WO2013099618A1 - 複合繊維、人工皮革用基体および人工皮革 - Google Patents
複合繊維、人工皮革用基体および人工皮革 Download PDFInfo
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- WO2013099618A1 WO2013099618A1 PCT/JP2012/082286 JP2012082286W WO2013099618A1 WO 2013099618 A1 WO2013099618 A1 WO 2013099618A1 JP 2012082286 W JP2012082286 W JP 2012082286W WO 2013099618 A1 WO2013099618 A1 WO 2013099618A1
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- artificial leather
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- polyester
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- 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
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/4383—Composite fibres sea-island
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43838—Ultrafine fibres, e.g. microfibres
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
- D06N3/0036—Polyester fibres
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/121—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds
- D06N3/123—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds with polyesters
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/12—Decorative or sun protection articles
- D06N2211/28—Artificial leather
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- 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
- Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
- Y10T428/2924—Composite
-
- 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
- Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
Definitions
- the present invention relates to a composite fiber suitable for producing an artificial leather comprising an artificial leather substrate having high density and quality, an artificial leather substrate and an artificial leather.
- the physical properties such as the quality and wear characteristics of artificial leather tend to be better as the fiber density of the non-woven fabric sheet constituting the artificial leather substrate is higher and denser. Therefore, as a base for artificial leather, it is generally required to make a high-entangled and high-density sheet.
- the polyester fiber used in the above-mentioned conventional technology using a copolymer polyester sea component has a lower fiber rigidity than a polymer typified by polystyrene or the like, the thickness direction at the initial stage of needle punching
- the thickness direction at the initial stage of needle punching there is a problem that it is difficult to increase the density, because it is difficult to increase the entanglement efficiency.
- an object of the present invention is to provide a composite fiber suitable for obtaining artificial leather made of a base for artificial leather having high entanglement efficiency in needle punching in view of the above-mentioned problems of the prior art.
- Another object of the present invention is to provide a base for artificial leather and artificial leather having high density and quality using the above-mentioned composite fiber.
- the present invention is to solve the above problems, and the conjugate fiber of the present invention is a conjugate fiber composed of a polyester-based elution component and a hardly-elution component, and the polyester-based elution component is 5 -A composite fiber comprising polyalkylene glycol in a copolyester obtained by copolymerizing 5 to 10 mol% of sodium sulfoisophthalic acid.
- the polyalkylene glycol is blended in a copolyester.
- the polyalkylene glycol is polyethylene glycol.
- the polyalkylene glycol is present in a streak shape extending in the longitudinal direction of the fiber in the longitudinal section of the conjugate fiber.
- the length of the polyalkylene glycol existing in a streaky shape extending in the longitudinal direction of the fiber in the conjugate fiber is 15 ⁇ m or more.
- the conjugate fiber is subjected to buckling crimp, and a crack and / or a crack exists in the buckled portion.
- the shrinkage rate of the conjugate fiber at 98 ° C. is in the range of 10 to 40%.
- a base for artificial leather can be manufactured using a composite fiber obtained by buckling and crimping the composite fiber, and an artificial leather can be manufactured using the base for artificial leather. it can.
- the method for producing a conjugate fiber of the present invention is a method for producing a conjugate fiber composed of a polyester-based easily-eluting component and a hardly-eluting component, and 5 to 10 mol% of 5-sodium sulfoisophthalic acid is copolymerized during melt spinning.
- a method for producing a composite fiber, comprising adding a polyalkylene glycol to a copolymerized polyester and spinning the resulting polyester.
- an artificial leather having a high surface quality and a high wear resistance can be obtained, which is composed of a base for artificial leather having high crimp retention, high entanglement and high density.
- FIG. 1 is a drawing-substituting photograph showing that polyalkylene glycol is present in the shape of a stripe extending in the longitudinal direction of the fiber in the composite fiber of the present invention.
- FIG. 2 is a drawing-substituting photograph showing the presence of cracks in the buckled portion of the conjugate fiber of the present invention.
- the composite fiber of the present invention is a composite fiber composed of a polyester-based easily eluting component and a hardly-eluting component, and the polyester-based easily eluting component is a copolymer obtained by copolymerizing 5-10 mol% of 5-sodium sulfoisophthalic acid. It is important that the polymerized polyester comprises a polyalkylene glycol.
- polyalkylene glycol contained in the polyester-based elution component constituting the conjugate fiber of the present invention examples include polyethylene glycol, polypropylene glycol, and polybutylene glycol. From the viewpoint of ease of use and weight loss to alkali, etc. Polyethylene glycol is preferably used.
- the composite fiber of the present invention is a composite fiber composed of a polyester-based easily eluting component and a hardly-eluting component, and the polyester-based easily eluting component is a copolymer obtained by copolymerizing 5-10 mol% of 5-sodium sulfoisophthalic acid. It is preferable that polyalkylene glycol is contained in the polymerized polyester, and the polyalkylene glycol is present in a streak shape extending in the longitudinal direction of the fiber in the longitudinal section of the composite fiber.
- the 5-sodium isophthalic acid component which is a copolymerization component
- the proportion of the copolymerization component is preferably in the range of 6 to 9 mol%.
- the fiber can be easily broken and fixed by heat.
- a 5-sodium isophthalic acid component as a copolymerization component in an amount of 10 mol% or less, an increase in melt viscosity can be suppressed and yarn breakage during composite fiber spinning is less likely to occur.
- the number average molecular weight of the polyalkylene glycol used in the present invention is preferably in the range of 5,000 to 50,000.
- the number average molecular weight is more preferably in the range of 10,000 to 30,000.
- the content of polyalkylene glycol in the polyester-based easily eluting component is preferably in the range of 1 to 10% by mass, more preferably in the range of 2 to 8% by mass.
- the content of the polyalkylene glycol is preferably in the range of 1 to 10% by mass, more preferably in the range of 2 to 8% by mass.
- polyalkylene glycol is present in a streak shape extending in the longitudinal direction of the fiber in the longitudinal section of the composite fiber.
- the sea component which is a polyester-based elution component of the composite fiber
- the polyalkylene glycol exists in a streak shape extending in the longitudinal direction of the fiber, so that when the composite fiber is buckled and crimped, Cracks and / or cracks are likely to occur, and the crimp retention characteristics are improved by fixing the cracks and / or cracks in the cracked portions.
- the crimp retention property can be confirmed by, for example, the compression recovery rate of the fiber web.
- the length of the streaky polyalkylene glycol in the longitudinal direction of the fiber is 10 ⁇ m or more.
- the presence of a polyalkylene glycol having a length of 10 ⁇ m or more, more preferably 15 ⁇ m or more, and more preferably 20 ⁇ m or more, extending in the longitudinal direction of the fiber in the longitudinal direction effectively causes cracking when buckling crimp is imparted. It becomes easy.
- the length of the streaky polyalkylene glycol is preferably 200 ⁇ m or less, more preferably 180 ⁇ m or less, and even more preferably 160 ⁇ m or less, cracks other than when crimping is applied, such as during spinning or needle punching. It becomes difficult to occur.
