Classifications

• • 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
  • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
  • D01F2/24—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives
  • D01F2/28—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives from organic cellulose esters or ethers, e.g. cellulose acetate
• • 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
  • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
  • D01F2/24—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from cellulose derivatives
• • 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
  • D06M11/32—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 oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
  • D06M11/36—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 oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
  • D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic Table
  • D06M11/385—Saponification of cellulose-acetate
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2913—Rod, strand, filament or fiber
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2913—Rod, strand, filament or fiber
  • Y10T428/2933—Coated or with bond, impregnation or core
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2913—Rod, strand, filament or fiber
  • Y10T428/2933—Coated or with bond, impregnation or core
  • Y10T428/2964—Artificial fiber or filament
  • Y10T428/2965—Cellulosic

Definitions

• the present invention relates to a novel rayon fiber which possesses characteristics similar to those of a viscose rayon fiber as to be suitable for use in clothes in addition to being produced at economical cost. Also, the present invention is concerned with a method for producing such a rayon fiber.
• rayon fiber is defined as a fiber made of a polymer of ⁇ -D- glucopyranose (hereinafter referred to as "cellulose") in which not more than 15% of the hydroxyl groups have been substituted
• Rayon fibers are used for high quality clothes by virtue of their characteristic gloss, specific gravity, and good sense to the touch.
• viscose rayon hereinafter referred to as "rayon"
• rayon fibers are made by spinning, in an aqueous solution of sulfuric acid and zinc sulfate, an aqueous sodium cellulose xanthate solution which is prepared by dissolving cellulose in a caustic soda solution using carbon disulfide (CS 2 ) •
• CS 2 carbon disulfide
• Lyocell fibers which are spun from a solution of cellulose in N-methylmorpholine-N-oxide, have not been processed into textile products owing to their excessive stiffness and expensive cost until a recent success of enzymatic processing.
• Fortisan a high tenacity viscose rayon manufactured by Celanese, is prepared by drawing cellulose acetate and saponifying the drawn cellulose acetate with alkali. With a tenacity as high as 7 gf/de and an elongation as low as 8 %, Fortisan can find numerous applications in the industrial fiber industry, including tire cords, conveyor belts, fire hoses and so on. Methods for preparing rayon from cellulose acetate can be found in Robert, W.
• a rayon fiber possessing a composite crystalline structure of cellulose II and IV, which is prepared by saponifying at least 75% of the total acetyl groups of a cellulose acetate fiber with a degree of substitution of at least 2.0 into hydroxyl groups .
• a method for preparing a rayon fiber comprising the step of treating a cellulose acetate fiber with a strong alkali alone or with a strong and a weak alkali m the same bath or different baths to saponify at least 75% of the total acetyl groups of the cellulose acetate fiber into hydroxyl groups, said cellulose acetate fiber having a degree of substitution of 2.0 or higher, whereby the rayon fiber has a composite crystalline structure of cellulose II and IV.
• a method for preparing a rayon fiber comprising the step of treating a fiber material comprising cellulose acetate fibers alone or in combination with other fibers with a strong alkali alone or with a strong and a weak alkali in the same bath or different baths to saponify at least 75% of the total acetyl groups of the cellulose acetate fibers into hydroxyl groups, said fiber material being selected from a woven fabric, knitted fabric and a non-woven fabric, which are made by weaving, knitting or niddle punching cellulose acetate fibers alone or in combination with other fibers, said cellulose acetate fibers having a degree of substitution of 2.0 or higher, whereby the rayon fiber has a composite crystalline structure of cellulose II and IV.
• a method for producing a rayon film comprising the step of treating a cellulose acetate film with a strong alkali alone or with a strong and a weak alkali m the same bath or different baths to saponify at least 75% of the total acetyl groups of the cellulose acetate film into hydroxyl groups, said cellulose acetate film having a degree of substitution of 2.0 or higher in degree of substitution, whereby the rayon film has a composite crystalline structure of cellulose II and IV.
• a rayon fiber product comprising a rayon fiber which possesses a composite crystalline structure of cellulose II and IV and is prepared by saponifying at least 75% of the total acetyl groups of a cellulose acetate fiber with a degree of substitution of 2.0 or higher into hydroxyl groups.
• a rayon film which is prepared from a cellulose acetate film with a degree of substitution of 2.0 or higher by saponifying at least 75 % of the total acetyl groups of the film into hydroxyl groups and possesses a composite crystalline structure of cellulose II and IV.
• Fig. 1 shows IR spectra for a viscose rayon fiber (a), a rayon fiber with a weight loss of 40.1 % (b) , a rayon fiber with a weight loss of 33.7 % (c) , and a cellulose acetate fiber which was not allowed to undergo weight loss (d) .
