及(i)在一加熱流體中浸入該物件；或(ii)以紅外線或微波輻射照射該物件，以製造一發泡物件，其中，該物件包含一非極性組分。該非極性組分是用於增加超臨界流體浸入物件的量。上述物件的具體例為鞋中底。
誠如前段說明，目前運用超臨界流體的發泡製程常見於鞋材製作(特別是鞋中底的製作)，尚未被運用於織物製作。在織物的相關製程中，僅有運用超臨界流體進行染色的製程；然，隨著織物的應用領域擴展，除了織物顏色的變化外，織物的形狀也被要求有更多樣的變化，並進而衍生出立體織物的研發。現有立體織物的製作主要是透過紗線編織方式達成，還須再進一步找尋其他製作方法。
因此，本發明之目的，即在提供一種可製備各種不同形狀或顏色變化的立體織物且利於後續加工及應用的發泡織物的製備方法。
於是，本發明發泡織物的製備方法，包含以下步驟： (a) 提供一種包括至少一編織層的織物，該至少一編織層含有多數條由第一可發泡高分子材料所製成之第一可發泡紗線； (b) 使該超臨界流體注入該織物中，獲得經處理織物； (c) 使該經處理織物於減壓環境下，以讓該至少一編織層進行預發泡並獲得預發泡織物； (d) 將該預發泡織物放置於模具內；及 (e) 加熱該模具而獲得經塑型發泡織物。
本發明之功效在於：透過該包括至少一含有多數條第一可發泡紗線之編織層的織物，並搭配超臨界流體進行發泡，可讓所製得的經塑型發泡織物呈現立體結構，且可具有各種不同的形狀或顏色變化，更能滿足後續的加工及其他各項應用。
以下就本發明內容進行詳細說明：
該步驟(a)是提供一種包括至少一編織層的織物，該至少一編織層含有多數條由第一可發泡高分子所製成之第一可發泡紗線。較佳地，於該步驟(a)中，該至少一編織層還含有多數條由第二可發泡高分子材料所製成之第二可發泡紗線，該等第二可發泡紗線是與該等第一可發泡紗線進行編織。更佳地，該第一可發泡高分子材料的發泡能力不同於該第二可發泡高分子材料的發泡能力；又更佳地，該第一可發泡高分子材料的發泡能力高於該第二可發泡高分子材料的發泡能力。該織物的型態可為單層織物或多層織物。該單層織物可透過編織機，將第一可發泡紗線及第二可發泡紗線進行編織而製成。該多層織物例如雙層織物或三層織物；以雙層織物為例，可包括一層由第二可發泡紗線所編織而成的基底層以及一層由第一可發泡紗線及第二可發泡紗線所編織而成的可發泡層。以三層織物為例，可包括一表面層、一中間層及一基底層，上述三層的至少一層是採用第一可發泡紗線及第二可發泡紗線所編織而製得。
該「可發泡紗線」泛指各種可以進行發泡的紗線，且由一種可發泡高分子材料所製成。該可發泡紗線的型態可為芯鞘型(core-sheath type)、中空型(hollow type)或異形斷面型(cross-section type)。該可發泡高分子材料例如但不限於：聚苯乙烯(polystyrene)、聚碳酸酯(polycarbonate)、聚胺基甲酸酯(polyurethane)、丙烯腈-丁二烯-苯乙烯共聚物(acrylonitrile-butadiene-styrene copolymer)、聚亞醯胺(polyimide)、聚醯胺(polyamide)、聚苯硫醚(polyphenylene sulfide)、聚醚碸(polyether sulfone)、聚氯乙烯(polyvinyl chloride)、天然橡膠(natural rubber)、矽酮橡膠(silicone rubber)、腈橡膠(nitrile rubber)、聚丙烯(polypropylene)、聚乙烯(polyethylene)、聚乳酸(polylactic acid)、聚對苯二甲酸乙二酯(polyethylene terephthalate)等，前述材料可單獨一種使用或混合多種使用。
該步驟(b)是使該超臨界流體注入該織物中，獲得經處理織物。該超臨界流體在注入該織物前是透過使流體在高於超臨界壓力及溫度的環境下轉變為超臨界流體，較佳地，該流體為二氧化碳。較佳地，該步驟(b)之超臨界流體是使二氧化碳於加壓及加熱的環境下所形成，當二氧化碳於加壓及加熱環境下，可提高二氧化碳超臨界流體注入該織物的量。特別值得一提的是，上述的加熱環境除了讓二氧化碳更快速轉變為超臨界流體外，也使超臨界流體具有熱能，而能藉此幫助超臨界流體進入該織物中，以增加織物中的超臨界流體注入量。更佳地，該加熱溫度範圍為90~180°C，當加熱溫度低於90°C，將可能導致步驟(c)之發泡不完全的情形更為嚴重，進而可能導致第一可發泡紗線部分發泡及部分呈現透明；當加熱溫度高於180°C時，將可能導致步驟(c)之預發泡織物出現不均勻與塌陷問題。又更佳地，該加熱溫度範圍為90~130°C。
