JPS6311466B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention uses a split-type composite yarn in which a polyamide component is divided into a plurality of pieces by a polyester component that is continuously present in the cross section of the fiber.
The present invention relates to a method for producing a knitted fabric using polyamide split yarns.

More specifically, in the splittable composite yarn of the present invention, the components to be composited, that is, the splitting component (polyester component) and the splitting component (polyamide component), are mutually anti-peeling components, and The present invention relates to a method in which the splitting component is a component whose hydrolysis rate by an alkali is extremely accelerated, and at least a part of the splitting component is eluted by treating the splittable composite yarn with an alkali to produce a knitted fabric using the polyamide split yarn.

A split-type composite in which an easily eluted component that is easily soluble in a certain solvent is arranged so that a non-(or poorly eluted) component that is soluble in a certain solvent is divided into a plurality of parts. Using thread, by removing easily eluted components with a solvent, it is possible to create split threads consisting of extremely fine denier, especially less than 1 denier, non-(or difficult to eluted) components. It is widely known for producing woven and knitted fabrics with a silk-like texture because it can be similar to the process of finishing silk fabrics by removing seciline. Points to be kept in mind when producing split threads using such split-type composite threads are: Only the split components show selectively high elubility in a certain solvent, or do they have to be separated into easily eluting components and poorly eluting components? The difference in elution rate between components must be sufficiently large.

The elution equipment, operation, and solvent are not special.
It should be safe and inexpensive without being corrosive to the elution device.

The constituent ingredients are not special and are inexpensive.

Stable processing is possible without problems such as thread breakage and separation of tension between easily eluted components and non- (or difficultly) eluted components in the processes leading up to the final product before elution processing, such as spinning, drawing, weaving, knitting and weaving.

etc.

Here, the non-eluted component is made into a polyamide with excellent physical properties such as high strength, high melting point, good electrical properties, abrasion resistance, and chemical resistance, and the purpose is to make a split composite yarn into a final product. , and the following examples are known in this regard.

JP-A-48-9021 describes a split-type composite yarn in which an insoluble polymer is divided into five or more parts by a polymer soluble in a certain solvent.

However, although there are examples of using polyamides as insoluble polymers, there are no specific examples of soluble polymers that take into account peeling resistance from polyamides or easily eluting polymers.

In an example of Japanese Patent Publication No. 39-29636, an example of a split-type composite yarn in which nylon 66 is divided into four parts using polyethylene terephthalate is described. However, such a split composite yarn simply consisting of a combination of polyethylene terephthalate and nylon 66 has the disadvantage that peeling occurs between the two components of the drawn yarn, causing fuzz and thread breakage during knitting and weaving processes. Furthermore, polyethylene terephthalate can be easily and quickly removed on an industrial scale, making it possible to remove polyethylene terephthalate from nylon.
It is also difficult to choose only 66.

Japanese Patent Publication No. 48-28005 describes an example of a split type composite yarn consisting of two components, polyester and polyamide, and also states that the polyester component can be removed by alkali treatment. However, there are no specific examples of polyester components that are designed to have resistance to separation from polyamide components or to be easily eluted.

Japanese Patent Publication No. 53-10170 describes an example in which the polyester component is a polyester containing 0.1 to 2.0 mol% of metal sulfonate in a composite yarn in which polyester and polyamide are alternately arranged in a hollow annular cross section. . As described in the text, the purpose of this invention is to make the composite yarn into short fibers, and when carding these short fibers, both components are bonded together, and after carding, the fiber structure obtained from the web is subjected to heat treatment, buffing, etc. The purpose of the present invention is to separate the adhesion by separating the adhesion and provide a composite yarn suitable for making a fiber structure consisting of both polyester and polyamide fibers. There are the following disadvantages in removing at least a portion of the polyamide yarn to form a split polyamide yarn.

That is, such a hollow annular composite yarn has the disadvantage that it is difficult to spin it stably for a long period of time, and when the final target fiber structure is a knitted fabric made only of polyamide, the metal sulfonate is 2.0% Below mol%, the adhesive strength of both components is insufficient to prevent fuzz and thread breakage during weaving and knitting processes, and there are disadvantages that it takes a long time to remove the polyester component with an alkaline aqueous solution. The disadvantage is that the yarn cross section of the polyamide fiber after the polyester component is removed is limited to a substantially rectangular shape, and the presence of hollow portions increases the yarn cross section of the composite yarn, making it difficult to create a high-density fabric during weaving. The drawback is that it is difficult to obtain.

