JP2010519422A - Durable thermoplastic fiber and cloth containing the same - Google Patents

Abstract

A thermoplastic fiber having excellent durability and a cloth including the same are provided.
In particular, a thermoplastic fiber includes fluoropolymer particles having an average particle size of 0.01 to 5.0 μm in a thermoplastic resin constituting the fiber. The thermoplastic fiber of the present invention is produced by a method in which fluoropolymer particles are added to the thermoplastic resin when producing the thermoplastic fiber by emitting the thermoplastic resin. The thermoplastic fiber of the present invention has excellent durability against friction and deformation, and is useful for footwear yarn, furniture yarn, rucksack yarn, abrasive yarn, sportswear yarn and the like.
[Selection] Figure 1

Description

  The present invention relates to a thermoplastic fiber having excellent durability and a cloth containing the same, and more specifically, a fluoropolymer particle having an average particle diameter of 0.01 to 5.0 μm in a thermoplastic resin constituting the fiber. It is related with the thermoplastic fiber excellent in the durability with respect to friction and a deformation | transformation, and the cloth containing this.

  In order to reinforce the durability of thermoplastic fibers such as polyamide and polyethylene terephthalate, the following methods are generally used.

  The first is a method of increasing the mechanical properties of the yarn itself by increasing the molecular weight of the basic resin in the thermoplastic fiber in the polymer polymerization stage.

  The second method is to increase the basic thickness of the thermoplastic fiber bundle in the radiation stage of the yarn. That is, the greater the yarn thickness, the so-called overall fineness, the lower the load level applied per unit area. It is a common fact that 10 denier is greater than 1 denier and 100 denier is greater than 10 denier.

  The third is a state in which one or all of the two conditions described above are satisfied by changing the yarn drawing conditions, giving high orientation and high crystallization in the radial drawing state, and increasing the strength through multistage drawing and heat treatment. It is a way to raise.

  In the polymerization stage, methods for increasing the molecular weight of the basic resin constituting the thermoplastic fiber are roughly classified into two methods. One is a method of maintaining the polymerization time longer. The longer the polymerization time, the larger the molecular weight to be polymerized. However, this is fundamentally limited in terms of time and efficiency. In the case of polyethylene terephthalate, the rate of increase of the initial molecular weight linearly correlates with time, but in the region where the intrinsic viscosity is 0.6 or more, the molecular weight increase with time tends to be very gradual. That is, there is a problem that the molecular weight does not increase so much with respect to many polymerization times. Furthermore, a side reaction occurs at a certain level of intrinsic viscosity, and the molecular weight tends to decrease.

  In order to solve such problems, in the case of polyethylene terephthalate, after polymerization so that the intrinsic viscosity becomes 0.5 to 0.7, a solid phase capable of uniformly applying a high temperature of 150 ° C. or higher Pass through a polymerization dryer to improve polymer crystallization. This is usually referred to as “solid phase polymerization” and usually increases the intrinsic viscosity to 1.0-1.3 levels. Such a method has a lot of time loss in the polymer polymerization process, and the loss is very large in terms of production volume and production cost. In particular, if the time and hot air are not adjusted properly during the solid-phase polymerization, an entanglement phenomenon occurs in the case of polyester, and an additional problem such as a yellowing phenomenon in which the hue changes to yellow in the case of a polyamide material. Many points occur. Therefore, there is a problem that solid-phase polymerization is difficult to apply except for special purposes.

In the radiation stage, the method of ensuring the required level of durability and wear while increasing the total fineness of the yarn has a problem that the fineness of the fiber cannot be increased without limitation depending on the application. For example, when applied as a clothing material, the standard weight of the fabric is suitably 50 to 300 g / m ² . If the weight of the fabric is less than that, the yarn material will open up too much, making it difficult to weave / knit. On the other hand, if it is more, it is too heavy for a person to wear and limits activity. In particular, as the fineness increases, the softness and flexibility of the cloth itself decreases and becomes more stiff. That is, there is a limit on the fineness of the fiber depending on the application.

  Furthermore, as a method for enhancing the strength of the yarn by changing the drawing conditions, a method of drawing in multiple stages such as two to three stages or four stages depending on the purpose is not widely used. Yes. At this time, the increase in the yarn elongation reduction rate relative strength is increased by the multi-stage drawing stage. At this time, it is effective to carry out heat treatment in order to improve the strength.