- the state existing in the form of a stripe extending in the longitudinal direction of the fiber refers to a state in which a ring is not formed. Specifically, both ends of one polyalkylene glycol chain are in contact with each other. It is preferable that the difference between the linear distance connecting both ends and the actually measured alkylene chain length is within 20% (if the line is a perfect straight line, the difference is 0%).
- FIG. 1 is a drawing-substituting photograph showing that polyalkylene glycol is present in the form of streaks extending in the longitudinal direction of the fiber in the conjugate fiber of the present invention
- FIG. 2 is a buckled portion of the conjugate fiber of the present invention
- FIG. 3 is a drawing substitute photograph showing that a crack exists in FIG.
- the maximum length of cracks and / or cracks is preferably 10 ⁇ m or more, more preferably 15 ⁇ m or more.
- the number of bucklings is preferably 5 to 30 per 2.52 cm, more preferably 10 to 25.
- the shape (angle) of the buckling portion is preferably an acute angle, but specifically, the buckling portion is preferably 120 ° or less, more preferably 90 ° or less.
- the angle of the buckling portion is preferably 20 ° or more because sufficient crimp retention characteristics cannot be obtained if the angle is too acute.
- the ratio of the polyester-based easily eluting component and the hardly eluting component constituting the conjugate fiber of the present invention is preferably 0.2 to 0.8, more preferably 0.8 by mass ratio of the hardly eluting component to the conjugate fiber. 3 to 0.7.
- the mass ratio of the difficult-to-elute component to the composite fiber is 0.2 or more, the removal rate of the polyester-based easily eluting component is reduced and the productivity is improved.
- the fiber-opening property of the fiber which consists of a difficult-to-elute component is improved by making mass ratio with respect to the composite fiber of a difficult-to-elute component 0.8 or less, and the joining of a difficultly-eluting component can be prevented.
- polyester-based elution component constituting the composite fiber of the present invention
- one component contains polyethylene terephthalate-based polyester mainly composed of ethylene terephthalate units, and a part of the terephthalic acid component is included in other components. It may be a polyester substituted with a bifunctional carboxylic acid component. Similarly, a polyester in which a part of the ethylene glycol component is replaced with another polyol component may be used.
- bifunctional carboxylic acid other than terephthalic acid used in the present invention examples include aromatics such as isophthalic acid, naphthalene dicarboxylic acid, diphenyldicarboxylic acid, adipic acid, sebacic acid, and 1,4-cyclohexanedicarboxylic acid, Aliphatic and alicyclic bifunctional carboxylic acids are preferably used.
- polyol compounds other than ethylene glycol include aliphatic, alicyclic, and aromatic such as tetramethylene glycol, hexamethylene glycol, cyclohexane-1,4-dimethanol, neopentyl glycol, bisphenol A, and bisphenol S. Group polyol compounds are preferably used.
- examples of the hardly eluting component constituting the composite fiber of the present invention include the above-mentioned polyester, polyamide, polyolefin, polyphenylene sulfide and the like.
- Polycondensation polymers typified by polyesters and polyamides are often used in the present invention because they have a high melting point and exhibit good performance when used, for example, in artificial leather.
- Specific examples of the polyester include polyethylene terephthalate, polybutylene terephthalate, and potytrimethylene terephthalate.
- Specific examples of the polyamide include nylon 6, nylon 66, nylon 12, and the like.
- conjugate fiber of the present invention As the conjugate fiber of the present invention, according to Japanese Patent Publication No. 48-2216, etc., a large number of difficult-to-elute components continuously arranged in the fiber axis direction gathered together to form a single fiber.
- the single fiber fineness of the composite fiber of the present invention is preferably in the range of 2 to 10 dtex, more preferably in the range of 3 to 9 dtex, from the viewpoint of entanglement such as a needle punching process.
- sea-island type composite fiber or mixed spun fiber can be preferably used from the viewpoint of luxury, quality and touch when used for artificial leather.
- the average single fiber diameter of the ultrafine fiber obtained from the composite fiber is preferably in the range of 0.1 to 10 ⁇ m.
- the average single fiber diameter is preferably 10 ⁇ m or less, preferably 5 ⁇ m or less, for example, when a suede-like artificial leather is used, a good touch can be obtained.
- the average single fiber diameter is 0.1 ⁇ m or more, preferably 0.5 ⁇ m or more, excellent fiber strength and rigidity can be maintained.
- polyester-based easily eluting and difficultly eluting components (polymers) constituting the composite fiber used in the present invention additives such as particles, flame retardants and antistatic agents may be added.
- the conjugate fiber of the present invention may be buckled.
- the crimp retention coefficient of the composite fiber to which buckling crimp is imparted is preferably 3.5 to 10, more preferably 4 to 10.
- the crimp retention coefficient is 3.5 or more, the rigidity in the thickness direction of the nonwoven fabric is improved when the nonwoven fabric is formed, and it is possible to maintain the entanglement in the entanglement process such as needle punching. Further, by setting the crimp retention coefficient to 10 or less, the fiber web is excellent in carding in carding without excessive crimping.
- the composite fiber of the present invention preferably has a shrinkage rate at 98 ° C. of 10 to 40%, more preferably 12 to 35%.
- the shrinkage rate is measured by first applying a load of 50 mg / dtex to a bundle of composite fibers and marking 30.0 cm (L 0 ). Then, it is treated with hot water at 98 ° C. for 10 minutes, the length (L 1 ) before and after the treatment is measured, and (L 0 ⁇ L 1 ) / L 0 ⁇ 100 is calculated. The measurement is carried out three times, and the average value is taken as the shrinkage rate.
- a fiber entangled body can be formed using the composite fiber of the present invention.
- the fiber entanglement include woven and knitted fabrics and nonwoven fabrics.
- a nonwoven fabric formed by entanglement of a bundle of ultrafine fibers is preferably used from the viewpoint of surface uniformity and strength.
- An artificial leather substrate is obtained by applying an elastic polymer or the like to the nonwoven fabric obtained in this manner.
- the ultrafine fibers may be somewhat separated from each other or may be partially bonded. And may be agglomerated.
- Nonwoven fabrics include short fiber nonwoven fabrics obtained by forming staple fiber webs using card or cross wrappers and then needle punching or water jet punching, and long fibers obtained from spunbonding or melt-blowing methods.
- a nonwoven fabric, a nonwoven fabric obtained by a papermaking method, and the like can be employed.
- short fiber nonwoven fabrics and spunbond nonwoven fabrics are preferably used because those having good thickness uniformity and the like can be obtained.
- the nonwoven fabric obtained using the conjugate fiber of the present invention has a compression recovery rate of 80 to 100 as measured by JIS L1097 (1982) “Synthetic Fiber Futonwata Test Method” in a state before entanglement treatment such as needle punching. % Is preferred.