較佳地，於步驟(b)中，該超臨界流體含有分散或溶解於其中的染料，並讓該染料進入該經處理織物中。更佳地，該染料是塗布於一個載體表面，且該表面含有染料的載體是放置於該超臨界流體中。上述的染料塗布方式例如滾輪塗布、靜電塗布、泡沫塗布、噴霧塗布或其他塗布方式等。上述的載體可為任何能吸附染料的薄膜、織物、活性碳、高分子固體等材料。
特別值得一提的是，當該步驟(b)的超臨界流體是於加壓及加熱(90~180°C)環境下所形成且該超臨界流體含有染料時，該具有熱能的超臨界流體將有利於讓染料從載體釋出，使更多量的染料分散或溶解於超臨界流體中，更有助於讓更多量的染料進入該織物中。
較佳地，該步驟(b)的超臨界流體還可含有其他助劑。該助劑例如但不限於成核劑、共溶劑等。該成核劑例如奈米黏土、碳黑等。該共溶劑例如醇類(如甲醇、乙醇、丙醇、異丙醇等)、離子液體等。
該步驟(b)的壓力範圍須高於超臨界流體的臨界壓力(以CO 2為例，須高於7.38 MPa)。較佳地，該步驟(b)的壓力範圍為8~25 MPa。於本發明的具體例中，該壓力為10 MPa。
該步驟(c)是使該經處理織物於減壓環境下，以讓該經處理織物的至少一編織層進行預發泡並獲得預發泡織物。較佳地，該步驟(c)是使該經處理織物迅速減壓至一大氣壓(1 atm，即0.101325 MPa)。
該步驟(d)是將預發泡織物放置於模具內。此模具主要是用於讓預發泡織物進行形狀的微調整，以更符合後續應用需求。
該步驟(e)是加熱該模具而獲得經塑型發泡織物。較佳地，該步驟(e)的加熱溫度範圍為90~180°C。該步驟(e)的加熱可透過微波、紅外線、蒸氣或電熱等方式提供。該步驟(e)的加熱時間可依據實際需要進行調整，較佳地，該加熱時間範圍為20至1500秒。
本發明將就以下實施例作進一步說明，但應瞭解的是，該實施例僅為例示說明之用，而不應被解釋為本發明實施之限制。
[ 實施例 1] 發泡織物的製備(a) 利用編織機，分別取多數條熱塑性聚胺酯(TPU)紗線及多數條聚酯全定向紗線(polyester fully oriented yarn)進行編織，以得到一織物，該織物是由表面層、中間層及基底層所構成。該表面層的重量比例為35%且由熱塑性聚胺酯紗線所組成，該中間層的重量比例為30%且由聚酯全定向紗線所組成，該基底層的重量比例為35%且由聚酯全定向紗線所組成； (b) 使二氧化碳經過高壓計量泵(設定壓力值為10 MPa)及加熱裝置(設定溫度為110°C)而轉變為超臨界流體。將該織物放入超臨界二氧化碳裝置內，並注入該超臨界流體，再將超臨界二氧化碳裝置的溫度控制在110°C，並持續處理120分鐘，以獲得經處理織物(該由多數條熱塑性聚胺酯紗線所製成之表面層的超臨界流體注入量高於該由多數條聚酯全定向紗線所製成之中間層或基底層的超臨界流體注入量)； (c) 將超臨界流體裝置的壓力降低至常壓，使該經處理織物於減壓環境下，以讓該經處理織物的可發泡紗線進行預發泡，以獲得預發泡織物； (d) 將該預發泡織物放置於模具內；及 (e) 加熱該模具而獲得經塑型發泡織物。
[ 實施例 2] 發泡染色織物的製備(a) 利用編織機，分別取多數條熱塑性聚胺酯紗線及多數條聚酯拉伸加工紗線(polyester draw textured yarn)進行編織，以得到一織物，該織物是由表面層、中間層及基底層所構成。該表面層的重量比例為55%且由聚酯拉伸加工紗線所組成，該中間層的重量比例為20%且由熱塑性聚胺酯紗線所組成，該基底層的重量比例為25%且由聚酯拉伸加工紗線所組成； (b) 使二氧化碳經過高壓計量泵(設定壓力值為10 MPa)及加熱裝置(設定溫度為110°C)而轉變為超臨界流體。將該織物放入超臨界二氧化碳裝置內，同時將表面有染料的載體(利用靜電塗布方式將染料塗布於載體上)放入該超臨界流體裝置內；接著再注入該超臨界流體，同時將超臨界二氧化碳裝置的溫度控制在110°C，並持續處理120分鐘，以獲得經處理織物； (c) 將超臨界流體裝置的壓力降低至常壓，使該經處理織物於減壓環境下，以讓該經處理織物的可發泡紗線進行預發泡，獲得預發泡染色織物； (d) 將該預發泡染色織物放置於模具內；及 (e) 加熱該模具而獲得經塑型發泡染色織物。