  However, the multistage heat treatment method is expected to be limited. That is, after the mother yarn is produced, it is allowed to stand so that a fixed time elapses, and then it is further redrawn with a multistage drawing machine. Alternatively, the mother yarn is produced on a multi-step radiation instant drawing machine. However, the heat treatment requires large-scale equipment, and the final drawing and winding speed becomes lower than the initial radiation speed, resulting in lower productivity, complicated processes, and lower yield. Therefore, this method is not preferable in terms of productivity.

  The aforementioned durability improvement conditions are basic conditions for weight reduction. However, it is often necessary to reduce the weight as a commercial premise. If the durability is ensured, a low-fineness fine thread material can be used to achieve a light weight effect, and the weight of the cloth is reduced while maintaining the same appearance.

  In most cases, it belongs to the latter, and the appearance must remain the same even when the weight is reduced. That is, in many cases, it cannot withstand the decrease in the density and thickness of the fabric due to the use of extra fine yarn.

  The most suitable material for such a condition is hollow fiber, and the apparent specific gravity of the yarn is lowered to the specific gravity of water, that is, 1.0 or less due to the hollow ratio inside. In particular, when a weight reduction of about 15% by weight or more in the case of a polyamide material and 25% by weight or more in the case of a polyester material is achieved, the apparent specific gravity is lowered to 1.0 or less, and a meaningful weight reduction can be achieved. At this time, the internal hollow ratio is measured by the ratio of the entire area of the hollow portion in the cross-sectional area of the fiber to the total cross-sectional area of the fiber.

  In the case of a hollow fiber, the internal hollow ratio is one condition for reducing the weight. The higher the hollow ratio, the lighter the appearance can be achieved, but the strength and elongation of the yarn itself are substantially reduced. In the case of hollow fibers, a radial draft that is 5 to 10 times higher than that produced when a yarn having a general circular cross section at the time of emission is produced, so that both the strength and elongation of the yarn itself are lowered. Therefore, even if the above-mentioned polymerization, radiation and stretching conditions are applied, the durability is substantially lowered. Even when compared with the same fineness and the reduced fineness, the durability of the hollow fiber is very low. This is because of severe deformation due to the influence of the cross-sectional area and substantially excessive stretching.

  On the other hand, the sea-island type composite fiber (also referred to as “sea-island fiber”) is a composite yarn in which the island component, which is a thermoplastic resin, and the sea component, which is an alkali-eluting resin, are in the form of a sea-island. It is mainly used to produce ultra-fine yarn that is made only from the island component of sea-island type composite fiber on the fabric by making the sea-island type composite fiber ultra-fine by eluting the sea component. .

  Sea-island composite fibers used as artificial leather and suede materials become ultrafine yarns with a single yarn fineness of 0.0001 to 0.3 denier after elution of sea components. The diameter of the polyester yarn of such ultrafine yarn is about 0.1 μm to 3 μm. Due to the fineness of the ultra-fine yarn, the fabric produced has one area as an important synthetic material due to its unique inherent effects such as extremely soft tactile sensation and lighting effect (ie lightening effect). Is building.

  However, although the strength and durability by unit fineness converted to 1 denier of the ultrafine yarn bundle are very excellent, the friction durability is substantially inferior due to the extremely fineness. Such artificial leather and suede cloth have been conventionally used only for garments, but their use is for non-garments such as furniture and sheets, and industrial use such as abrasives and wiping cloths. The range has expanded to use.

  Due to such a trend, improvement in mechanical property values is required for the characteristics unique to the suede. That is, in order to expand its application to non-garments and industrial use, durability, that is, friction fastness / wear resistance characteristics must be improved. The fact that the level of friction fastness to date is from the first grade to the first to second grade, and it is the fact that it is inferior.

  An object of the present invention is to provide a thermoplastic fiber excellent in durability and a cloth including the same by solving the conventional problem that it is difficult to improve the durability of the yarn.

  Another object of the present invention is to provide a thermoplastic hollow fiber excellent in both durability and light weight, and a fabric including the same.

  Another object of the present invention is to improve the durability, i.e., friction fastness and wear resistance, of a superfine yarn having only the island component eluted from the sea component of the sea-island composite fiber.

  Another object of the present invention is to improve the durability of the sea-island type composite fiber so that the sea-island type composite fiber can be used not only for clothing yarn but also for furniture yarn, sheet yarn, polishing yarn and the like.