- the compression recovery rate is more preferably in the range of 85 to 100%.
- the nonwoven fabric obtained by using the conjugate fiber of the present invention may be laminated with a woven fabric or a knitted fabric for the purpose of improving the strength.
- the yarn of the woven or knitted fabric is a strong twisted yarn in order to prevent damage to the fibers constituting the woven or knitted fabric by the needle punch.
- the number of twists of the yarn constituting the woven or knitted fabric is preferably in the range of 700 T / m to 4500 T / m.
- the fiber diameter of the woven or knitted fabric may be the same as or thinner than the fiber diameter of the ultrafine fiber nonwoven fabric.
- An elastic polymer may be imparted to the nonwoven fabric obtained using the conjugate fiber of the present invention. Not only can the composite fiber be prevented from falling out of the artificial leather due to the binder effect of the elastic polymer, but also an appropriate cushioning property can be imparted.
- Examples of the elastic polymer imparted to the nonwoven fabric obtained using the conjugate fiber of the present invention include polyurethane, polyurea, polyurethane / polyurea elastomer, polyacrylic acid, acrylonitrile / butadiene elastomer, and styrene / butadiene elastomer. From the viewpoint of flexibility and cushioning properties, polyurethane is preferably used.
- polyurethane examples include at least one polymer diol selected from polymer diols such as polyester diol having an average molecular weight of 500 to 3000, polyether diol, polycarbonate diol, or polyester polyether diol, and 4,4′-diphenylmethane.
- polymer diols such as polyester diol having an average molecular weight of 500 to 3000, polyether diol, polycarbonate diol, or polyester polyether diol, and 4,4′-diphenylmethane.
- At least one kind of diisocyanate selected from aromatic diisocyanates such as diisocyanate, alicyclic diisocyanates such as isophorone diisocyanate and aliphatic diisocyanates such as hexamethylene diisocyanate, ethylene glycol, butanediol, ethylenediamine and 4,4 ′ -Polyurethane obtained by reacting at least one low molecular weight compound having two or more active hydrogen atoms such as diaminodiphenylmethane at a predetermined molar ratio and its Modified products thereof.
- aromatic diisocyanates such as diisocyanate
- alicyclic diisocyanates such as isophorone diisocyanate
- aliphatic diisocyanates such as hexamethylene diisocyanate, ethylene glycol, butanediol, ethylenediamine and 4,4 ′ -Polyurethane obtained by reacting at least one low molecular weight compound
- the elastic polymer may contain an elastomer resin such as polyester, polyamide, and polyolefin, an acrylic resin, and an ethylene-vinyl acetate resin.
- an elastomer resin such as polyester, polyamide, and polyolefin, an acrylic resin, and an ethylene-vinyl acetate resin.
- the elastic polymer used in the present invention may include pigments such as carbon black, dye antioxidants, antioxidants, light-proofing agents, antistatic agents, dispersants, softeners, coagulation modifiers, difficulty if necessary.
- Additives such as a flame retardant, an antibacterial agent and a deodorant may be blended.
- the elastic polymer may be either dissolved in an organic solvent or dispersed in water.
- the content of the elastic polymer is preferably 5 to 200% by mass with respect to the nonwoven fabric in which the ultrafine fiber bundles are entangled.
- the surface state, cushioning properties, hardness, strength, etc. of the artificial leather can be adjusted.
- the content is 5% by mass or more, more preferably 20% by mass or more, and still more preferably 30% by mass or more, fiber dropping can be reduced.
- the content is 200% by mass or less, more preferably 100% by mass or less, and still more preferably 80% by mass or less, a state in which ultrafine fibers are uniformly dispersed on the sheet surface can be obtained.
- the basis weight of the base body for artificial leather comprising ultrafine fiber bundles is preferably 100 to 500 g / m 2 .
- the basis weight is preferably 100 g / m 2 or more, more preferably 150 g / m 2 or more, sufficient form stability and dimensional stability can be obtained for the substrate for artificial leather.
- the basis weight is preferably 500 g / m 2 or less, more preferably 300 g / m 2 or less, sufficient flexibility for the artificial leather substrate can be obtained.
- the thickness of the artificial leather substrate of the present invention is preferably 0.1 to 10 mm.
- the thickness is preferably 0.1 mm or more, preferably 0.3 mm or more, sufficient form stability and dimensional stability can be obtained.
- sufficient flexibility can be obtained by setting the thickness to preferably 10 mm or less, more preferably 5 mm or less.
- the substrate for artificial leather of the present invention is preferably subjected to napping treatment on at least one side. By doing in this way, when it is set as suede-like artificial leather, a precise touch is obtained.
- thermoplastic resins having different solubility in a solvent or the like are used for the sea component and the island component, and the sea component is dissolved and removed by using a solvent or the like in a later step.
- sea-island fiber which is an ultrafine fiber
- peelable composite fiber that splits each component into ultrafine fibers by arranging two components of thermoplastic resin alternately in a radial or multilayer fashion on the fiber cross section. can do.
- a process of creating a composite fiber web using the composite fiber of the present invention, and a fiber entanglement (nonwoven fabric) can be obtained by subjecting the composite fiber web to an entanglement treatment. From the obtained non-woven fabric, the polymer of the easily soluble component of the composite fiber is dissolved and removed, or peeled and divided by physical or chemical action to make polyurethane a main component before and / or after raising the fibers.
- a base for artificial leather can be obtained by applying the elastic polymer to the nonwoven fabric, substantially solidifying and solidifying the elastic polymer, and raising the surface to form a napped surface to make the thickness uniform. Further, artificial leather is obtained through a process of finishing by dyeing.
- sea-island type composite fibers that use the sea-island type composite base to spin the sea component and the island component with each other are spun and mixed, and the sea component and the island component are mixed and spun to mix.
- sea-island type composite fibers are particularly preferably used because ultrafine fibers with uniform fineness can be obtained, and because a sufficiently long ultrafine fiber is obtained and contributes to the strength of the base for artificial leather. .
- polyester-based easily-eluting component that is a sea component of sea-island type fibers
- polyalkylene glycol is contained in a copolyester obtained by copolymerizing 5 to 10 mol% of 5-sodium sulfoisophthalic acid.
- 5-sodium sulfoisophthalic acid is preferably added and copolymerized during the polymer polymerization reaction, and polyalkylene glycol is preferably added during spinning.
- the molecular chain of polyalkylene glycol needs to exist in the shape of a stripe extending in the longitudinal direction of the composite fiber (polyester-based elution component). Due to the presence of polyalkylene glycol in the longitudinal direction of the fiber, cracks are easily imparted to the composite fiber surface during buckling crimp, and in addition, the polyalkylene glycol is dissolved and solidified by heat. Is expressed.
- the molecular chain of the polyalkylene glycol has a stable structure, so that it has a round or elliptical structure and is difficult to be deformed into a streak extending in the longitudinal direction during spinning.