The present invention was achieved as a result of intensive studies aimed at solving the drawbacks of the prior art. That is, the present invention uses dilute alkali treatment, which does not cause peeling between the polyester component (easily eluted component) and the polyamide component (non-eluted component), and which facilitates the leaching treatment, prior to elution treatment such as stretching, weaving, or knitting. A method for producing knitted fabrics using polyamide split yarns by using splittable composite yarns that can elute polyester components (easily eluted components) almost completely and without causing uneven splitting in the length direction of the yarns by alkali treatment. It provides:

That is, in the present invention, the polyamide component is divided into a plurality of pieces by the polyester component that exists continuously in the yarn cross section, and the polyester component is composed of ethylene 5-2. Sodium sulfoisophthalate,
A splittable composite yarn containing ethylene terephthalate of 70 mol% or more and peeling resistance of 1,000 times or more is used as a knitted fabric, scouring and shape fixing treatment without causing wrinkles, and then treated with an alkaline aqueous solution to form a polyester component. This is a method for producing a knitted fabric using split polyamide yarn, characterized in that at least a part of the polyamide split yarn is eluted and split. (However, peeling resistance is determined by twisting the yarn 2.5 times and
It is expressed as the number of times until fuzz occurs when the yarns at the twisted part are squeezed together at 45°, yarn tension 0.2 g/d, and ironing frequency 100 times/minute. ) The yarn cross-sectional shape of the split yarn obtained in the present invention is
FIG. 2 schematically shows the cross-sectional shape of the splittable composite yarn used to obtain this splitted yarn. In FIGS. 1 and 2, A is a polyester component and B is a polyamide component. In FIG. 2, all the polyester components are present continuously in the yarn cross section.
In FIGS. 2a, b, and c, the polyamide component is divided into 2, 3, and 6 parts, respectively, depending on the polyester component in the round cross section.

When these splittable composite yarns are treated with alkali to remove the polyester component, they become as shown in Figure 1a, respectively.
This results in split threads having shapes such as b and c.

Figure 2 d shows a sea-island type split composite yarn in which the polyester component is a sea and the polyamide component is an island. When the polyester component is removed by alkali treatment, 14 denier mix yarns of approximately 7 sizes each, as shown in FIG. 1d, are obtained. Second
While the split-type composite yarns in Figures a to d have a circular cross section, Figure 2 e has a trilobal cross section, in which the polyamide component is divided into three by the polyester component, and the polyester component is removed by alkali treatment. When removed, it becomes a split thread having the form as shown in FIG. 1e. The cross-sectional shape of the split yarn and the cross-sectional shape of the split-type composite yarn are not limited to the shapes shown in FIGS. 1 and 2, and any known shapes can be applied.

When the splittable composite yarn is passed through high-order processing steps such as knitting and weaving, if fuzz or yarn breakage occurs, the knitting and weaving performance will deteriorate, and the quality of the knitted fabric will deteriorate, which is not desirable.

The present invention has made it possible to pass through such high-order processing steps without causing problems such as fuzz and yarn breakage. More than 2.4 mol% of units are ethylene 5
- Sodium sulfoisophthalate, and
It is a polyester in which 70 mol% or more is ethylene terephthalate, and the splittable composite yarn is characterized by having peeling resistance of 1000 times or more. A high-order processing process that is likely to cause fluff and thread breakage is when splittable composite yarns are used as warp yarns.In this case, the splittable composite yarns are repeatedly saturated on the loom by sheathing, etc. If the peeling resistance between the component and the polyamide component is low, the polyester component and polyamide component will peel off,
The separated single fibers or fibrils are cut and become fuzz, and further fuzz is generated, eventually leading to breakage.

The ease with which fuzz occurs and yarn breakage corresponds well to the values measured using the peeling resistance ^measurement method described below. The number of strokes until
The number of times of ironing must be 2,000 times or more, and the more the number of times of ironing until the thread breaks, the fewer warp threads will break, so it is preferably 2,500 times or more.

The number of fuzz on the resulting fabric is at a level that does not pose a practical problem as long as the number of ironings until fuzz occurs is 1000 times or more. When looking at this peeling resistance from the viewpoint of the amount of ethylene 5-sodium sulfoisophthalate, the peeling resistance improves as the copolymerization rate increases, and surprisingly, at around 2.4 mol %, the peeling resistance improves. The amount of ethylene 5-sodium sulfoisophthalate must be 2.4 mol% or more in order to rapidly improve the quality of the material and pass through higher processing steps without causing problems such as fuzz and thread breakage. is necessary.

