JPH0146624B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Field of Application] The present invention relates to a fibrous sheet material having excellent flexibility and abrasion resistance, and a method for producing the same. [Prior Art] In the conventional technology for obtaining a flexible fiber sheet, the main focus of investigation has been on how to create a non-adhesive structure between the fibers and the binder. However, such techniques mainly involve a so-called post-sea removal method in which, for example, a binder is applied to a nonwoven fabric and then sea components are removed. Therefore, when the base material is removed from the sea, the base material becomes tired and undergoes large dimensional changes, resulting in extremely poor workability.
In addition, in order to obtain higher flexibility, the only option was to increase the amount of sea removal, increase the void ratio, or reduce the amount of binder applied. However, in such a case,
On the other hand, the hair loss of the product and the dynamic physical properties, particularly the abrasion resistance, deteriorate, resulting in an imbalance in the physical properties of the product. Therefore, the prior art could only be applied within a very limited range, and its uses were also limited. Furthermore, it goes without saying that if a nonwoven fabric is not provided with a shape-retaining agent, the instability of dimensional changes during sea removal will be greatly increased. [Problems to be Solved by the Invention] The present inventors have developed a fiber that does not have the above-mentioned drawbacks, has stable processability, and has well-balanced product properties and excellent texture, flexibility, and abrasion resistance. As a result of extensive research into sheet-like products and methods for producing the sheet-like products, the present invention was finally discovered. That is, the object of the present invention is to provide a sheet-like article with excellent flexibility and abrasion resistance, which has a structure in which finely divided ultrafine fiber bundles are intertwined, and a structure in which ultrafine fibers are densely intertwined, and the production thereof. The purpose is to provide a method. A further object of the present invention is to provide a method for producing suede-like, nubuck-like, or pigtail-like artificial leather with excellent texture and quality. [Means for Solving the Problems] The present invention that achieves the above-mentioned objects has the following configuration. In other words, the sheet-like article of the present invention has ultrafine fiber bundles made of at least one type of ultrafine fibers entangled with each other, and at least one type of ultrafine fibers that is thinner than or has the same thickness as the ultrafine fibers. A flexibility characterized in that the other ultrafine fiber components substantially surround the ultrafine fiber bundle and have an entangled structure in which the at least one other ultrafine fiber components are intertwined with each other. , a fiber sheet-like material with excellent abrasion resistance. In addition, the method for producing a fiber sheet having excellent flexibility and abrasion resistance of the present invention is such that a plurality of island components/sea components are formed so as to substantially surround the primary split conjugate fibers consisting of a plurality of island components/sea components. A sheet is formed using a multi-component conjugate fiber having a structure in which secondary split conjugate fibers made of a sea component are arranged, and after the second split conjugate fibers of the sheet are divided, they are entangled, and then This is a method for producing a fiber sheet with excellent flexibility and abrasion resistance, which is characterized by dividing primary split composite structural fibers. [Function] The present invention will be explained in detail below. The fiber sheet-like article of the present invention has ultrafine fiber bundles made of at least one type of ultrafine fiber component obtained from the first split conjugate fibers, and which is obtained from the second split conjugate fibers and The ultrafine fiber bundle is made up of at least one other type of ultrafine fiber component that is thinner than the ultrafine fibers or has an equivalent thickness,
substantially surrounding the ultrafine fiber bundle,
It has an entangled structure in which the at least one type of other ultrafine fiber components are intertwined with each other, and has excellent flexibility, abrasion resistance, and strength. Furthermore, the method for producing a fiber sheet with excellent flexibility and abrasion resistance of the present invention typically involves forming a plurality of sets of island components with different divisibility into the same multicomponent composite fiber.