- the composite fiber of the present invention is preferably buckled. This is because buckling crimps improve the entanglement between the fibers when a short fiber nonwoven fabric is formed, and enables high density and high entanglement.
- a normal stuffing box type crimper is preferably used, but in order to obtain a preferable crimp retention coefficient in the present invention, the processing fineness, crimper temperature, crimper weight and It is preferable to appropriately adjust the indentation pressure and the like. Of these, the most important is the crimper temperature (temperature at the time of crimping), and the preferred temperature is in the range of 40 to 80 ° C.
- the presence of the polyalkylene glycol, which is an easily eluting polyester-based component, on the surface of the composite fiber makes it easy for the polyalkylene glycol existing portion on the surface of the composite fiber to buckle when crimped.
- the temperature during crimping to 40 ° C. or higher, dissolution of the polyalkylene glycol component and destruction of the fiber surface are likely to occur.
- the temperature at the time of crimping to 80 ° C. or lower, it is possible to prevent the composite fiber from being excessively heat-set and suppressing the shrinkage behavior in the next step.
- the effect appears notably by making the temperature at the time of crimp provision into the said temperature range.
- the dissolution and removal of the sea component of the composite fiber of the present invention may be performed at any stage after the raising treatment, before applying the elastic polymer, when applying the elastic leather substrate.
- a method for obtaining a nonwoven fabric composed of a composite fiber a method in which a fiber web is entangled with a needle punch or a water jet punch, a spun bond method, a melt blow method, and a paper making method can be employed.
- a method that undergoes treatment such as needle punching or water jet punching is preferable.
- the number of needle barbs is preferably 1-9. By using one or more needle barbs, efficient fiber entanglement becomes possible. On the other hand, by making the needle barb preferably 9 or less, fiber damage can be suppressed.
- the number of punching is preferably 1000 to 8000 / cm 2 .
- the number of punchings is preferably 1000 / cm 2 or more, denseness can be obtained and high-precision finishing can be obtained.
- the number of punching is preferably 8000 / cm 2 or less, deterioration of workability, fiber damage, and strength reduction can be prevented.
- the barb direction of the needle of the needle punch at the time of lamination is preferably 90 ⁇ 15 ° which is perpendicular to the traveling direction of the sheet, It becomes difficult to catch easily damaged wefts.
- water jet punching process it is preferable to perform the water in a columnar flow state.
- water is preferably ejected from a nozzle having a diameter of 0.05 to 1.0 mm at a pressure of 1 to 60 MPa.
- the apparent density of the nonwoven fabric composed of the composite fiber after the needle punching process or the water jet punching process is preferably 0.15 to 0.45 g / cm 3 .
- the substrate for artificial leather has sufficient form stability and dimensional stability.
- the apparent density is preferably 0.45 g / cm 3 or less, a sufficient space for applying the elastic polymer can be maintained.
- the ultrafine fiber-generating fiber nonwoven fabric obtained in this way is a preferable embodiment from the viewpoint of densification, shrinking with dry heat or wet heat or both to further increase the density.
- an alkaline aqueous solution such as sodium hydroxide can be used if the sea component is polylactic acid or copolymer polyester.
- the ultrafine fiber generation processing can be performed by immersing a nonwoven fabric made of ultrafine fiber generation type fibers in a solvent and squeezing it.
- ultrafine fiber generation processing known apparatuses such as a continuous dyeing machine, a vibro-washer type seawater removal machine, a liquid dyeing machine, a Wins dyeing machine, and a jigger dyeing machine can be used.
- the ultrafine fiber generation processing may be performed before the napping treatment or after the napping treatment.
- the elastic polymer may be applied before the ultrafine fiber generation processing or after the ultrafine fiber generation processing.
- N, N′-dimethylformamide, dimethyl sulfoxide, or the like is preferably used as a solvent used for imparting polyurethane as an elastic polymer, but a water-dispersed polyurethane liquid in which polyurethane is dispersed as an emulsion in water may be used. .
- the elastic polymer is applied to the non-woven fabric by immersing the non-woven fabric in an elastic polymer solution dissolved in a solvent, and then dried to substantially solidify and solidify the elastic polymer.
- a solvent-based polyurethane solution it can be solidified by immersing it in an insoluble solvent, and in the case of a water-dispersed polyurethane liquid having gelling properties, a dry coagulation method for drying after gelation, etc. Can be solidified. In drying, you may heat at the temperature which does not impair the performance of a nonwoven fabric and an elastic polymer.
- the substrate for artificial leather of the present invention may be raised at least on one side.
- the napping treatment can be performed using sandpaper, a roll sander or the like.
- sandpaper uniform and dense napping can be formed.
- the number of buffs is multi-stage buffing with 3 or more buffs, and the sandpaper count used in each stage is in the range of No. 150 to 600 of JIS regulations. It is.
- the substrate for artificial leather comprising ultrafine fibers obtained from the conjugate fiber of the present invention includes, for example, dyes, pigments, softeners, anti-pilling agents, antibacterial agents, deodorants, water repellents, light proofing agents and weathering agents. It may contain a functional drug.
- the substrate for artificial leather made of ultrafine fibers obtained from the conjugate fiber of the present invention is preferably dyed.
- a liquid dyeing machine is preferably used because it can be softened by adding a stagnation effect simultaneously with dyeing the artificial leather substrate.
- the dyeing temperature is preferably 70 to 120 ° C.
- a disperse dye is preferably used when the hardly-eluting component is polyester. Further, reduction washing may be performed after dyeing.
- finishing treatments such as a softener such as silicone, an antistatic agent, a water repellent, a flame retardant, and a light proofing agent may be performed.
- the finishing treatment may be performed after dyeing in the same bath as dyeing.
- artificial leather can be obtained by dyeing the artificial leather substrate.
- the substrate for artificial leather obtained using the conjugate fiber of the present invention and the artificial leather using the substrate have good quality and are particularly excellent in friction resistance, so that they are used for clothing, miscellaneous goods, CD, DVD. It is suitably used for industrial materials such as curtains, polishing cloths, cleaning tapes and wiping cloths.
- MFR Melt flow rate 4-5 g of sample pellets are placed in a cylinder of an MFR meter electric furnace, and the amount of resin extruded in 10 minutes using a Toyo Seiki melt indexer (S101) under a load of 2160 gf and a temperature of 285 ° C. (g) was measured. The same measurement was repeated 3 times, and the average value was defined as MFR.
- S101 Toyo Seiki melt indexer
- crimping a load of 6 mg / dtex to retention factor composite fiber crimp was imparted to accurately measure the fiber length (30.0 cm), and its length as L 0. Thereafter, weighting was performed, and the fiber length (elongation from 30.0 cm) when the crimp was fully extended was measured.
- -Crimp retention coefficient (W / L-L 0 ) 1/2
- W Crimp extinction load (load when crimp is fully extended: mg / dtex)
- L Fiber length under crimp extinction weight (cm)
- L 0 Fiber length (cm) under 60 mg / dtex. 30.0 cm was marked.
