JPH0797743A - New microfiber cloth - Google Patents

Abstract

(57) [Abstract] [Purpose] A microfiber cloth having an extremely natural and good feel that has never been obtained by using a composite fiber made of a combination of mutually incompatible polymers and having a thick and thin structure. provide. A composite fiber composed of at least two kinds of polymer components which are incompatible with each other and which are arranged alternately in the cross-sectional direction of the fiber, and which has a thick portion and a thin portion in the fiber axial direction is formed as a warp and / or a composite fiber. In the woven fabric used for wefts, at least a part of the composite fiber is opened and fibrillated into each component forming the composite fiber, and MMD (average deviation of friction coefficient) and SMD (surface measured by KES-FB4) The average deviation of roughness) is a microfiber woven fabric satisfying the following formula. MMD: 0.010 to 0.030 SMD: 1.300 to 3.000 μm

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a microfiber cloth having a novel surface touch and appearance and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, many fabrics using microfibers have been proposed.

For example, JP-A-52-27822 and JP-B-53-3
5633, JP 61-282445, JP 62-8535
Japanese Patent Laid-Open No. 60-215869, Japanese Patent Laid-Open No. 61-34276, and the like propose composite fibers and fine fibers mainly composed of polyester / nylon. However, in the above-mentioned conventionally proposed methods, only fibers having an excessively uniform shape are obtained, and therefore, a woven fabric has a natural appearance and a natural texture produced from the natural appearance. Couldn't get.

[0004]

The present inventors have arrived at the present invention as a result of earnest research. That is, an object of the present invention is to obtain a microfiber woven fabric having an unprecedented Kasuri-shaped light and shade portion, and another object is to easily and inexpensively manufacture a microfiber cloth having an unprecedented Kasuri-shaped light and shade portion. It is to provide a manufacturing method to.

[0005]

SUMMARY OF THE INVENTION The present invention comprises at least two different polymer components that are incompatible with each other, and the components are arranged alternately in the cross-sectional direction of the fiber, and the thick portion and the thin portion in the fiber axis direction. In a woven fabric using a composite fiber having a warp and / or weft, at least a part of the composite fiber is opened / fibrillated into each component forming the composite fiber,
This is a microfiber woven fabric in which the values of MMD (average deviation of friction coefficient) and SMD (average deviation of surface roughness) measured by KES-FB4 satisfy the following formula. MMD: 0.010 to 0.030 SMD: 1.300 to 3.000 μm

The fiber of the present invention is a composite fiber composed of at least two different polymers which are incompatible with each other. The phrase “incompatible with each other” means that when the polymers are mixed in a molten state, they are merely mixed without being dissolved and forming a uniform phase. When the substances which are incompatible with each other are mixed, the mixture generally becomes cloudy. Further, even if the mixture is not clouded, each phase can be confirmed when the mixture is observed with a different phase contrast microscope or an electron microscope. Alternatively, when the mixture is subjected to thermal analysis by differential calorimetry, mutual melting points are observed.

As an example, combinations of polyester with polyamide, polyurethane, polyacrylonitrile, polyethylene, polypropylene etc. are incompatible with each other. Similarly, polyamide is incompatible with polyester, polypropylene, polyethylene, polytetrafluoroethylene, polyacrylonitrile and the like. Alternatively, many other combinations are incompatible with each other. More specifically, for example, as the polyamide component, nylon 4, nylon 6, nylon 7, nylon 11, nylon 1
2. Nylon 66, nylon 610, polymethaxylene adipamide, polyparaxylylene decanamide, polybiscyclohexylmethane decanamide, and copolyamides containing them are well known. As the polyester, polyethylene terephthalate, polytetramethylene terephthalate, polyethyleneoxybenzoate, poly 1,4-dimethylcyclohexane terephthalate,
Polypivalolactone and copolyesters containing them are well known.

The composite fiber is composed of a combination of polymers having poor mutual affinity as proposed in Japanese Patent Publication No. 62-8535, Japanese Patent Publication No. 52-27822, and Japanese Patent Publication No. 61-282445. Although a thing can be used, a thing with other shapes can also be used. One example is shown in FIG. Among them, b, e (radial), f (radial), h (radial) in FIG.
Preferred are k and n (hollow ring). In particular, a combination of polymers in which one component contracts extremely greatly with a specific organic solvent such as benzyl alcohol described in JP-B-53-35633 is preferable. A combination of polyester and polyamide is particularly preferable.