  Hereinafter, the present invention will be described in detail.

  The thermoplastic fiber of the present invention contains a thermoplastic resin, and contains fluoropolymer particles having an average particle size of 0.01 to 5.0 μm in the thermoplastic resin.

  The fluoropolymer includes a polytetrafluoroethylene polymer, a copolymer of tetrafluoroethylene and hexafluoropropene, a copolymer of tetrafluoroethylene and perfluoroalkyl vinyl ether, and a group consisting of these terpolymers. One or more selected.

  Examples of perfluoroalkyl vinyl ethers include perfluoropropyl vinyl ether and perfluoroethyl vinyl ether.

  The fluoropolymer particles are contained in the thermoplastic resin constituting the fiber and serve to reduce the coefficient of friction of the fiber.

  That is, when the fluoropolymer particles in the thermoplastic resin are located on the surface of the fiber, the metal friction coefficient of the yarn is reduced to protect the thermoplastic fiber itself.

  The content of the fluoropolymer particles in the thermoplastic resin is preferably 0.1 to 9.0% by weight.

  When this content is less than 0.1% by weight, it is difficult to ensure the wear resistance and durability of the fiber. On the other hand, when the content exceeds 9% by weight, it is possible to realize wear resistance and durability exceeding a required level. However, in order to produce the fiber, tension and frictional force above a certain level are required, and the yarn path swings very seriously during radiation, and the angle of the yarn wound on the winding drum is adjusted. However, the processability becomes very fragile, for example, the yarn path is collapsed.

  The average particle diameter of the fluoropolymer particles is preferably 0.01 to 5.0 μm, more preferably 0.1 to 1.0 μm, when measured with an optical microscope or an electron microscope. If it is less than 0.01 μm, it is difficult to solve the yield that can be obtained by pulverizing the fluoropolymer and the phenomenon of entanglement due to the ultrafine diameter. On the other hand, when the average particle diameter exceeds 5.0 μm, the inorganic particles do not exhibit continuity, function as the weakest point during radiation when producing fibers with thermoplastic resin, This is a direct cause of process performance degradation.

  As the thermoplastic fiber, a normal yarn containing a thermoplastic resin, a sea-island type composite fiber in which an island component having a single yarn fineness of 0.01 to 0.3 denier is dispersed in a sea component of an alkali-eluting polymer, or Examples thereof include a thermoplastic hollow fiber in which a hollow portion is formed on the yarn cross section.

  When the thermoplastic fiber is a sea-island type composite fiber, the fluoropolymer particles having an average particle size of 0.01 to 5.0 μm are contained in the island component.

  The hollow ratio of the thermoplastic hollow fiber varies depending on the kind of the thermoplastic resin, but if it is generally 10 to 40% level, it is sufficient. When the hollowness is lower than 10%, it is difficult to obtain a substantial lightening effect. If it is higher than 40%, even if the hollow is formed well, it tends to be easily broken by an external force.

  The present invention includes a cloth having thermoplastic fibers in which fluoropolymer particles having an average particle diameter of 0.01 to 5.0 μm are contained in a thermoplastic resin. The thermoplastic fiber content in the cloth is preferably 40 to 100% by weight.

  The fabric according to the present invention is excellent in durability and lightness.

  For example, in the case of a polyester carpet that requires a wear resistance of 2000 times under ASTM-D3884, if a conventional polyester yarn of 150 denier is used, 1400 even if the carpet structure or dyeing processing conditions are changed. It is difficult to obtain wear resistance more than once.

  However, when the thermoplastic fiber (common fiber) according to the present invention is used, a wear resistance of 2000 times or more can be realized even with a 150 denier material.

  Furthermore, even for a 75 denier grade material with a frequency of 350 times of friction resistance, the level can be improved to 500 times or more, and the effect is doubled when a temporary stretching process is performed.

It is a cross-sectional illustration figure of the thermoplastic hollow fiber which concerns on this invention. It is a cross-sectional illustration figure of the thermoplastic hollow fiber which concerns on this invention.

1 Hollow fiber A Thermoplastic resin B Hollow part

  Hereinafter, the present invention will be described more specifically through the following examples and comparative examples with reference to the accompanying drawings. However, the scope of the present invention is not limited to the following examples.

  A master batch containing 15% by weight of polytetrafluoroethylene particles having an average particle diameter of 0.5 μm as measured with an electron microscope was produced using polyethylene terephthalate as a basic polymer.