- Example 1 ⁇ Raw cotton> (Island component polymer) Polyethylene terephthalate (PET) having a melting point of 260 ° C. and MFR 46.5 was used.
- PET polyethylene terephthalate
- PET copolymerized PET1 having a melting point of 240 ° C. and 8 mol% of MFR100 sodium 5-sulfoisophthalate was used.
- the film was stretched in two stages in a liquid bath at a temperature of 72 ° C. so that the total magnification was 3.4 times, and crimped at a crimper temperature of 65 ° C. using a stuffing box type crimper.
- the obtained conjugate fiber had a single fiber fineness of 4.5 dtex, a crimp retention coefficient of 5.6, and a shrinkage rate at 98 ° C. of 18.5%.
- This composite fiber was cut into a fiber length of 51 mm to obtain a raw cotton of sea-island type composite fiber.
- polyethylene glycol was present in the form of streaks extending in the longitudinal direction of the fiber, and the maximum length was 27 ⁇ m.
- 10 or more buckled portions with cracks having a length of 15 ⁇ m or more were observed in the buckled portions of the crimps.
- ⁇ Nonwoven fabric> Using the raw cotton, a laminated fiber web was formed through a card and a cross wrapper process. The compression recovery rate of the laminated fiber web before needle punching was 89.0%, and the feeling of rebound was high. Next, using a needle punch machine in which one needle having a total barb depth of 0.075 mm was implanted, needle punching was performed at a needle depth of 7 mm and a number of punches of 4500 / cm 2 , with a basis weight of 805 g / m 2 and an apparent density of 0. A non-woven fabric of 275 g / cm 3 was produced. There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. Also, the longitudinal / lateral elongation ratio was balanced with 0.96.
- the nonwoven fabric was subjected to hot water shrinkage at a temperature of 98 ° C. for 3 minutes and dried at a temperature of 100 ° C. for 5 minutes. Then, the above-mentioned water-dispersed polyurethane liquid is applied to the obtained nonwoven fabric, and hot-air drying is performed at a drying temperature of 125 ° C. for 5 minutes, and the polyurethane adhesion amount is 35% by mass with respect to the island component of the nonwoven fabric. Got.
- the above nonwoven fabric with polyurethane was immersed in a 20 g / L sodium hydroxide aqueous solution heated to 90 ° C. and treated for 30 minutes to dissolve and remove sea components from the sea-island composite fibers. Thereafter, the substrate was cut in the thickness direction by a half-cutting machine having an endless band knife, and the non-half-cut surface was ground in three steps using a JIS # 320 sandpaper to form napped hairs to produce a base for artificial leather.
- the artificial leather substrate was dyed with a disperse dye using a circular dryer to obtain artificial leather.
- the quality of the obtained artificial leather was dense and good.
- the weight loss by abrasion was 2.5 mg and the surface quality was 4.5.
- Table 1 composite fiber
- Table 2 fiber web, nonwoven fabric, artificial leather.
- Example 2 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 89.5% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 811 g / m 2 and an apparent density of 0.278 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.97.
- ⁇ Artificial leather> A base for artificial leather and artificial leather were obtained in the same manner as in Example 1 except that the above nonwoven fabric was used. The quality of the obtained artificial leather was fine and good. The weight loss by abrasion was 2.4 mg and the surface quality was good at 5.0. The results are shown in Tables 1 and 2.
- Example 3 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and a cross wrapper process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 88.0% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 794 g / m 2 and an apparent density of 0.270 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also balanced with 0.95.
- ⁇ Artificial leather> A base for artificial leather and artificial leather were obtained in the same manner as in Example 1 except that the above nonwoven fabric was used. The quality of the obtained artificial leather was fine and good. The weight loss by abrasion was 2.7 mg, and the surface quality was 4.5, which was good. The results are shown in Tables 1 and 2.
- Example 4 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 86.0% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 780 g / m 2 and an apparent density of 0.262 g / cm 3 . Although the dimensional change in the length direction of the sheet at the time of needle punching was slightly large, it was possible to increase the density. The longitudinal / lateral elongation ratio was 0.91.
- Example 5 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- the single fiber fineness is 4.5 dtex and the crimp retention coefficient is 5.5 in the same manner as in Example 1 except that the above sea component polymer and island component polymer are used and the molecular weight of polyethylene glycol is 11,000. 1.
- a composite fiber having a shrinkage rate of 17.9% at 98 ° C. was obtained.
- the obtained conjugate fiber was cut to a fiber length of 51 mm to obtain a sea-island type conjugate fiber raw cotton.
- polyethylene glycol was present in the form of streaks extending in the longitudinal direction of the fiber, and the maximum length was 23 ⁇ m. Further, 10 or more buckled portions with cracks having a length of 15 ⁇ m or more were observed in the buckled portions of the crimps.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high resilience with a compression recovery rate of 87.8% was obtained. The obtained laminated fiber web was subjected to needle punching to obtain a nonwoven fabric having a basis weight of 801 g / m 2 and an apparent density of 0.270 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.94.
- Example 6 ⁇ Raw cotton> (Island component polymer) The same one as used in Example 1 was used.
- PET copolymerized PET2 obtained by copolymerizing 5 mol% of sodium 5-sulfoisophthalate having a melting point of 255 ° C. and MFR 95.0 was used.
- the single fiber fineness is 4.5 dtex, the crimp retention coefficient is 5.5, and the shrinkage rate at 98 ° C. is 18. except that the above sea component polymer and island component polymer are used.
- 3% conjugate fiber was obtained.
- the obtained composite fiber was cut into a fiber length of 51 mm to obtain raw cotton of a sea-island type composite fiber.
- polyethylene glycol was present in the form of streaks extending in the longitudinal direction of the fiber, and the maximum length was 25 ⁇ m. Further, 10 or more buckled portions with cracks having a length of 15 ⁇ m or more were observed in the buckled portions of the crimps.
- ⁇ Artificial leather> A base for artificial leather and artificial leather were obtained in the same manner as in Example 1 except that the above nonwoven fabric was used. The quality of the obtained artificial leather was fine and good. The weight loss by abrasion was 2.8 mg, and the surface quality was 4.5, which was good. The results are shown in Tables 1 and 2.
- Example 7 ⁇ Raw cotton> (Island component polymer) Polypropylene terephthalate having a melting point of 230 ° C. and MFR 52.0 was used.
- Nonwoven fabric> Using the raw cotton, processing was performed in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 87.0% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 789 g / m 2 and an apparent density of 0.269 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.94.
- ⁇ Artificial leather> A base for artificial leather and artificial leather were obtained in the same manner as in Example 1 except that the above nonwoven fabric was used. The quality of the obtained artificial leather was fine and good. The weight loss by abrasion was 3.0 mg and the surface quality was 4.0, which was good. The results are shown in Tables 1 and 2.
- Example 8 ⁇ Raw cotton> (Island component polymer) Nylon 6 having a melting point of 220 ° C. and MFR 58.5 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 86.2% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 802 g / m 2 and an apparent density of 0.272 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.96.