• Fig. 2 shows X-ray diffraction spectra for a viscose rayon fiber (a), a rayon fiber with a weight loss of 40.1 % (b) , a rayon fiber with a weight loss of 33.7 % (c) , and a cellulose acetate fiber which was not allowed to undergo weight loss (d) .
• the present invention contemplates a rayon fiber which is featured in that a cellulose acetate fiber with a degree of substitution of 2.0 (combined acetic acid 45%) or greater is saponified at 75 % or greater of its total acetyl groups into hydroxyl groups and shows a composite crystalline structure of cellulose II and cellulose IV.
• rayon fibers such as viscose rayon, cupra ammonium rayon, Bemberg rayon, high tenacity rayon, and Fortisan, have a crystalline structure of cellulose II in the crystalline region (see: P. H. Hermans, Makromolecules, Chem., Vol. 6, pp 25- 29; J. Dyer and G. C. Daul, Handbook of Fiber Science and Technology, Vol. IV; edited by M. Lewin and E. M. Pearce; Fiber Chemistry, p 968, Marcel Dekker 1985) .
• the rayon fiber of the present invention shows a cellulose II and a cellulose IV crystalline structure together at the crystalline region.
• 75 % or greater of the total acetyl groups of cellulose acetate must be saponified into hydroxy; otherwise, it is not defined as rayon.
• the rayon fiber of the present invention Compared with a cellulose acetate fiber, that is, its source, the rayon fiber of the present invention has an increased breaking strength, a similar or higher breaking elongation, and a decreased birefringence, but increased in crystallinity, specific gravity and moisture regain.
• the rayon fiber of the present invention is found to range, in crystallinity, from 14 to 34 % and, in birefringence, from 0.012 to 0.024.
• the rayon fiber of the present invention is increased to 1.48-1.51 gm/cm 3 , similar to that of a viscose rayon fiber and higher than that of a cellulose acetate fiber, which is in the range of 1.32 (cellulose diacetate) -1.33 gm/cm 3 (cellulose triacetate) .
• the rayon fiber of the present invention shows a breaking strength of 1.2-2.5 gf/de and a breaking elongation of 20- 50 % .
• the breaking strength and breaking elongation of the rayon fiber of the present invention are found to be similar to those of preexisting viscose rayon.
• the rayon fiber of the present invention is similar to preexisting viscose rayon in mechanical properties, such as strength and elongation, m physical properties, such as gravity, crystallinity and orientation degree, m dissolution property against organic solvent, and in moisture regain, the rayon fiber of the present invention can be applied for the same uses of the preexisting viscose rayon.
• the rayon fiber of the present invention shows superb dyeing properties as high as those of mercerized cotton or viscose rayon.
• the rayon fiber of the present invention is dissolved in organic solvent for cellulose, such as N-methylmorpholm-N-oxide, lithium chloride/dimethylacetam de, and cadoxene .
• Material suitable for the rayon fiber of the present invention are cellulose acetate fibers which have a degree of substitution of 2.0 (combined acetic acid 45 %) or greater and preferably a degree of substitution of 2.0-3.0 (combined acetic acid 45-62.5 %) .
• a diacetate fiber with a degree of substitution from 2.0 to 2.75 (combined acetic acid 45 to 59.5 %) , a triacetate fiber w th a degree of substitution of 2.75 or greater (combined acetic acid 59.5 % or greater), or a mixture thereof may be used.
• a detailed description will be given of the preparation of the rayon fiber of the present invention with reference to various examples, which is set forth to illustrate, but not limit the present invention.
• the rayon fiber of the present invention can be prepared through a saponification process in which an appropriate cellulose acetate fiber is treated with a strong alkali alone and with a strong and a weak alkali in a same bath manner or a different bath manner.
• woven fabrics, knitted or non-woven fabrics made by weaving or knitting cellulose acetate fibers alone or in combination with other fibers may be subject to a saponification process comprising treatment with a strong alkali alone and with a strong and a weak alkali in a same bath or different baths.
• a cellulose acetate film may be used as a material for the rayon film of the present invention. That is, a cellulose acetate film is saponified by being treated with a strong alkali alone or a strong and a weak alkali in the same bath or in different baths.
• a quaternary ammonium salt or a phosphonium salt may be used along with alkali.
• the saponification process is preferably conducted at 80 °C.
• alkali metal hydroxides such as sodium hydroxide
• alkaline earth metal hydroxides such as calcium hydroxide
• alkali metal salts such as sodium carbonate.
• Such an alkali compound may be used alone or in combination with a saponification accelerators.
• a commercially available saponification accelerator is exemplified by NEORATE NCB (Korea Fine Chemicals Co. Ltd.) as a phosphonium salt prompter; and KF NEORATE NA-40 (Korea Fine Chemicals Co. Ltd.), DYK-1125 and DXY-10N (Iposya) , CASERIN PES, CASERIN PEL and CASERIN PEF (Meisei Kagaku Co.
