JP5631282B2 - Heat resistant composite spun yarn - Google Patents

Description

  The present invention relates to a spun yarn having heat resistance, scattering resistance and biosolubility. As a use, it is processed into a rope, a sleep, a tape, a woven fabric, a knit or the like.

  Conventionally, spun yarns mainly made of ceramic fibers and woven fabrics thereof have been used for heat resistance. For example, it is used for lining and expansion sheets for high-heat ducts, high-temperature packing materials, welding spark-proof cloths, high-temperature heat-insulating sheets, heat-resistant sound-absorbing sheets, and the like. In addition to woven fabrics, ropes, sleeps, tapes, knits, etc. are also widely used.

  However, it has been known that ceramic fibers may be harmful to health such as carcinogenicity.

  For this reason, biosoluble ceramic fibers have attracted attention and there is an alternative movement (Patent Document 1). However, biosoluble ceramic fibers are weak because the fiber strength is weak, they are easily damaged, fall in the production process of spun yarn, the yield is remarkably bad, and the processed product has many fibers falling off and scattering when used. There's a problem.

  In addition, those using glass fiber spun yarns are inferior in heat resistance and are damaged at the time of use at high temperatures.

  In view of this, a heat-resistant yarn manufacturing method in which silica filament yarn is used as a core and silica staple fiber is wound around the yarn by a friction spinning method has been considered (Patent Document 2). However, in this method, there is a problem that the silica staple fiber is broken in the production process and falls off as the fiber length is shortened, and the yield is remarkably reduced. Silica fibers tend to be damaged during the manufacturing process and have a short fiber length. Furthermore, when the product is used, the scattering of the fibers is severe, and there is a problem that the working environment is deteriorated and the life of the product is reduced.

JP 2004-183153 A European Patent Publication No. EP0837165A3

  Accordingly, an object of the present invention is to provide a heat-resistant spun yarn and a processed product thereof that are heat-resistant, have a good product yield at the time of manufacture, and have little fiber scattering during use.

The heat-resistant composite spun yarn of the present invention is formed by using a spun yarn made of organic fibers as a core yarn, covering the core yarn with staple fibers (short fibers) including at least silica fibers and glass fibers, and twisting them. It is characterized by that .

  By using a spun yarn made of organic fibers as the core yarn, the organic fibers that are fuzzy on the surface of the core yarn increase the entanglement with the silica fibers (and glass fibers), and the fiber length tends to be shortened as described above. Silica fibers can be smoothly entangled and coated and twisted. Further, when glass fiber is added, the glass fiber softens at a temperature lower than that of the silica fiber at a high temperature and bonds the silica fiber, so that the scattering of the fiber can be reduced during use. Hereinafter, exemplary embodiments of each element of the present invention will be described. In addition, the compounding ratio (mass%) of each element illustrated below is a value when the whole heat resistant composite spun yarn is 100 mass%.

1. Core yarn A spun yarn made of organic fibers is used.

1-1. Organic fiber Although it does not specifically limit as an organic fiber, Synthetic fibers, such as natural plant fibers, such as cotton, hemp, and flax, rayon, and polyester, can be illustrated.

1-2. Compounding The compounding ratio of the core yarn is not particularly limited, but is preferably 1 to 9% by mass. If the core yarn is less than 1% by mass, the strength is weak and easily cut, and if it exceeds 9% by mass, anxiety of ignitability increases. The core yarn can be further reinforced by mixing a filament yarn made of long glass fibers and a metal wire. As an effect, the strength can be further increased.

2. Staple fibers Staple fibers containing at least silica fibers and glass fibers are used. Silica fiber is amorphous and maintains the shape of the fiber even under a temperature environment of 1000 ° C. However, when the silica fiber is exposed to a high temperature state, the flexibility of the fiber is impaired, the mechanical strength is lowered, and the fiber is easily dropped or scattered. Therefore, by blending the glass fiber with the silica fiber, the glass fiber surface is dissolved and fused with the silica fiber in a use environment where the surface of the glass fiber is above the softening temperature, and the fiber is less likely to be scattered. Become. In particular, in the present invention, the anti-scattering effect of the composite spun yarn can be expected in the use range from −100 ° C. to + 100 ° C. of the softening point of the glass fiber.

2-1. Compounding The compounding ratio of the silica fibers is not particularly limited, but is preferably 50 to 95% by mass. When the silica fiber is less than 50% by mass, the heat resistance is remarkably lowered, and when it exceeds 95% by mass, the silica fiber is easily scattered at a high temperature. The compounding ratio of the glass fibers is not particularly limited, but is preferably 3 to 48% by mass. If the glass fiber is less than 3%, the bonding strength between the silica fibers at the time of softening at high temperature is not sufficient, and if it exceeds 48%, the heat resistance is lowered.

  It is preferable that 1 to 20% by mass of crimped fibers such as cotton and flame resistant fibers is further mixed into the staple fibers. As the effect, the yield is increased, the workability is improved, and the scattering of the fibers is reduced during use. It is preferable that the staple fibers are further reinforced by mixing filament fibers made of long glass fibers, metal wires, and the like with the staple fibers. As an effect, the strength can be further increased.