- a substrate for artificial leather was obtained in the same manner as in Example 1 except that the above-mentioned nonwoven fabric was used.
- the condition was that the metal-containing dye was 4.0% owf, the temperature was 60 ° C., the bath ratio was 1: 100, and the pH was 7. And dyed for 120 minutes to obtain artificial leather.
- the quality of the obtained artificial leather was good.
- the weight loss by abrasion was 3.7 mg and the surface quality was 4.0, which was good.
- Example 9 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapper process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 87.4% was obtained. Needle punching was performed on the obtained laminated fiber web to obtain a nonwoven fabric having a basis weight of 803 g / m 2 and an apparent density of 0.274 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.94.
- Example 10 ⁇ Raw cotton> (Island component polymer and sea component polymer) The same one as used in Example 1 was used.
- the polyethylene glycol / polypropylene glycol copolymer was present in the form of streaks extending in the longitudinal direction of the fiber, and the maximum length was 29 ⁇ m. Further, 10 or more buckled portions with cracks having a length of 15 ⁇ m or more were observed in the buckled portions of the crimps.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and cross wrapping process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 88.1% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 800 g / m 2 and an apparent density of 0.273 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was also well balanced with 0.94.
- ⁇ Artificial leather> A base for artificial leather and artificial leather were obtained in the same manner as in Example 1 except that the above nonwoven fabric was used. The quality of the obtained artificial leather was fine and good. The weight loss by abrasion was 2.7 mg, and the surface quality was 4.0, which was good. The results are shown in Tables 1 and 2.
- Example 11 ⁇ Raw cotton> (Island component polymer) The same one as used in Example 1 was used.
- Example 2 Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated web was formed through a card and a cross wrapper process, and a laminated fiber web having a high rebound feeling with a compression recovery rate of 85.1% was obtained. The obtained laminated fiber web was needle punched to obtain a nonwoven fabric having a basis weight of 785 g / m 2 and an apparent density of 0.261 g / cm 3 . There was almost no dimensional change in the length direction of the sheet during needle punching, and high density was possible. The longitudinal / lateral elongation ratio was 0.91, which was inferior to that of Example 1.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and a cross wrapper process, and a laminated fiber web having a low rebound feeling with a compression recovery rate of 82.1% was obtained. Needle punching was performed on the obtained laminated fiber web to obtain a nonwoven fabric having a basis weight of 763 g / m 2 and an apparent density of 0.251 g / cm 3 . The result was a great elongation of the sheet during needle punching. The longitudinal / lateral elongation ratio was 0.80, which was poorly balanced.
- PET having a melting point of 260 ° C. and MFR 46.5 was used.
- Nonwoven fabric> Using the above raw cotton, processing was carried out in the same manner as in Example 1. A laminated fiber web was formed through a card and a cross wrapper process, and a laminated fiber web having a low rebound feeling with a compression recovery rate of 83.0% was obtained. The obtained laminated fiber web was subjected to needle punching to obtain a nonwoven fabric having a basis weight of 765 g / m 2 and an apparent density of 0.250 g / cm 3 . The result was a great elongation of the sheet during needle punching. The longitudinal / lateral elongation ratio was 0.81, which was poorly balanced.
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Abstract
Description
・捲縮保持係数=(W/L-L0)1/2
W:捲縮消滅荷重(捲縮が伸びきった時点の荷重:mg/dtex)
L:捲縮消滅加重下の繊維長(cm)
L0:6mg/dtex下での繊維長(cm)。30.0cmをマーキングする。
(1)融点
パーキンエルマー社(Perkin Elmaer)製DSC-7を用いて、2nd runでポリマーの溶融を示すピークトップ温度をポリマーの融点とした。このときの昇温速度は16℃/分で、サンプル量は10mgとした。測定は2回行い、その平均値を融点とした。
試料ペレット4~5gを、MFR計電気炉のシリンダーに入れ、東洋精機製メルトインデクサー(S101)を用いて、荷重2160gf、温度285℃の条件で、10分間に押し出される樹脂の量(g)を測定した。同様の測定を3回繰り返し、平均値をMFRとした。
複合繊維をエポキシ樹脂に包埋しウルトラミクロトーム(ライカ製:Ultracut-S)で断面を作製し、OsO4染色を行い、再度ウルトラミクロトームで超薄切片を作製し試料とした。本試料を用いて、TEM観察を実施した。TEM装置は、日立製H-7100を用い、加速電圧100kV、3000倍で観察した。繊維の長手方向にのびる筋状に存在しているポリアルキレングリコール3ヶ所を抽出し、その最大長さを記録した。
複合繊維の捲縮部分(座屈部分)を走査型電子顕微鏡(SEM キーエンス社製VE-7800型)で、1000倍で観察し、120°以下の角度を有する捲縮を抽出し、その座屈部分の割れおよび/または亀裂を観察した。座屈部分を30ヶ所観察し、15μm以上の割れおよび/または亀裂のある座屈部分が5ヶ所以上見られた場合、「割れおよび/または亀裂有」と判定した。
捲縮を付与した複合繊維に6mg/dtexの荷重を付与し繊維長(30.0cm)を正確に測定し、その長さをL0とした。その後、加重を行い、捲縮が伸びきったときの繊維長(30.0cmからの伸び)を測定し、その長さをLとした。捲縮が伸びきったときの荷重:Wを用い、次の計算式により算出した。なお、測定の方法としては、まず、試料に100mg/dtexの荷重をかけ、その後、10mg/dtex刻みで荷重を増加させ、その都度、捲縮の状態を確認した。
・捲縮保持係数=(W/L-L0)1/2
W:捲縮消滅荷重(捲縮が伸びきった時点の荷重:mg/dtex)
L:捲縮消滅加重下の繊維長(cm)
L0:60mg/dtex下での繊維長(cm)。30.0cmをマーキングした。
複合繊維の束に50mg/dtexの荷重をかけ、30.0cmをマーキングした(L0)。その後、98℃の熱水で10分間処理し、処理前後の長さ(L1)を測定し、(L0-L1)/L0×100を算出した。測定は3回実施し、その平均値を収縮率とした。
複合繊維の極細繊維を含む不織布の厚み方向に垂直な断面を、走査型電子顕微鏡(SEM キーエンス社製VE-7800型)で、3000倍で観察し、30μm×30μmの視野内で無作為に抽出した50本の単繊維直径を測定した。ただし、これを3ヶ所で行い、合計150本の単繊維の直径を測定し、小数点以下を四捨五入して平均値を算出した。極細繊維が異形断面の場合、まず単繊維の断面積を測定し、当該断面を円形と見立てた場合の直径を算出することによって単繊維の直径を求めた。