A composite fiber having a sea component at the same time is used to form a sheet, the island component/sea component of the second split composite fiber is divided, and the finely divided fibers are subjected to an entanglement treatment,
Particularly preferably, by spraying treatment with high-speed fluid,
A fiber sheet is obtained by performing a dense entangling process and then dividing the island component/sea component of the first split conjugate fiber, and more preferably subjecting the sheet to a napping process. It is. Furthermore, the present invention will be explained in detail by showing specific examples using drawings and the like. The fiber-forming polymers used for the island component in the primary split conjugate fibers and the secondary split conjugate fibers surrounding the primary split conjugate fibers used in the present invention include polyethylene terephthalate, polybutylene terephthalate, copolymerized polyethylene terephthalate, and copolymerized polybutylene. Polyesters such as terephthalate, polyamides such as nylon 6, nylon 66, nylon 12, copolymerized nylon, polyurethane,
Examples include polyacrylonitrile and vinyl polymers. Among these, polyesters and polyamides are preferred. Furthermore, the fiber-forming polymers used for the sea component constituting these primary split conjugate fibers and secondary split conjugate fibers include polystyrene, copolymerized polystyrene, polyethylene, polypropylene, hot water soluble polymers, Examples include polyamides, polyesters, polyurethanes, and the like. As an example of the structure of the primary split conjugate fiber (component A/component B) and the secondary split fiber surrounding it (component A'/component B') that can be used in the present invention,
It has a cross-sectional structure as shown in FIGS. That is, as shown in these figures, for example, a chrysanthemum-like structure in which A/B or A'/B' are dispersed radially, or A/B'
Bimetallic structure consisting of repeating B/A or A'/B'/A', or A/B or
Examples include an A'/B' mixed type structure or a polymer mutual array type structure. These fiber structures may be determined in a specific combination depending on the specific purpose and use of the sheet, and taking into account spinnability and the like. Among these, a combination of polymer mutually aligned structures is preferred in terms of ease of spinning and ease of controlling the denier of the A and A' fiber components. The dividing treatment in the present invention refers to a method of chemically dissolving and removing the sea component with a solvent and dividing the island component into ultra-fine pieces, or a method of dividing the island component and the sea component by heat treatment, mechanical treatment, or a combination thereof. It is possible to adopt methods such as peeling off the material and dividing it into smaller pieces. Therefore, the split composite fibers are selected from among the above-mentioned island component polymers and sea component polymers, or polymers that have different solvent solubility from each other, or splittable polymers. They can be manufactured by combining them as appropriate while taking into consideration the dyeability and the like. In order to further facilitate understanding of the present invention, the first
Specific examples of combinations of the constituent components will be explained using model diagrams of multicomponent composite fibers shown in FIGS. 8 to 8. First, taking as an example the case of the multicomponent composite fiber structure that can be used in the present invention shown in FIGS. 1 and 2,
To explain the polymer combinations of A/B and A'/B', polyethylene terephthalate is used as the island component A, polyamide-based hot water soluble polymer is used as the sea component B, and a first split composite such as a polymer interlayer array fiber is used. Spinning multicomponent composite fibers that have a structure in which fibers are formed and surrounded by secondary split composite fibers, such as polymer mutual array fibers using polyethylene terephthalate as the island component A' and polystyrene as the sea component B'. do. In this example, component B is soluble in hot water, component B' is soluble in trichlorethylene, and A and A' are insoluble in both solvents B and B'. Therefore, the above multi-component composite fiber was made into a sheet and first treated with trichlorethylene.
The fiber sheet of the present invention can be obtained by removing the B' component, finely dividing the A' component, subjecting it to an entanglement treatment, and then removing the B component in hot water. In addition, in the case of the multi-component composite fiber structures that can be used in the present invention shown in FIGS. 3, 4, 5, and 6, the island component A is polyethylene terephthalate, and the sea component B is nylon 66. A chrysanthemum-shaped or multi-phase bimetal type primary split conjugate fiber is formed using the above method, and the primary split conjugate fiber is mixed with a polymer interlayer using polyethylene terephthalate as the island component A' and polystyrene as the sea component B'. A multicomponent composite fiber having a structure surrounded by secondary split composite fibers such as an array type or a sea-island blend type is spun.
In this example, component B' is soluble in trichlorethylene, and components A, B, and A' are insoluble. Therefore, the above multicomponent composite fibers are made into a sheet,
First, the B component is removed with trichlorethylene, the A' component is finely divided, this is subjected to an entanglement treatment, and then the A component and the B component are peeled and separated in hot water or benzyl alcohol. , the fiber sheet-like article of the present invention is obtained. Furthermore, in the example structure of the multicomponent composite fiber that can be used in the present invention shown in FIGS. 7 and 8,
Polyethylene terephthalate is used as the island component A, and polystyrene is used as the sea component B to form a primary split conjugate fiber such as a polymer interlayer array fiber, and further,
A multicomponent composite fiber having a structure in which the fiber is surrounded by secondary split composite fibers such as a multiphase bimetallic fiber using polyethylene terephthalate as the island component A' and nylon 66 as the sea component B' is spun.