The ratio of the two polymers according to the invention is usually 5 /
1 to 1/5 (weight ratio), preferably 3/1 to 1 /
3 (weight ratio). In a special case, it may be out of this range. For example, in the case of a combination of nylon and polyester, nylon easily contracts during the peeling treatment. Therefore, the ratio of nylon component / polyester component is preferably 2/1 to 1/3, more preferably 1/1 to 1/2.

The conjugate fiber of the present invention can be produced by a usual method for producing a conjugate fiber. The denier of the single yarn before opening and fibrillation is preferably about 1 to 10 denier, more preferably 2 to 5 denier. The denier after opening and fibrillating each component constituting the composite fiber is at most 1 denier, preferably at most 0.5 denier, and more preferably 0.2 to 0.05 denier. The denier of each fibril after opening and fibrillating each filament may be the same or different.

If the denier of the fiber before opening and fibrillation is less than 1 denier, there is a problem in terms of operability. On the other hand, if it exceeds 10 denier, the denier after opening of each component becomes large, and there is a possibility that the characteristic performance and texture of the target microfiber may not be obtained.

The T portion & t portion (hereinafter referred to as thick and thin) referred to in the present invention means that the denier is discontinuous in the fiber axis direction. Usually, the ratio of the cross-sectional areas of the T portion and the t portion is at least 1.5, more preferably at least 2, and particularly preferably 2.5 to 10. The length of the T portion is preferably at least 3 mm or more, more preferably at least 5 mm or more, particularly preferably 10 to 50 mm. Moreover, it is natural that the frequency of appearance of the T part varies, but it is usually 30
1 or more per cm, preferably 1 or more per 20 cm,
More preferably, it is 1 or more per 10 cm. The ratio of the T portion to the whole fiber is usually at least 2%, preferably at least 5%, more preferably 10 to 60%. When the T portion is a multifilament, it is preferable that the phases are the same as much as possible. That is, it is preferable for clarifying the color difference and improving the feeling of fluffiness and the touch.

Any method may be used to make sick and thin, but the most common method is to draw an undrawn yarn at a draw ratio lower than the natural draw ratio. The natural draw ratio refers to a draw ratio at which, when a yarn after spinning is applied, the drawing proceeds by necking and the entire yarn becomes a completely drawn yarn. For example, a fiber wound at a spinning speed of 1200 m / min usually has a natural draw ratio of about 3.5 to 4.0. Therefore, if the draw ratio is smaller than that value, the undrawn part remains in the fiber and the thick and thin It becomes a thread. The lower the draw ratio than the natural draw ratio, the easier the thick and thin film appears and the more noticeable the difference between the T and t parts. How to select the stretching conditions (stretch ratio, stretching temperature, set temperature) depends on what polymer was used, what spinning speed was used, and what form of thick and thin was desired. . It is necessary to select the optimum conditions according to the purpose and conditions.

When weaving, fibers having thick and thin are used as warp and / or weft. Use for at least one. Of course, this usage amount also needs to be changed depending on how much such a surface change the product has. If it is used for both warp and weft, it will be a cloth with a cross-hatched pattern of darkened color, and if it is used for either warp or weft, it will be clearly darkened in the longitudinal or transverse direction. The fabric has a faint pattern. The patterning that pays attention to the difference in the dyeability of these so-called microfiber raw yarns due to thick and thin has not been proposed so far, and has a very large commercial value. The lightness and darkness of the color of the T portion and the t portion may be such that they can be clearly discriminated visually. For example, the ΔL value of the CIE standard color system is about 2 or more. Moreover, regarding the texture, there is a feel like that of a cloth that has been subjected to a raising treatment without the raising treatment.

However, by further raising the fabric of the present invention such as sanding, a peach-skin-like or suede-like texture and surface feeling can be further developed.

That is, the fiber has an unstretched portion (T
Parts) and stretched parts (t parts) are present alternately, and the fiber diameter ratio is at least 1.5 or more, preferably 2 or more, and more preferably 2.5 to 7, so that opening and fibrillation are performed. The shrinkage rate and elongation rate of the subsequent fibers are different, and as a result, a large loop is formed on the fabric surface due to the difference in the yarn length, and the loop just gives a feeling of raising the surface by sanding treatment or the like. A schematic diagram is shown in FIG.

The size of this loop is shown by H in FIG.
Usually at least 15 μm, preferably at least 20 μm
m, more preferably 30 to 100 μm. The number of the loops is determined by the number of thick and thin fibers of the present invention and the amount of the fibers used, and the size and length of the loops are determined by the combination of polymers and the size and number of T and t portions. .