In addition, the faster the elution of the polyester component by alkali treatment, the better.
- As the amount of sodium sulfoisophthalate increases, the elution time of the polyester component becomes faster. Moreover, here as well, the elution time becomes rapidly faster when the amount of ethylene 5-sodium sulfoisophthalate reaches around 2.4 mol%, so the amount of ethylene 5-sodium sulfoisophthalate is increased to 2.4 mol% or more. This is necessary from the point of view of elution rate, and 3.0
It is more preferable to set it to mol% or more.

The amount of ethylene 5-sodium sulfoisophthalate in the polyester component must be less than 20 mol% in order to prevent a decrease in yarn strength as a splittable composite yarn.

Polyamide in the present invention means ordinary synthetic linear polyamides, such as nylon 6, nylon 10, nylon 11, nylon 12, nylon 66,
Examples include nylon 610 and copolyamides containing these as main components, but among them, nylon 6
and nylon 66 are preferably applied. The polyester may contain structural units other than ethylene terephthalate units and ethylene 5-sodium sulfoisophthalate units. Specifically, aliphatic dicarboxylic acids such as adipic acid, sebacic acid, and dodecanoic acid, alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, and aromatic dicarboxylic acids such as isophthalic acid and 2,6-naphthalene dicarboxylic acid. , butylene glycol, aliphatic diols such as neopentyl glycol, 1,4-
Alicyclic diols such as cyclohexanedimethanol, xylylene glycol, 2,2-bis(β-
Examples include structural units such as aromatic diols such as hydroxyethoxyphenyl)propane, oxycarboxylic acids such as 4-β-hydroxyethoxybenzoic acid, and polyoxyalkylene glycols such as polyethylene glycol.

Furthermore, the modified polyester may be copolymerized with a small amount of a compound having three or more ester-forming functional groups, such as trimellitic acid or trimethylolpropane, if necessary, to the extent that the effects of the present invention are not impaired. good. It is also possible to incorporate well-known additives such as a quenching agent, an antioxidant, a fluorescent whitening agent, a flame retardant, and an ultraviolet absorber into the polyamide component and/or polyester component.

When manufacturing the splittable composite yarn to obtain the polyamide split yarn of the present invention by composite spinning and drawing, one structural unit in the fiber cross section of the polyamide component is
After elution of the polyester component, it is possible to produce a woven or knitted fabric consisting of yarns of 1 denier or less, exhibiting excellent drape properties, soft texture, and feel.

The ratio of the polyester component and the polyamide component in the splittable composite yarn, that is, the composite ratio, is such that the more the polyester component is, the easier it is to split by elution, but on the other hand, if it is too large, the strength and elongation of the splittable composite yarn will decrease. The weight ratio of the polyester component to the polyamide component is preferably in the range of 40:60 to 2:98, more preferably in the range of 30:70 to 5:95.

In addition, changing the composition of the polyamide polymer between the non-eluted components within one thread of the splittable composite yarn,
Any known technique can be applied, such as changing the denier between the non-eluted components, or making the non-eluted components a bonded or core-sheath type composite yarn.

In the present invention, the purpose can be achieved if at least a part of the polyester component of the splittable composite yarn is eluted by an alkali treatment to form split polyamide threads having a number corresponding to a predetermined number of divisions. It is not necessary to elute everything. However, if a portion of the polyester component remains together with the polyamide split yarn, uneven dyeing may occur in the length direction of the split thread or within one cross section after the split, or the hue may change, so the polyester component is , it is preferable that all of them are eluted.

Alkaline treatment can be carried out directly on splittable composite yarns, but post-treatment of splittable composite yarns as knitted fabrics is more efficient, and the space left after the polyester component has eluted is removed from the knitted fabrics. Bulky,
This is necessary because it is effective in improving the soft feel. In the latter case, it is necessary to perform scouring and shape fixing treatment under conditions that do not cause wrinkles in the knitted fabric after knitting and weaving, and then to elute the polyester component by an alkali treatment. The shape fixing treatment may be a well-known moist heat or dry heat treatment, but this treatment reduces the adhesion between split yarns, especially the adhesion between non-eluted components in the split composite yarn before splitting, and improves the uniformity of the surface of the knitted fabric. It greatly contributes to improving the appearance, bulkiness, soft feel, and drapability.