Component B is soluble in trichlorethylene,
Components A' and B' are insoluble in trichlorethylene. Therefore, the multicomponent fiber sheet is first heat-treated, and the second split composite fibers are divided into A' and B'. This is subjected to an entanglement process, and then the first
The fiber sheet of the present invention can be obtained by dissolving and removing component B of the subdivided conjugate fiber with trichlorethylene. In the structural examples of multicomponent composite fibers shown in FIGS. 1 to 8, the components of the remaining fibers after the splitting treatment may be the same or different. Regarding this point, it may be selected appropriately depending on the purpose and use of the sheet. As a method for obtaining the above-mentioned multicomponent composite fiber used in the present invention, for example, in the case of a fiber having a cross-sectional structure as shown in FIG. 1, a three-component spinning machine or a four-component spinning machine is used. , patent registration no.
By using a spinneret as disclosed in No. 1179643 and partially improving the polymer flow path, stable and easy spinning can be achieved. Figure 9 shows
It is a sectional view of such a multi-component composite base, and A
The components are distributed by a plurality of pipes 1, and the B component passes through a polymer channel 2 and is led to an intermediate section 3,
It becomes a core-sheath composite flow and is guided to the first collecting plate 5, at which point a first split composite fiber is formed, and further guided to the second collecting plate 9. On the other hand, the A' component passes through the polymer channel 4 and is distributed by a plurality of pipes 7. The B' component passes through the polymer flow path 6, is guided to the interlayer section 8, becomes a core-sheath composite flow, and is guided to the second gathering plate 9, forming a second split composite fiber. Thus,
A structure in which the first split conjugate fibers are surrounded by the second split conjugate fibers is formed in the second aggregate plate 9, and the multicomponent conjugate fibers used in the present invention are discharged from the discharge holes 10, that is, Secondary split conjugate fibers surrounding the first split conjugate fibers are obtained. The sheet in the present invention refers to a nonwoven fabric, a woven or knitted fabric, or a combination thereof. The sheet forming method is not particularly limited, and methods such as a combination of ordinary cards, cross wrapper, random wet bar, etc., needle punch,
A method of spraying a high-speed fluid, a method of forming a nonwoven fabric by a papermaking method, or a known method of forming a woven or knitted fabric may be used. The high-speed fluid spraying process refers to a process in which a liquid or gas is sprayed to perform an entanglement process, and liquids are usually preferably used because they can perform entanglement and dispersion at the same time and from the standpoint of safety. A swelling agent, a solvent, or the like may be mixed into the liquid to perform segmentation and entanglement treatment. Considering shape retention in the post-processing process, it is preferable to perform entanglement by needle punching or high-speed fluid spraying before dividing.
The present invention can also be applied in a web state by performing high-speed fluid treatment using hot water or a solvent to subdivide and entangle the secondary split conjugate fibers and at the same time entangle the primary split conjugate fibers. This does not impair the effectiveness of the Rather, in this case, it may be preferable to obtain dense and highly entangled secondary split conjugate fibers. Solvents for splitting the primary and secondary split composite fibers vary depending on the combined polymers, so it cannot be generalized, but examples include chlorinated solvents such as trichlorethylene and perchlorethylene, toluene, and benzene. Aromatic solvents such as phenols, alkalis, acids, etc. are used. Of course, other solvents can also be used as long as they have dissolving power, and it goes without saying that the solvent is not limited to these. The method for reentangling the fibers obtained by finely dividing the finely divided secondary split conjugate fibers is to obtain dense entanglement by spraying high-speed fluid, but also to reentangle the fibers obtained by finely dividing the finely divided secondary split composite fibers. This is preferable in terms of increasing entanglement with composite fibers. In addition, after applying a binder to the treated sheet, when removing any one of the island component/sea component of the first split conjugate fibers, the second split conjugate fibers are densely entangled. Unlike conventional techniques, it is possible to obtain a fiber sheet with extremely stable processability, flexibility, and excellent abrasion resistance with well-balanced physical properties. In the spraying process using a high-speed fluid, the fluid is sprayed from a nozzle with a small hole diameter or a narrowly spaced