  Moreover, since glass fiber and silica fiber are inferior in converging property and have low wear resistance, the spun yarn may be processed with a binder. Examples of the binder material used for the binder treatment include acrylic, polyvinyl, gelatin, and starch. Further, a lubricant such as a surfactant and vegetable oil may be added. These may be processed in a spun yarn process, or may be processed after processing of a woven fabric or the like.

2-2. Silica fiber As a silica fiber, the high silicate glass fiber formed by acid-treating glass fiber can be illustrated. For example, by immersing E glass fiber using acid such as hydrochloric acid having a concentration of 9 to 12% by mass at a temperature of 40 to 70 ° C. for about 30 minutes to several hours, the surface layer portion of E glass fiber or the like Silica fibers having a SiO ₂ content of 80% by weight or more and heat resistance can be obtained.

SiO ₂ content of the surface layer of the silica fibers is preferably 80 to 96 wt%. Here, the surface layer portion of the fiber is a portion from the fiber surface to a depth of less than about 1 μm. When the SiO ₂ content is less than 80%, the heat resistance is remarkably lowered, and when it exceeds 96%, the biosolubility is lowered. By reducing the acid concentration during the acid treatment or lowering the temperature setting, the type and amount of the eluted element from the fiber surface, the thickness of the surface layer, and the like can be adjusted.

  The silica fiber is preferably a porous fiber, and is a porous fiber having a water absorption of 2 to 10% by mass (the weight of silica fiber before drying at 110 ° C. for 1 hour is 100%). More preferred. This is because moisture from the atmosphere is easily adsorbed and contributes to an endothermic action that is self-cooling protection at the time of increasing the adhesion between fibers and raising temperature. If the water absorption is less than 2%, the above effect cannot be expected sufficiently, and if it exceeds 10%, the fiber strength is lowered.

2-3. Glass fiber Glass fiber is not particularly limited. Although heat-resistant T glass and S glass are suitable, since these are expensive, general-purpose E glass may be used. The water absorption is generally 1% by mass or less. As a sizing agent, an organic component (for example, about 1% by mass) may be attached.

2-4. Fiber length The average fiber length of silica fibers and the average fiber length of glass fibers are not particularly limited, but are preferably 10 mm or more, and more preferably 15 to 50 mm. When the average fiber length is less than 10 mm, the yarn surface has a very large amount of fluff, and is poor in resistance to squeaking in the spun yarn process, the textile process, or in use. And the work and usage environment will deteriorate. When the average fiber length exceeds 50 mm, fluff on the surface of the yarn is extremely reduced, the bulkiness that is characteristic of the spun yarn is reduced, and after forming a woven fabric, when the surface is coated with a resin or an inorganic binder, the fibers and The conformability is lowered, and the joining force is likely to be lowered.

2-5. Fiber Diameter The fiber diameter of the silica fiber and the fiber diameter of the glass fiber are not particularly limited, but are preferably 4 to 15 μm, more preferably 5 to 10 μm. When the fiber diameter is 3 μm or less, the heat resistance is lowered, and the risk of health inhibition to the lungs (inhalable fiber for persons defined by WHO) is expected. When the fiber diameter exceeds 15 μm, mechanical breakage of the fiber is likely to occur, and dropout and scattering are likely to occur.

3. 3. Heat resistant composite spun yarn 3-1. Coated twisting The Tex count of the heat-resistant composite spun yarn is not particularly limited, but 100 to 1000 Tex is preferable in production.
The number of twists of the heat-resistant composite spun yarn is not particularly limited, but about 1 per inch (25.4 mm) for a single yarn, and about 4 for both the upper and lower twists of a twin yarn are appropriate values based on torsional rigidity.
Heat-resistant composite spun yarn with an appropriate bulky treatment is well-suited with resin and has a surface with various functions such as heat resistance, heat insulation, sound insulation, vibration resistance, waterproofness, and antifouling. Suitable for coated processed products.

3-2. Applications Heat-resistant applications are not particularly limited, and examples thereof include linings and expansion sheets for high-heat ducts, high-temperature packing materials, weld spark crosses, high-temperature heat-insulating sheets, and heat-resistant sound-absorbing sheets.
The heat-resistant composite spun yarn can be used not only for yarn but also for processed products such as woven fabric, rope, sleep, tape, and knit.

  According to the present invention, it is possible to provide a heat-resistant spun yarn and a processed product thereof that are heat-resistant, have a good product yield at the time of manufacture, and have little fiber scattering during use.

FIG. 1 is an enlarged front view showing a heat-resistant composite spun yarn according to the present invention with a part thereof broken.

  The heat-resistant composite spun yarn is obtained by using a spun yarn made of an organic fiber as a core yarn, and covering and twisting a staple fiber (short fiber) including at least silica fiber and glass fiber around the core yarn. .