• an alkali is dissolved at an amount of 10-60 % by weight based on the total weight of cellulose acetate in water.
• the saponification can be achieved by immersing cellulose acetate in the aqueous alkaline solution at 70-130 °C and preferably at 80 °C. This saponification procedure is preferably, but not limitatively, conducted for 1-60 mm once or twice in the aqueous alkaline solution.
• cellulose IV crystalline structure in the crystalline region of the rayon fiber of the present invention.
• cellulose II and III crystals are treated at 250-
• molecular chains of cellulose acetate are altered into those of cellulose while the molecular chains undergo the rearrangement of folding and packing so as for crystallization to occur.
• the birefringence which indicates the orientation degree of the molecular chain, is lowered with a prevalence of a crystal region.
• the method of producing a rayon fiber in which a cellulose II crystalline structure coexists with a cellulose IV crystalline structure enjoys advantages of being very simple and low in production cost. Unlike conventional production methods of viscose rayon which use highly concentrated alkali solutions, carbon disulfide and sulfuric acid, the method according to the present invention does not produce serious pollutants, and is not a complicated process.
• the method of the present invention can employ various cellulose acetate fibers or products to produce rayon in an environment-friendly and simple process .
• a rayon film is prepared from a cellulose acetate film with a degree of substitution of 2.0 or higher by saponifying 75% or greater of the total acetyl groups of the cellulose acetate film into hydroxyl groups.
• the rayon film of the present invention has a composite crystalline structure of cellulose II and IV.
• the rayon film can be prepared in a similar manner to that for the rayon fiber.
• a cellulose acetate with a substitution of 2.0 or higher is treated with a strong alkali alone or with a strong alkali and a weak alkali in a same bath or different baths to saponify 75 % or greater of the total acetyl groups of the cellulose acetate into hydroxyl groups and produce a composite crystalline structure of cellulose II and IV.
• Weight loss a sample was measured for its weight change before and after an alkali treatment and calculated through the following equation:
• Deacetylation identified by IR spectroscopic analysis using an IR spectrophotometer, such as that manufactured by Nicolet, USA, identified as MAGNA 750. For its quantitative determination, the C- O stretching peak of ⁇ -D-glucopyranose, which was read at 1160 cm “1 , and the carbonyl band of acetyl groups, which was read at 1760 cm “1 , were calculated by integration and the ratio between them was obtained.
• Crystalline Structure identified using a CuK ⁇ line filtered through a nickel filter with the aid of an X-ray diffractometer, such as that manufactured by Mac Science, Japan, identified as M18XHF.
• p is a density of a sample
• p c is a density of a crystalline region (1.615)
• p a is a density of an amorphous region (1.436) .
• Breaking Strength and Breaking Elongation of Fiber measured by a universal testing machine (ZWICK 1425) while a sample 50 mm long was stretched at a tension speed of 200 mm/mm.
• Birefringence of Fiber ( ⁇ n) calculated from the refractive indexes of polarized lights which vibrated in the directions perpendicular and parallel to the axis of a fiber, respectively, were measured with the aid of a polarized microscope, such as that manufactured by Leitz, Germany, identified as VRRIO ORTHOMAT-II.
• Moisture Regain of Fiber measured according to the KS-K 0220 oven method.
• Dyeing Property a sample was dyed at 90 °C for 30 mm with a 1 % o.w.f concentration of C. I. Direct Blue 200 (Nippon Kayaku; Kayarus Supra Blue 4BL) , followed by soaping and rinsing at 70 °C in an ordinary process .
• the dyed sample was measured for reflectance by use of a spectrophotometer, such as that manufactured by Macbeth USA, identified as Color-Eye 7000A) . From the reflectance obtained, the color strength of the dyeing was determined through the following equation
• 75d/20f cellulose diacetate fibers with a degree of substitution of 2.55 (combined acetic acid 56.9 %) was scoured and dried. Separately, water was poured into a dyeing machine and added with caustic soda at an amount of 31.3-40 % by weight based on the weight of the cellulose diacetate fibers. After being immersed in the aqueous caustic solution, the degummed and dried diacetate fibers were heated at a rate of 2 °C/mm from 30 °C to 98 °C, then treated for 30 mm at the dyeing temperature, and cooled at a rate of 2 °C/mm to 30 °C, followed by the drainage of the liquid.
• the fibers were washed with water at room temperature to remove residual alkali and then dried.
• saponification conditions and percent weight loss are summarized in Table 1, below.
• the final weights of the fibers were reduced at a weight loss of 34-40 % compared with the initial ones.
• curve (a) is responsible for the 75d/24f viscose rayon manufactured by Cherkassy, Ukraine, serving as a control.