[ 測試 ]使實施例1所獲得的經塑型發泡織物及實施例2所獲得的經塑型發泡染色織物進行泡孔密度及直徑測試。另外，再將實施例2所獲得的經塑型發泡染色織物進行以下的色牢度相關測試。測試結果整理於表1中。 1. 泡孔密度(cell density，cells/cm 3)：利用掃描式電子顯微鏡進行觀察及量測。 2. 泡孔直徑(cell diameter，mm)：利用掃描式電子顯微鏡進行觀察及量測。 3. 色牢度相關測試： (1) 耐汗染色堅牢度 (Color Fastness To Perspiration)：依據ISO 105 E04標準方法進行測試。目前業界可接受的耐汗染色堅牢度為3級。 (2) 耐水洗染色堅牢度(Color Fastness To Water)：依據ISO 105 E01標準方法進行測試。目前業界可接受的耐水洗染色堅牢度為3級。 (3) 耐溶劑染色堅牢度(Color Fastness To Organic Solvents)：依據ISO 105 X05標準方法進行測試。目前業界可接受的耐溶劑染色堅牢度為3級。 (4) 耐洗衣粉染色堅牢度(Color Fastness To Washing)：依據ISO 105 C06標準方法進行測試。目前業界可接受的耐洗衣粉染色堅牢度為3級。 (5) 耐黃變測試(Color Fastness To QUV)：依據ISO 105 E01標準方法進行測試。目前業界可接受的耐黃變測試為3級。 (6) 耐酚變褪色測試(Phenolic Yellowing)：依據ISO 105 X18標準方法進行測試。目前業界可接受的耐酚變褪色測試為3級。
表1 <TABLE border="1" borderColor="#000000" width="85%"><TBODY><tr><td> </td><td> </td><td> 實施例1 </td><td> 實施例2 </td></tr><tr><td> 發泡紗線 </td><td> 泡孔密度(×10<sup>7</sup> cells/cm<sup>3</sup>) </td><td> 2.52 </td><td> 50 </td></tr><tr><td> 泡孔直徑(mm) </td><td> 35.5 </td><td> 35.7 </td></tr><tr><td> 色牢度相關測試 </td><td> 耐汗染色堅牢度 </td><td> - </td><td> 3級 </td></tr><tr><td> 耐水洗染色堅牢度 </td><td> - </td><td> 3級 </td></tr><tr><td> 耐溶劑染色堅牢度 </td><td> - </td><td> 3級 </td></tr><tr><td> 耐洗衣粉染色堅牢度 </td><td> - </td><td> 3級 </td></tr><tr><td> 耐黃變測試 </td><td> - </td><td> 3級 </td></tr><tr><td> 耐酚變褪色測試 </td><td> - </td><td> 3級 </td></tr></TBODY></TABLE>
由表1的結果，證實本發明發泡織物的製備方法可製得符合產業利用的經塑型發泡織物或經塑型發泡染色織物。
綜上所述，本發明發泡織物的製備方法透過使用特殊包括至少一含有多數條第一可發泡紗線之編織層的織物，並搭配超臨界流體進行發泡，可讓所製得的經塑型發泡織物呈現立體結構，並可具有各種不同的形狀或顏色變化，更能滿足後續的加工及其他各項應用，故確實能達成本發明之目的。
惟以上所述者，僅為本發明之實施例而已，當不能以此限定本發明實施之範圍，凡是依本發明申請專利範圍及專利說明書內容所作之簡單的等效變化與修飾，皆仍屬本發明專利涵蓋之範圍內。

Claims (8)

  1. 一種發泡織物的製備方法，包含以下步驟：(a)提供一種包括至少一編織層的織物，該至少一編織層含有多數條由第一可發泡高分子材料所製成之第一可發泡紗線；(b)使超臨界流體注入該織物中，獲得經處理織物；(c)使該經處理織物於減壓環境下，以讓該至少一編織層進行預發泡並獲得預發泡織物；(d)將該預發泡織物放置於模具內；及(e)加熱該模具而獲得經塑型發泡織物。
  2. 如請求項1所述的發泡織物的製備方法，其中，該步驟(b)之超臨界流體是使二氧化碳於加壓及加熱的環境下所形成，其中，該加熱溫度範圍為90~180℃。
  3. 如請求項1所述的發泡織物的製備方法，其中，於該步驟(b)中，該超臨界流體含有分散或溶解於其中的染料，並讓該染料進入該經處理織物中。
  4. 如請求項3所述的發泡織物的製備方法，其中，該染料是塗佈於一個載體表面，且該表面含有染料的載體是放置於該超臨界流體中。
  5. 如請求項1所述的發泡織物的製備方法，其中，於該步驟(a)中，該至少一編織層還含有多數條由第二可發泡高分子材料所製成的第二可發泡紗線，該等第二可發泡紗線是與該等第一可發泡紗線進行編織。
  6. 如請求項5所述的發泡織物的製備方法，其中，該第一可發泡高分子材料的發泡能力不同於該第二可發泡高分子材料的發泡能力。
  7. 如請求項2所述的發泡織物的製備方法，其中，該步驟(b)的壓力範圍為8~25MPa。
  8. 如請求項1所述的發泡織物的製備方法，其中，該步驟(e)的加熱溫度範圍為90~180℃。
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