The fabric of the present invention is extremely characteristic in terms of texture due to the above-mentioned surface structure. As a quantitative evaluation of texture,
There is a KES system (Kato Tech Co., Ltd.), which is used for quantitative evaluation of the texture of men's clothing materials and women's clothing materials.

The fabric according to the present invention is the KES-FB
4 The characteristics can be clearly defined by the measurement and evaluation system. MM, which is a parameter that particularly indicates the surface condition of the fabric
It is a microfiber woven fabric in which the values of D (average deviation of friction coefficient) and SMD (average deviation of surface roughness) satisfy the following formula. MMD: 0.010 to 0.030 SMD: 1.300 to 3.000 μm MMD less than 0.010 and greater than 0.030 and SMD less than 1.300 and greater than 3.000 μm are smooth and It does not give a peach skin tone. Preferably, MMD: 0.015 to 0.
0.25, SMD: 1.500 to 2.500 μm.

The present invention will be specifically described by showing an example of a method for producing the fabric of the present invention. First, at least two kinds of polymer components which are incompatible with each other and are different from each other are spun using a spinneret that is arranged alternately in the fiber cross-section direction to obtain a composite fiber having a cross-section as shown in the attached FIG.

For example, it is easy to obtain a fiber having a cross section as shown in FIG. 1 by composite spinning a nylon component and a polyester component at a discharge ratio of 1/2. Spinning speed is usually 7
Wind up at a winding speed of at least 00 m / min. When the winding speed is about 700 to 2000 m / min, undrawn yarn having a low orientation state can be obtained.

Next, the unstretched yarn is stretched to give the strength and elongation of the yarn which can withstand the normal specifications. Here, it is characterized in that the unstretched part is left in a part of the fiber without being completely stretched. . For this purpose, the draw ratio is lower than the natural draw ratio of the undrawn yarn. Usually, the natural stretching ratio is 0.95 times at most, preferably 0.90 times at most, and preferably 0.65 to 0.85 times. If the draw ratio exceeds 0.95 times the natural draw ratio at most, the target thick and thin becomes unclear. The stretching temperature is usually near the glass transition point of the polymer, but preferably the glass transition point-
It is carried out at 10 ° C. to the glass transition point + 10 ° C. so that the phases generated at the T portion are matched as much as possible.

When the spinning speed is more than 2000 m / min, the fibers after spinning form a partially oriented state (POY), and this POY yarn also forms thick and thin by lowering the draw ratio. I can do things.

By leaving the yarn for a while after spinning, for example, for one day or more, preferably for two days or more (aging), thick and thin can be formed more clearly during drawing.

The composite fiber obtained after drawing may be used as it is as a raw yarn or as a processed yarn such as false twist.

In the woven fabric, the composite fiber is used as a warp and / or a weft. When using, warp or weft 1
It may be 00% or may be woven with other yarn. When mixed with other threads, the size of the Kasuri pattern on the product can be changed relatively freely. Further, a mixed yarn of the composite fiber and another fiber may be used.

After forming the woven fabric, one of the composite fibers is treated with a chemical for swelling, and each component of the composite fiber is opened and fibrillated. The opening and fibrillation may be performed in the entire length direction of the fiber or a part of the fiber. For example, if the thin portion is opened and fibrillated and the thick portion is left as it is, the expression of the different color effect and the texture becomes more preferable.

For example, in the case of a composite fiber composed of nylon and polyester, it is more efficient and cheaper to use a chemical that swells nylon. For example, the woven fabric is immersed in an emulsified water dispersion liquid of benzyl alcohol, phenylethyl alcohol, phenol or the like, and then washed with warm water. During this treatment, the nylon component of the composite fiber swells and shrinks in the solvent, and the fibers are opened and fibrillated between the polyester components having poor compatibility. As the nylon component shrinks, the polyester component floats up, forming loops on the fabric surface. The number of loops is proportional to the amount of the composite fiber used,
The size of the loop can be controlled by the amount of tension applied to the fabric during the treatment.

In the dyeing, both fibers forming the conjugate fiber can be dyed, but it is also possible to dye only one fibril by using a dye having an affinity for one of the components. If dyes of different colors having affinity for both components forming the composite fiber are used, a special deep dyeing effect is exhibited.

After dyeing, there is no particular problem in adding a hydrophilic treatment, a water repellent treatment, an antistatic treatment, an antifouling treatment or the like which is generally performed.

The present invention will be described in more detail below with reference to examples, but the present invention is not limited thereto.