FIG. 1 shows a heat-resistant composite spun yarn 1 of Examples 1-7. Table 1 shows the mixing ratios of Examples 1 to 4, and Table 2 shows the mixing ratios of Examples 5 to 7 and Comparative Examples 1 and 2. However, Examples 4 and 7 in which the staple fiber does not contain glass fiber are reference examples.
In Examples 1 to 4, a spun yarn of cotton fiber is used as the core yarn 2, and the staple fiber 3 made of silica fiber and E glass fiber (in Example 4 only silica fiber) is coated around the core yarn 2 and added. Twisted yarn is used to create a twin yarn TEX count 760TEX, and the blending ratio of the fibers is different from each other in the examples. As the silica fiber, the E glass fiber is immersed in hydrochloric acid having a concentration of 10% by mass at a temperature of 80 ° C. for about 120 minutes, so that the surface layer portion of the E glass fiber or the like has a SiO ₂ content of 78 to 97% by weight. % Silica glass made of silica glass with heat resistance.
Example 5 was carried out only in that the core yarn 2 and the staple fiber 3 were further twisted by adding one thin wire made of stainless steel (SUS316L), the blending ratio of the fiber, and the TEX count 880TEX was made. This is different from Examples 1 to 4.
Example 6 is different from Examples 1 to 4 only in that the staple fiber 3 made of silica fiber, E glass fiber, and cotton fiber is used.
Example 7 is different from Examples 1 to 4 only in that the staple fiber 3 composed of silica fiber and flameproof fiber is used.
In Comparative Example 1, a twin-thread TEX count 760TEX was created using a spun yarn made of 100% E glass fiber without using a core yarn.
In Comparative Example 2, a twin-thread TEX count 760TEX was created using a spun yarn made of 100% silica fiber without using a core yarn.

About each Example and the comparative example, the following 3 characteristics were investigated and comprehensive evaluation was carried out. Tables 1 and 2 also show the results.
1. Raw material yield of spun yarn process (% by mass)
2. High temperature heat resistance: The prepared composite spun yarn was placed in a thermostat at 800 ° C. for 48 hours, and then the state of the fiber was examined.
3. The weight change rate after 6 months was obtained by mounting on an expansion sheet for the inside of a high heat duct.
As the evaluation criteria for comprehensive evaluation, ○ is appropriate, Δ is slightly appropriate (can be used), and × is inappropriate.
Each of Examples 2, 3, 5, and 7 was excellent in each characteristic and evaluated as appropriate.
In Examples 1, 4 and 6, all of the characteristics were slightly inferior to those of Example 2 and the like. However, they were in a usable range and were evaluated as being somewhat appropriate.
Comparative Examples 1 and 2 were judged to be unsuitable due to many breakages and scattering when using a high-temperature duct cloth.

Next, as shown in Table 3, changes in the physiological saline dissolution rate and the high-temperature heat resistance due to the change in the SiO ₂ content in the surface portion of the silica fiber were examined.
For silica fiber, the one obtained by acid-treating E glass fiber as in Examples 1 to 7, except that by changing the acid treatment conditions, the SiO ₂ content of the surface portion of the silica fiber was changed, and each It adjusted to the sample (silica fiber 1-4). Specifically, the E glass fiber is immersed in a hydrochloric acid having a concentration of 10% by mass at a temperature of 60 to 80 ° C. for about 3 to 180 minutes, so that the surface layer of the E glass fiber has a SiO ₂ content of 78. ˜97 wt% siliceous glass. The SiO ₂ content of the surface portion of the silica fiber was measured using a fluorescent X-ray elemental analyzer under the apparatus conditions for the composition of the portion from the fiber surface to a depth of less than about 1 μm. As a comparative example, a sample of general-purpose refractory ceramic fiber was used.
The physiological saline dissolution rate was measured by adding 450 cc of physiological saline mixed as shown in Table 4 to 3.0 g of the fiber sample, sealing it in a 500 cc container made of polypropylene resin, and leaving it in a drying oven at 40 ° C. for 50 hours. The rate of change in dry weight was measured. The evaluation is 1% or more as good and is represented by a circle. Less than 0.1% was deemed unsatisfactory as x.
As for the high temperature heat resistance, the fiber state was examined after being placed in a constant temperature oven at 800 ° C. for 48 hours as in the above example.
When the SiO ₂ content of the surface layer portion of the silica fiber is 80 to 96% by mass, the physiological saline dissolution rate is high (thus, it is difficult to stay in the human body), and high-temperature heat resistance is also appropriate.

1 Heat-resistant composite spun yarn 2 Core yarn 3 Staple fiber

Claims (4)

  A heat-resistant composite spun yarn in which a spun yarn made of an organic fiber is used as a core yarn, and a staple fiber including at least silica fiber and glass fiber is coated and twisted around the core yarn.   The heat-resistant composite spun yarn according to claim 1, wherein a blending ratio of the silica fibers is 50 to 95 mass%, and a blending ratio of the glass fibers is 3 to 48 mass%. The silica fiber is a high silicate glass fiber obtained by acid-treating a glass fiber, the SiO ₂ content of the surface portion of the fiber is 80 to 96% by mass, and the fiber is a porous fiber. Or the heat-resistant composite spun yarn of 2.   4. The heat-resistant composite spun yarn according to claim 1, wherein the core yarn or the staple fiber is reinforced by mixing a filament yarn or a metal wire made of a long glass fiber.

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