  Using this masterbatch and a base polymer of polyethylene terephthalate, polyethylene terephthalate fibers containing 36 filaments of 75 denier were produced by a direct radiation drawing method. At this time, the content of the master batch was adjusted so that the content of the polytetrafluoroethylene particles in the fiber was 1% by weight.

  88 pieces of this were further produced on a 4 kg drum, weaved with a 22 gauge interlac circular knitting machine, and dyed at 130 ° C. for 60 minutes. Then, it dried with the hot air dryer at the speed | rate of 30 m / min, and manufactured the circular knitted fabric.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  The polyethylene terephthalate was the same as in Example 1 except that the average particle size of the polytetrafluoroethylene particles was changed to 1.0 μm and the content of the polytetrafluoroethylene particles in the polyethylene terephthalate fiber was changed to 2% by weight. Rate fibers and their circular knitted fabrics were produced.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  A polyethylene terephthalate fiber (polytetrafluoroethylene content in the fiber is 1% by weight) produced under the same conditions as in Example 1 was pre-drawn to produce a polyethylene terephthalate pre-drawn yarn, which was then used. A circular knitted fabric was produced under the same conditions as in Example 1.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  A polyethylene terephthalate fiber (polytetrafluoroethylene content in the fiber: 2% by weight) produced under the same conditions as in Example 2 was pre-drawn to produce a polyethylene terephthalate pre-drawn yarn, which was then used. A circular knitted fabric was produced under the same conditions as in Example 1.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  A master batch containing 15% by weight of polytetrafluoroethylene particles having an average particle diameter of 2.0 μm as measured with an electron microscope was produced using polyethylene terephthalate as an island component as a basic polymer.

  Using this masterbatch, a 36-divided sea-island type composite fiber containing 24 denier yarns of 75 denier was produced by a radial direct drawing method. The ratio of the island component in the fiber was 70% by weight, and an alkali-eluting polymer was added as a sea component at a rate of 30% by weight. At this time, the content of the master batch was adjusted so that the content of the polytetrafluoroethylene particles in the polymer as the island component was 1% by weight.

  A further 88 sea-island type composite fibers were produced in a drum of 4 kg capacity, pre-drawn, and highly shrinkable yarn containing 12 filaments of 30 denier (when immersed in hot water at 100 ° C. for 30 minutes, the shrinkage of the yarn was 25 %) To produce 105 denier 36 filament yarns. After weaving this with a 32 gauge interlac circular knitting machine, it was processed with a raising machine so that the cloth width was reduced to 50%, and sheared to produce a basic cloth. Subsequently, a 50% pure NaOH strong alkali solution was added to this at 100 ° C. hot water to adjust the overall weight loss concentration to 1% by weight. At this time, the weight ratio of the total weight of the weight reducing liquid to the cloth to be added was adjusted to be 40: 1. This was reduced to about 24% by weight of the total cloth weight over 60 minutes, then scoured and washed with water. This was further dyed at 130 ° C. for 60 minutes, then dried with a hot air drier at 180 ° C. at a speed of 30 m / min, and then a circular knitted fabric was knitted through a brushing process.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  A master batch containing 15% by weight of polytetrafluoroethylene having an average particle diameter of 0.5 μm as measured with an electron microscope was produced using polyethylene terephthalate as a basic polymer.

  Using the aforementioned masterbatch, polyethylene terephthalate hollow fibers containing 48 denier of 150 denier were produced by a direct radiation drawing method. At this time, the content of the master batch was adjusted so that the content of polytetrafluoroethylene in the hollow fiber was 1% by weight. The hollow ratio of the hollow fiber was 30%.

  88 pieces of this were further produced with a 4 kg capacity drum, woven with a 22 gauge interlac circular knitting machine, and then dyed at 130 ° C. for 60 minutes. Subsequently, the circular knitted fabric was knitted by drying with a hot air dryer at 180 ° C. at a speed of 30 m / min.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

  A master batch containing 15% by weight of polytetrafluoroethylene having an average particle diameter of 1.8 μm as measured with an electron microscope was produced using polyethylene terephthalate as a basic polymer.