Example 1 Intrinsic viscosity ([η]) of 0.65 measured at 20 ° C. with a solvent of phenol / tetrachloroethane (6/4)
Nylon 6 having a relative viscosity of 2.75 measured at 25 ° C. at a polymer concentration of 1 g / dl using polyethylene terephthalate and concentrated sulfuric acid solvent was spun at a composite ratio of 1: 2 to obtain the composite fiber shown in FIG. 1f. Obtained. Spinning speed is 900m / min,
The stretching conditions were 65 ° C. and 2.85 times. Thick and thin were clearly expressed in the drawn yarn, and the ratio of denier in the T part to denier in the t part was about 5 times. The length of the T portion was about 5 to 25 mm, and the frequency of expression was about 5 per 20 cm. This fiber was used for warp and weft to make a plain weave. Then, after soaking in a water emulsion of 20% benzyl alcohol, washing was carried out in warm water at 60 ° C. High density of warp density (thread density before opening) 158 yarns / inch, weft density (thread density before opening) 124 yarns / inch by shrinking about 15% in the longitudinal direction and about 22% in the transverse direction during this process. A woven fabric was obtained.

Dyeing was carried out using a jet dyeing machine. Disperse dye (CIDisperse Blue 270 5%, CIDisperse Red 828
1%) was dyed at 130 ° C for 30 minutes, then immersed in a 4% tannic acid aqueous solution at 80 ° C for 20 minutes, washed and dried to obtain a fabric.

In the obtained dyed fabric, the vertical and horizontal shades of Kasuri pattern were clearly confirmed. In addition, it had a peach-skin touch, which was a very smooth touch. As a result of the electron micrograph of the surface of the fiber, each component of the composite fiber was opened and fibrillated, and a good loop was developed on the surface of the fabric, and T section and t section were formed on the cross section of the fiber. I knew it existed. As a result of measurement with KES-FB4, M
MD = 0.185 and SMD = 1.65, and the texture was well expressed.

As a comparative example, the stretching condition is 65 ° C.,
Samples were taken as 3.95 times. The fiber was stretched uniformly and showed no thick and thin. Fabrication and dyeing were carried out by the same process and conditions as above. No clear kasuri pattern was found on the fabric, and there was no special texture, and a fluffy paper-like fabric was obtained. Similarly, as a result of measurement by KES-FB4, MMD = 0.00
95, SMD = 1.30, which expresses the texture of flicker.

Example 2 Using the same polymer combination as in Example 1, Figure 1b
A composite fiber having a cross section of was obtained. Then, weaving and processing were performed in the same manner as in Example 1 to obtain a woven fabric. The obtained fabric had a Kasuri-like appearance and a peach skin touch texture. The conjugate fiber of FIG. 1b had a remarkable effect of the loop of the ultrafine fibers and had a peach skin touch to suede touch appearance and texture. As a result of measurement by KES-FB4, MMD = 0.175 and SMD = 1.85, and the texture was well expressed.

[0036]

EFFECTS OF THE INVENTION According to the present invention, a microfiber cloth, which has had only a very artificial and very uniform surface state until now, has a special appearance and state even without relying on a special dyeing method such as printing. Like Further, in the print, only a certain repetitive pattern can be applied, but in the present invention, a completely random non-repeating pattern can be expressed, which gives the cloth a very natural feeling. In addition, it is possible to have a feeling of fluffiness and a special touch without feeling sanding or raising treatment. That is, there is a great industrial advantage that a completely new surface state that has never existed can be obtained very easily and at very low cost. In particular, in a high-density fabric, it provides a very excellent material material having waterproofness, windproofness, moisture permeability, excellent texture, and wearability.

[Brief description of drawings]

FIG. 1 shows an example of a cross-sectional shape of a composite fiber that can be used in the present invention. The presence or absence of diagonal lines in the figure indicates different polymers that are incompatible with each other.

FIG. 2 shows the state of loops on the surface of the invention. H in the figure
Indicates the size of the loop.

[Explanation of symbols]

 1 warp or weft 2 warp or weft

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display area // D06M 101: 16

Claims (2)

[Claims] 1. A composite fiber comprising at least two types of polymer components which are incompatible with each other and which are alternately arranged in the cross-sectional direction of the fiber, and which has a thick portion and a thin portion in the fiber axial direction as warp and In the woven fabric used for the weft yarn, at least a part of the composite fiber is opened / fibrillated into each component forming the composite fiber, and MMD (average deviation of friction coefficient) and SMD measured by KES-FB4. A microfiber woven fabric whose value of (average deviation of surface roughness) satisfies the following formula. MMD: 0.010 to 0.030 SMD: 1.300 to 3.000 μm 2. The cloth according to claim 1, wherein the ratio of the cross-sectional areas of the thick portion and the thin portion of the composite fiber is at least twice or more.