20×20cmの厚板の重量を、0.93g/cm2とした以外は、JIS L1097(1982)「合成繊維ふとんわた試験方法」に順じ、繊維ウェブの圧縮回復率を測定した。85%以上の圧縮回復率のものを性能良好とした。
JIS L1913 6.2(2010)に準じて目付(g/m2)を測定し、ダイヤルシックネスゲージ(株)尾崎製作所、商品名“ピーコックH”(登録商標)により厚み(mm)を測定した。目付と厚みの値を用い、見掛け密度(g/cm3)を算出した。
JIS L1913 6.3(2010)に準じて引張り試験を実施した。不織布の長手方向(縦)と幅方向(横)の破断時の伸度を測定し、縦/横の比を評価し、1.0に近いものを良好とした。
JIS L1096(1999)8.17.5 E法(マーチンデール法)家具用荷重(12kPa)に準じて測定される耐摩耗試験において、20000回の回数を摩耗した後の人工皮革の質量減を評価した。摩耗減量4.0mg以下を性能良好とした。
得られた人工皮革を、健康な男女20名による官能評価によって官能評価を実施した。評価は、立毛長がそろっていること、立毛繊維の分散性が良好なことについて、5.0が最も良好、0.0が最も不良とし、5.0~0.0の間0.5刻みで判定した。評価結果が3.5以上で、品位良好とした。
<原綿>
(島成分ポリマー)
融点260℃、MFR46.5のポリエチレンテレフタレート(PET)を用いた。
融点240℃、MFR100の5-スルホイソフタル酸ナトリウムを8モル%共重合したPET(共重合PET1)を用いた。
上記の海成分ポリマーと島成分ポリマーを用い、海成分に分子量20,000のポリエチレングリコール2.0質量%をメルトブレンドし、16島/ホールの海島型複合紡糸口金を用いて、紡糸温度285℃、島/海質量比率55/45、吐出量1.8g/分・ホール、紡糸速度1200m/分の条件で溶融紡糸した。
上記の原綿を用い、カードとクロスラッパー工程を経て積層繊維ウェブを形成した。ニードルパンチ前の積層繊維ウェブの圧縮回復率は、89.0%と反発感が高いものであった。次いで、トータルバーブデプス0.075mmのニードル1本を植込んだニードルパンチ機を用いて、針深度7mm、パンチ本数4500本/cm2でニードルパンチし、目付が805g/m2、見掛け密度が0.275g/cm3の不織布を作製した。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。また、縦横伸度比も0.96とバランスのとれたものであった。
非イオン系強制乳化型ポリウレタンエマルジョン(ポリカーボネート系)に、感熱ゲル化剤として硫酸ナトリウムをポリウレタン固形分対比3質量%添加し、ポリウレタン液濃度が10質量%となるように<水分散型ポリウレタン液>を調整した。
上記の不織布を98℃の温度で3分間熱水収縮、100℃の温度で5分間乾燥させた。その後、得られた不織布に上記の水分散型ポリウレタン液を付与し、乾燥温度125℃で5分間熱風乾燥して、ポリウレタンの付着量が不織布の島成分に対して35質量%であるポリウレタン付不織布を得た。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、分子量20,000のポリエチレングリコールを5.0質量%メルトブレンドしたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が6.1、98℃における収縮率が19.1%の複合繊維を得た。の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは59μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が89.5%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が811g/m2、見掛け密度が0.278g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.97とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は緻密で良好であった。摩耗減量は2.4mg、表面品位は5.0と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、分子量20,000のポリエチレングリコールを10.0質量%メルトブレンドしたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が5.0、98℃における収縮率が18.8%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは112μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が88.0%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が794g/m2、見掛け密度が0.270g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.95とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は緻密で良好であった。摩耗減量は2.7mg、表面品位は4.5と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、分子量20,000のポリエチレングリコールを0.5質量%メルトブレンドしたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が3.6、98℃における収縮率が18.4%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは18μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が86.0%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が780g/m2、見掛け密度が0.262g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化が若干大きかったものの、高密度化が可能であった。縦横伸度比は0.91であった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は良好であった。摩耗減量は3.1mg、表面品位は4.0と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、ポリエチレングリコールの分子量を11,000としたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が5.1、98℃における収縮率が17.9%の複合繊維を得た。得られた複合繊維を、繊維長51mmにカットし海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは23μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が87.8%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が801g/m2、見掛け密度が0.270g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.94とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は良好であった。摩耗減量は3.3mg、表面品位は4.5と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマー)
実施例1で用いたものと同じものを用いた。
融点255℃、MFR95.0の5-スルホイソフタル酸ナトリウムを5モル%共重合したPET(共重合PET2)を用いた。
上記の海成分ポリマーと島成分ポリマーを用いたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が5.5、98℃における収縮率が18.3%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは25μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が88.5%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が803g/m2、見掛け密度が0.271g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.95とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は緻密で良好であった。摩耗減量は2.8mg、表面品位は4.5と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマー)
融点230℃、MFR52.0のポリプロピレンテレフタレートを用いた。
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用いたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が4.9、98℃における収縮率が18.9%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは30μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が8ヶ所以上観察された。
上記原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が87.0%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が789g/m2、見掛け密度が0.269g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.94とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は緻密で良好であった。摩耗減量は3.0mg、表面品位は4.0と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマー)
融点220℃、MFR58.5のナイロン6を用いた。
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用いたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が5.2、98℃における収縮率が19.3%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは28μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が8ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が86.2%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が802g/m2、見掛け密度が0.272g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.96とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体を得、含金染料を4.0%owf、温度を60℃、浴比1:100、pH=7の条件で120分間染色し、人工皮革を得た。得られた人工皮革の品位は良好であった。摩耗減量は3.7mg、表面品位は4.0と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、延伸工程で液浴温度を95℃にしたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が4.0、98℃における収縮率が8.4%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは28μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が5ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が87.4%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が803g/m2、見掛け密度が0.274g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.94とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は、原綿の収縮率が8.4%と低かったため、緻密感に欠けるものであった。