slit, and the fluid is sprayed as a high-speed columnar flow or curtain flow. As for the pressure conditions, a range of about 5 to 300 kg/cm ² can be used. At a pressure lower than 5 Kg/cm ² , the entanglement effect is small, and at a pressure higher than 300 Kg/cm ² , impact defects and deformation occur, which is not preferable. It is usually preferable to use the amount in the range of 20 to 150 kg/cm ² . One side or both sides of the sheet may be treated. In addition, a method of increasing the number of passes is effective for increasing the dense entanglement of the finely divided secondary split conjugate fibers and the entanglement with the first split conjugate fibers. The denier of the multicomponent composite fiber of the present invention and the denier of the finely divided remaining fibers after splitting are not particularly limited, but the former is usually 0.5 to 20
It is preferable to select a denier in a range where the latter is thinner than 0.5 denier. In addition, the residual fiber denier after splitting the first split conjugate fiber and the second split conjugate fiber is such that the remaining fiber denier in the first split conjugate fiber ≧ the remaining fiber denier in the second split conjugate fiber. It is more convenient to set this to obtain the effects of the present invention. The remaining fiber denier in the secondary split composite fiber is
If the fiber denier is thicker than the residual fiber denier in the primary split conjugate fiber, it will be difficult to obtain dense entanglement during the entanglement treatment by high-speed fluid jetting, the abrasion resistance will decrease, and it will be difficult to obtain a soft texture. This is not desirable because it makes you want to eat. In the second split composite fiber, either the island component or the sea component may remain, or both the island component and the sea component may remain in the final product. The important point is to subdivide A' and B' and use them to form a more dense entanglement in the mutual entanglement of the remaining fibers in the first split conjugate fiber.
The aim of the primary split conjugate fiber is to maintain surface quality, flexibility, etc. in the final product, as well as the entanglement effect. Therefore, the island component/
In order to obtain the effects of the present invention, it is preferable that any one of the sea components substantially remain. This means that if, for example, a binder is applied after the secondary split conjugate fibers are finely divided and reentangled, the first
The residual fibers of the subdivided conjugate fibers and the binder are substantially non-adherent or have a reduced adhesion surface, which is effective for exhibiting flexibility. Furthermore, in the method of the present invention, after the secondary split conjugate fibers are finely divided and reentangled, shrinkage, pressing, gluing, and binder application may be performed in combination. After the composite fibers are subdivided, a napping process may be performed. Further, in order to increase the added value of the product, high-order processing such as dyeing, softening, and rolling may be performed. The fiber sheet-like product of the present invention thus obtained is
Products with excellent texture flexibility and abrasion resistance, and especially those with raised naps to which a binder has been added, have excellent characteristics in not only flexibility but also abrasion resistance and shape retention in wet conditions. This material is preferably used not only in the field of artificial leather clothing where texture is important, but also in cassette pads, wiping cloths, various filters, towel cloths, gripping members such as grips, various polishing cloths, polishing cloths, and the like. [Example] The present invention will be explained in detail below with reference to Examples.
The present invention is not restricted or limited by these Examples. Rather, it brings about the next application development. Example 1 Using a die as shown in FIG. 9, polyethylene terephthalate was used as the primary split composite fiber component, and polyether polyamide copolymer was used as B, A:B=50:50% by weight, A:B=50:50% by weight. number of islands is 6
As a main component, as a secondary split composite fiber component,
A′ is polyethylene terephthalate, B′ is polystyrene, A:B=50:50% by weight, number of Shimamotos in A′ is 96
As shown in Fig. 1, a composite fiber denier of approximately 5.0 denier, a cut length of 51 mm, and a shrinkage number of approximately
Obtained 13 piles/in of staples. This polymeric mutually arranged fiber was passed through a card, a cross lapper, and needle punched to make felt. Then, polystyrene was removed using trichlorethylene.
B' was divided by dissolution and then waterjet punched on both sides of the sheet.
Furthermore, the hot water-soluble polymer B was dissolved and removed using hot water to obtain a fiber sheet of the present invention. Moreover, the workability during this period was stable. The obtained fiber sheet material has a single fiber denier.