• the diacetate fiber used as a raw material contains a large quantity of carbonyl groups which produced the large peak at 1760 cm "1 .
• the carbonyl peak at 1760 cm "1 was greatly reduced in the rayon fiber which showed a weight loss of 34 % as a result of the saponification treatment.
• m the rayon fiber which had a weight loss of 40 %, the carbonyl peaks completely disappeared.
• the hydroxy stretching peak at 3400 cm 1 intensified w th increasing weight loss.
• Curve (b) shows the same spectral pattern as Curve (a) as almost all of the acetyl groups are substituted with hydroxyl groups.
• Fig. 2 With reference to Fig. 2, there are shown X-ray diffraction spectra of the fibers prepared above.
• a 75d/24f viscose rayon fiber manufactured by Cherkassy was used as a control and its X-ray diffraction spectrum is given as curve (a) .
• Analysis of crystalline structures from the X-ray spectra was referred to ⁇ . Ellefsen, J. Polymer Science Vol. 58, pp 769-779, 1962. No developed crystal components are detected in the cellulose disacetate, curve (d) which was not reduced in weight.
• the control fiber shows a crystalline structure of cellulose II.
• the rayon fiber, (b) which was reduced to the weight loss of 40.1 % shows a crystalline structure of cellulose II as Bragg angles (2 ⁇ ) appear at 12.4°, 22.2° and 40.7° as well as a very developed crystalline structure of cellulose IV as great Bragg angles (2 ⁇ ) appear at 16.1°, 20.7°, 28.3° and 36.5°. Therefore, the rayon fiber of curve (b) has a composite crystalline structure of cellulose II and IV.
• a plain fabric (warp 75d/20f, weft SB 120d/33f, weft density 67 yarns/inch) consisting of triacetate fiber with a degree of substitution of 2.92 (combined acetic acid 61.5 %) was immersed in an aqueous solution which contained caustic soda at an amount of 45-60 % by weight based on the total weight of the triacetate fibers, followed by conducting the treatment procedure of Preparation Example I.
• the detailed amounts of caustic soda used in the saponification and the resulting weight loss percentages are given in Table 3, below. As seen in the data, the triacetate fibers experienced a weight loss of 35-43 %.
• aqueous solution containing soda ash at an amount of 10-30 % by weight based on the total weight of the diacetate fiber was poured into a dyeing machine, and the scoured fabric was immersed.
• the dyeing bath was heated at a rate of 2 "C/min from 30 °C to 98 °C, then treated for 30 mm at the highest temperature, and then cooled down to 30 °C at a rate of 2 °C/mm, followed by the drainage of the aqueous solution.
• the fibers were washed with fresh water to complete the primary process of weight reduction. A small amount of the fabric was taken, dried in a drier maintained at 120 °C, and weighed.
• the primarily weight-reduced fabric was subjected to secondary weight reduction process by treatment at 98 °C for 30 mm, washed at room temperature with water to remove residual alkali, and then dried.
• the fabrics were measured for dry weight before and after the treatment and resolved in acetone. Then, the polyester portion, which remained unresolved, was measured for dry weight.
• Plain fabrics consisting of diacetate fibers with a degree of substitution of 2.55 (combined acetic acid 56.9 %) were scoured and dried.
• aqueous solutions containing caustic soda at an amount of 40 % by weight based on the weight of the diacetate fiber were respectively added with one of the following saponification accelerators at a concentration of 2g/l: NEORATE NCB (a phosphonium compound, Korea Fine Chemicals Co. Ltd.); KF NEORATE NA-40 (Korea Fine Co.
• the rayon fiber of the present invention has a composite crystalline structure of cellulose II and IV and possesses characteristics similar to those of a viscose rayon fiber as to be suitable for use m clothes. Also, the method according to the present invention is simple and produces the rayon fiber at low cost without producing pollution of the environment.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)
• Artificial Filaments (AREA)
• Woven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Manufacture Of Macromolecular Shaped Articles (AREA)

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• 2000
  • 2000-03-27 KR KR10-2000-0015443A patent/KR100471004B1/ko not_active Expired - Lifetime
  • 2000-11-07 US US09/706,721 patent/US6361862B1/en not_active Expired - Lifetime
  • 2000-11-09 AU AU2001215582A patent/AU2001215582A1/en not_active Abandoned
  • 2000-11-09 WO PCT/KR2000/001280 patent/WO2001073172A1/en not_active Ceased
  • 2000-11-09 CN CNB008193797A patent/CN1188553C/zh not_active Expired - Lifetime
  • 2000-11-09 JP JP2001570879A patent/JP2003528993A/ja active Pending
  • 2000-11-09 EP EP00978089A patent/EP1272694A4/en not_active Withdrawn
• 2002
  • 2002-01-11 US US10/042,243 patent/US6802869B2/en not_active Expired - Lifetime
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