摩耗減量は3.9mg、表面品位は3.5であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、ポリエチレングリコールのかわりに、ポリエチレングリコール/ポリプロピレングリコール共重合体、分子量20,000(三洋化成工業(株)製:ニューボールPE-128)としたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が5.4、98℃における収縮率が19.5%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコール/ポリプロピレングリコール共重合体が繊維の長手方向にのびる筋状に存在しており、その最大長さは29μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が10ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が88.1%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が800g/m2、見掛け密度が0.273g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.94とバランスのとれたものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は緻密で良好であった。摩耗減量は2.7mg、表面品位は4.0と良好であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマー)
実施例1で用いたものと同じものを用いた。
実施例1で用いた共重合PET1を重合する過程で、エステル交換反応後、280℃、真空下で3時間反応させた後、重合終了30分前に、実施例1で用いた分子量20,000のポリエチレングリコールを2.0wt%添加(混合)したポリマーを用いた。
上記の海成分ポリマーと島成分ポリマーを用いたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が3.8、98℃における収縮率が18.2%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは14μmであった。また、捲縮の座屈部分には長さ15μm以上の割れのある座屈部分が5ヶ所以上観察された。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層ウェブを形成し、圧縮回復率が85.1%と反発感の高い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が785g/m2、見掛け密度が0.261g/cm3の不織布を得た。ニードルパンチ時のシートの長さ方向の寸法変化がほとんどなく、高密度化が可能であった。縦横伸度比も0.91と実施例1に比べ劣るものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。得られた人工皮革の品位は良好であった。摩耗減量は3.8mg、表面品位は3.5であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマーと海成分ポリマー)
実施例1で用いたものと同じものを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、ポリエチレングリコールをメルトブレンドしなかったこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が2.7、98℃における収縮率が17.8%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しておらず、捲縮の座屈部分には割れが全く見られなかった。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が83.5%と反発感が低い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が773g/m2、見掛け密度が0.254g/cm3の不織布を得た。ニードルパンチ時のシートの長さ伸びが大きい結果であった。縦横伸度比は0.82とバランスの悪いものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。摩耗減量は4.3mg、表面品位は3.0と、実施例1に比べて悪い結果であった。結果を、表1(複合繊維)と表2(繊維ウェブ、不織布、人工皮革)に示す。
<原綿>
(島成分ポリマー)
実施例1で用いたものと同じものを用いた。
融点255℃、MFR96.0の5-ナトリウムスルホイソフタル酸を4モル%共重合したPET(共重合PET3)を用いた。
上記の海成分ポリマーと島成分ポリマーを用いたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が2.4、98℃における収縮率が19.3%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、ポリエチレングリコールが繊維の長手方向にのびる筋状に存在しており、その最大長さは25μmであった。しかしながら、5-ナトリウムスルホイソフタル酸4モル%しか存在しないため、長さ15μm以上の割れのある捲縮の座屈部分は観察されなかった。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が82.1%と反発感が低い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が763g/m2、見掛け密度が0.251g/cm3の不織布を得た。ニードルパンチ時のシートの長さ伸びが大きい結果であった。縦横伸度比は0.80とバランスの悪いものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。磨耗減量は5.9mg、表面品位は3.0と、実施例1に比べて劣る結果であった。結果を表1と表2に示す。
<原綿>
(島成分ポリマー)
融点240℃、MFR100の5-ナトリウムスルホイソフタル酸を8モル%共重合したPET(共重合PET1)を用いた。
融点260℃、MFR46.5のPETを用いた。
上記の海成分ポリマーと島成分ポリマーを用い、島成分ポリマー(共重合PET1)へ、分子量20,000のポリエチレングリコールを2.0質量%メルトブレンドしたこと以外は、実施例1と同様の方法で、単繊維繊度が4.5dtex、捲縮保持係数が2.5、98℃における収縮率が17.6%の複合繊維を得た。得られた複合繊維を繊維長51mmにカットして、海島型複合繊維の原綿を得た。複合繊維の断面をTEM観察した結果、海成分(PET)中にはポリエチレングリコールが存在しないため、捲縮の座屈部分には割れが観察されなかった。
上記の原綿を用い、実施例1と同様にして、加工を実施した。カードとクロスラッパー工程を経て積層繊維ウェブを形成し、圧縮回復率が83.0%と反発感が低い積層繊維ウェブを得た。得られた積層繊維ウェブにニードルパンチを行い、目付が765g/m2、見掛け密度が0.250g/cm3の不織布を得た。ニードルパンチ時のシートの長さ伸びが大きい結果であった。縦横伸度比は0.81とバランスの悪いものであった。
上記の不織布を用いたこと以外は、実施例1と同様にして人工皮革用基体と人工皮革を得た。磨耗減量は6.5mg、表面品位は2.0と、実施例1に比べて劣る結果であった。結果を表1と表2に示す。
Claims (12)
- ポリエステル系易溶出成分と難溶出成分からなる複合繊維であって、前記ポリエステル系易溶出成分が、5-ナトリウムスルホイソフタル酸を5~10モル%共重合してなる共重合ポリエステルにポリアルキレングリコールを含んでなることを特徴とする複合繊維。
- ポリアルキレングリコールが、共重合ポリエステル中にブレンドされていることを特徴とする請求項1記載の複合繊維。
- ポリエステル系易溶出成分におけるポリアルキレングリコールの含有量が1~10質量%であることを特徴とする請求項1または2のいずれかに記載の複合繊維。
- ポリアルキレングリコールが、ポリエチレングリコールであることを特徴とする請求項1~3のいずれかに記載の複合繊維。
- 複合繊維縦断面中にポリアルキレングリコールが、繊維の長手方向にのびる筋状に存在していることを特徴とする請求項1~4のいずれかに記載の複合繊維。
- 複合繊維中の繊維の長手方向にのびる筋状に存在しているポリアルキレングリコールの長さが15μm以上であることを特徴とする請求項1~5のいずれかに記載の複合繊維。
- 座屈捲縮が施されてなることを特徴とする請求項1~6のいずれかに記載の複合繊維。
- 座屈捲縮が施され、座屈部分に割れおよび/または亀裂が存在することを特徴とする請求項1~7のいずれかに記載の複合繊維。
- 98℃における収縮率が10~40%の範囲であることを特徴とする1~8のいずれかに記載の複合繊維。
- 請求項1~9のいずれかに記載の複合繊維を用いてなる人工皮革用基体。
- 請求項10記載の人工皮革用基体を用いてなる人工皮革。
- ポリエステル系易溶出成分と難溶出成分からなる複合繊維を製造する方法であって、溶融紡糸時に、5-ナトリウムスルホイソフタル酸を5~10モル%共重合してなる共重合ポリエステルに、ポリアルキレングリコールを添加して紡糸することを特徴とする複合繊維の製造方法。
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US14/368,176 US9970129B2 (en) | 2011-12-27 | 2012-12-13 | Conjugated fiber, base body for artificial leather, and artificial leather |
EP12863483.9A EP2799601B1 (en) | 2011-12-27 | 2012-12-13 | Conjugated fiber, base body for artificial leather, and artificial leather |
JP2013507481A JP6090156B2 (ja) | 2011-12-27 | 2012-12-13 | 複合繊維、人工皮革用基体および人工皮革 |
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CN116575142B (zh) * | 2023-07-14 | 2023-09-22 | 江苏恒力化纤股份有限公司 | 一种多孔隙服装用聚苯硫醚纤维的制备方法 |
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EP2799601A1 (en) | 2014-11-05 |
TW201333290A (zh) | 2013-08-16 |
KR20140109879A (ko) | 2014-09-16 |
JPWO2013099618A1 (ja) | 2015-04-30 |
US20140370283A1 (en) | 2014-12-18 |
JP6090156B2 (ja) | 2017-03-08 |
US9970129B2 (en) | 2018-05-15 |
CN104024496A (zh) | 2014-09-03 |
KR101933959B1 (ko) | 2018-12-31 |
EP2799601A4 (en) | 2015-08-05 |
EP2799601B1 (en) | 2020-04-22 |
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