The fiber sheet had a structure in which ultrafine fibers A of 0.21 denier polyethylene terephthalate were intertwined, and further entangled with single fiber denier and ultrafine fibers A' of 0.013 denier polyethylene terephthalate, and had an extremely soft texture. Example 2 Using the same polymer interlayer array fibers used in Example 1, a waterjet-treated sheet was prepared in the same manner, subjected to hot water shrinkage treatment, and dried. After applying polyvinyl alcohol to this material and drying it,
DMF polyurethane was applied and wet coagulated. Next, the hot water-soluble polymer B was dissolved and removed using hot water. This material is sliced using a slicing device.
It was cut into approximately equal halves, and both sides were subjected to a napping treatment using a sandpaper buffing device. This gray fabric was dyed using a blue disperse dye. As a comparative example, the same polystyrene (sea component) and polyethylene terephthalate (island component) as in Example 1 were used, sea component: island component = 50:50% by weight,
Composite fiber denier: approx. 5.0 denier, cut length: approx.
Example 1 A staple of 51 mm, approximately 14 fibers per inch, and 16 Shimamoto fibers of polymeric mutual array was prepared.
Felt was made under the same conditions. The felt was subjected to hot water shrinkage treatment, then impregnated with polyvinyl alcohol in the same amount as the product of the present invention, dried, impregnated with DMF polyurethane in the same amount as the product of the present invention, and wet-processed. It solidified. Then,
After drying, polystyrene was dissolved and removed using trichlorethylene. This material was cut into approximately equal halves using a slicing device, and both sides were subjected to a napping treatment using a sandpaper buffing device. This gray fabric was dyed under the same conditions as the products of the present invention. As shown in Table 1, a comparison of the physical properties of the two types of fibrous sheet products thus obtained shows that the fibrous sheet of the present invention had well-balanced product physical properties with excellent flexibility and abrasion resistance. In addition, the processability of the fiber sheet during processing was extremely poor, whereas the comparative example became tired and had large dimensional changes when removed from the sea, whereas the sheet of the present invention also had excellent processing stability.

〔Effect of the invention〕

The fiber sheet material according to the present invention has excellent flexibility and abrasion resistance, less shedding, and excellent strength. Furthermore, by selecting the fiber denier, it is possible to obtain a color with a three-dimensional effect. In the method for producing a fiber sheet of the present invention, a uniform fiber sheet can be obtained because the same multi-component composite fiber is used instead of a cotton blend, and the processing method also makes it possible to obtain a uniform fiber sheet during leather tanning. It has good shape retention and excellent processing stability.

[Brief explanation of drawings]

FIGS. 1 to 8 are various schematic diagrams of cross-sectional shapes showing examples of multicomponent composite fibers used in the present invention, and FIG. 9 shows multicomponent composite fibers as shown in FIG. 1. FIG. 1, 7: pipe, 2, 4, 6: polymer channel,
3, 8: Between part, 5, 9: Collection plate, 1
0: Discharge hole.

Claims (1)

[Scope of Claims] 1. Ultrafine fiber bundles made of at least one type of ultrafine fiber are entangled with each other, and at least one other type of ultrafine fiber is thinner than the ultrafine fiber or has an equivalent thickness. Flexibility and wear resistance, characterized in that the ultrafine fiber components substantially surround the ultrafine fiber bundle and have an entangled structure in which at least one other type of ultrafine fiber components are intertwined with each other. Fiber sheet material with excellent properties. 2. A multi-component composite having a structure in which secondary split conjugate fibers made of a plurality of island components/sea components are arranged so as to substantially surround the first split conjugate fibers made of a plurality of island components/sea components. Flexibility and abrasion resistance characterized by forming a sheet using fibers, dividing the second split conjugate fibers of the sheet, subjecting the sheet to an entanglement treatment, and then splitting the first split conjugate structural fibers. A method for producing fiber sheet materials with excellent properties. 3 The sea component constituting the primary split composite fiber and the secondary
3. The method for producing a fiber sheet having excellent flexibility and abrasion resistance according to claim 2, wherein the sea components constituting the sub-split conjugate fibers have different solvent solubility. 4 Claim No. 4, characterized in that the sea component constituting the first split conjugate fiber and/or the second split conjugate fiber can be split from the island component by heat treatment or mechanical treatment. A method for producing a fibrous sheet material having excellent flexibility and abrasion resistance as described in item 2 or 3.