A polyethylene terephthalate hollow fiber containing 48 denier of 150 denier was produced by the direct radiation drawing method using the above masterbatch. At this time, the content of the master batch was adjusted so that the content of polytetrafluoroethylene in the hollow fiber was 2% by weight. The hollow ratio of the hollow fiber was 30%.
88 pieces of this were further produced with a 4 kg capacity drum, woven with a 22 gauge interlac circular knitting machine, and then dyed at 130 ° C. for 60 minutes. Subsequently, a circular knitted fabric was knitted by drying at a rate of 30 m / min with a hot air dryer at 180 ° C.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative Example 1>
A 75 denier / 36 filament polyethylene terephthalate fiber and its circular knitted fabric were produced in the same manner as in Example 1 except that polyethylene terephthalate containing no polytetrafluoroethylene was used.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative example 2>
A polyethylene terephthalate fiber and a circular knitted fabric thereof were produced in the same manner as in Example 1 except that the average particle diameter of the polytetrafluoroethylene particles was changed to 0.001 μm.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative Example 3>
A sea-island type composite fiber and a circular knitted fabric including the same were produced in the same manner as in Example 5 except that polyethylene terephthalate containing no polytetrafluoroethylene was used as the island component.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative example 4>
A sea-island composite fiber and a circular knitted fabric including the same were produced in the same manner as in Example 5 except that the average particle size of the polytetrafluoroethylene particles was changed to 0.001 μm.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative Example 5>
A 150 denier / 48 filament polyethylene terephthalate hollow fiber and its circular knitted fabric were produced in the same manner as in Example 6, except that polyethylene terephthalate containing no polytetrafluoroethylene was used.

  The number of wear resistance of the manufactured circular knitted fabric was measured, and the results are shown in Table 1.

<Comparative Example 6>
Except that the average particle size of the polytetrafluoroethylene particles was changed to 7.0 μm, an attempt was made to produce a polyethylene terephthalate hollow fiber in the same manner as in Example 6. Polyethylene terephthalate hollow fibers could not be produced on a commercial scale.

  For Examples 1 to 7 and Comparative Examples 1 to 6, the wear resistance of the circular knitted fabric was measured by the knitted fabric test method of ASTM-D3884, and the Martin abrasion resistance measuring instrument was used as the evaluation equipment. The friction cloth used was 320 Cw sandpaper, and the load was 500 g.

  As described in detail above, the thermoplastic fiber of the present invention is excellent in durability and can be applied to various fields. In particular, the thermoplastic fiber of the present invention can complement the durability and wear resistance of a lightweight material having a low overall fineness and can be used as clothing. On the other hand, the thermoplastic fiber of the present invention can be applied to materials for footwear and furniture whose strength and wear resistance are important, clothing products such as motorcycles and riding clothes, and is also widely used as materials for mountain climbing and mountain backpacks. Can be used. Furthermore, it can be applied as an abrasive material in which surface friction characteristics are important.

Claims (10)

  A thermoplastic fiber excellent in durability, comprising a thermoplastic resin, wherein the thermoplastic resin contains fluoropolymer particles having an average particle diameter of 0.01 to 5.0 μm.   The thermoplastic fiber according to claim 1, wherein the single yarn fineness is 20 denier or less.   The thermoplastic fiber according to claim 1, wherein a content of the fluoropolymer in the thermoplastic resin is 0.1 to 9.0% by weight.   The thermoplastic fiber according to claim 1, wherein the fluoropolymer has an average particle size of 0.1 to 1.0 µm.   The fluoropolymer includes a polytetrafluoroethylene polymer, a copolymer of tetrafluoroethylene and hexafluoropropene, a copolymer of tetrafluoroethylene and perfluoroalkyl vinyl ether, and a group consisting of these terpolymers. The thermoplastic fiber according to claim 1, comprising one or more selected from the group.   2. The thermoplastic fiber according to claim 1, wherein the thermoplastic fiber is a sea-island type composite fiber having a single yarn fineness of 0.001 to 0.3 denier and including an island component dispersed in a sea component of an alkali-eluting polymer.   The thermoplastic fiber according to claim 5, comprising fluoropolymer particles having an average particle diameter of 0.01 to 5.0 µm in the island component.   The thermoplastic fiber according to claim 1, which is a thermoplastic hollow fiber having a hollow portion formed in a yarn cross section.   The thermoplastic fiber according to claim 1, wherein the hollow ratio of the thermoplastic hollow fiber is 10 to 40%.   A fabric comprising the thermoplastic fiber according to claim 1.

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