Alkali treatment involves treating yarn or woven or knitted fabrics with a heated aqueous solution of alkali metal hydroxide using a batch method, jitzker, wince, beam, hanging tank, etc. Any known method may be used. good. In order to speed up the elution rate of the polyester component, a phenolic substance, an amine substance, a quaternary ammonium salt, a high boiling point polyhydric alcohol, etc. can be added to the alkaline aqueous solution.

Among the alkali metal hydroxides, it is preferable to use sodium hydroxide because it is low in cost and has a large elution ability.
It is preferable to use it as °C. Further, the alkali treatment time can be determined by checking the elution state as appropriate while processing the yarn or woven or knitted fabric, but in the case of quantitative treatment, it is preferable to check and determine the elution state in advance by a preliminary test. In addition, in the method for producing split polyamide yarn according to the present invention, the easily eluted components were eluted very quickly in the alkali treatment, the polyamide component was not easily eluted, and the effect of the treatment time after the elution of the polyester component was small and stable. It has the characteristic that it can be treated with alkali.

According to the splittable yarn manufacturing method of the present invention, the splittable composite yarn is easy to handle before splitting, the splitting process can be performed extremely quickly and without uneven splitting, and after splitting, the splitting is less than 1 denier. It is also possible to obtain knitted fabrics using ultra-fine split yarns or ultra-fine split yarns with irregular cross-sections.

Using ordinary spinning and drawing methods to obtain ultrafine yarns of 1 denier or less not only has the drawback of easily causing problems such as yarn breakage and fluffing during the spinning and drawing processes, but also has similar problems in higher-order processes such as weaving, knitting, and weaving. There's a problem. On the other hand, the composite yarn has a denier larger than 1 denier, and by designing the composite yarn so that it becomes an ultra-fine split yarn with a denier or less of 1 denier after splitting, spinning,
It is possible to stably pass through the stretching, knitting and weaving processes.

Therefore, it can be applied to the production of suede-like knitted fabrics made of ultra-fine yarns or silk-like knitted fabrics with an elegant luster and flexible texture, and can also be applied to twisting and knitting by taking advantage of the ease of handling in the weaving process. It can be used for warp threads without any similar convergence processing such as gluing.

The peeling resistance in the present invention is determined by twisting the yarn 2.5 times, twisting angle 45°, yarn tension 0.2g/d,
It is expressed as the number of times until fuzz occurs when the threads in the twisted portion are squeezed together at a squeezing frequency of 1000 times/minute. Next, the method for measuring peeling resistance in the present invention will be explained in more detail with reference to FIG. 4, which is a schematic plan view of a measuring device (a yarn friction binding force tester manufactured by Toyo Seiki Seisakusho). This device has left and right vibration tables 21 to 2 on the left side.
6, thread fixing terminals 11 and 16 and rotation guides 12 to 15 are mounted, respectively, as shown in the figure.
The vibrating tables 21, 23, and 25 can move simultaneously in the same direction, and the vibrating tables 22, 24, and 26 can simultaneously move in the opposite direction. The moving distance is 3 cm on each side. A yarn path regulation rotation guide 30 is located in the center. In the part that becomes the thread path on the right side, there are free rotating bodies 41 to 45 with grooves, and the free rotating bodies are connected to the support body 5.
Load 60 to the right through 0 (0.2 per thread)
g/d). The sample thread 10 is tied at one end to the thread fixed end 11 as shown in the figure.
Pass the thread through to the other fixed thread end 16. however,
In the twisting section 70, the threads are twisted 2.5 times, and the twisting angle θ is 45°. After setting in this condition, move the vibrating table at a speed of 100 times per minute to squeeze the string. Measure the number of strokes until fluffing and thread breakage occur, and use the average value of the 10 measurements as the measured value.

The present invention will be specifically explained below with reference to Examples.

Example 1 Nylon 6 with a sulfuric acid viscosity of 2.4 was used as the polyamide component, and ethylene 5-sodium sulfoisophthalate (5 mol%)/ethylene terephthalate (95 mol%) copolymer with an intrinsic viscosity of 0.53 in orthochlorophenol was used as the polyester component. Using the composite spinning apparatus shown in Japanese Patent Publication No. 47-2485 as shown in Figure 3, a split composite yarn having a cross section as shown in Figure 2 e was obtained at a spinning temperature of 280°C and a spinning speed of 1200 m/min. Ta. In this splittable composite yarn, the polyester component accounts for 15% by weight of the entire yarn. Continue stretching speed 400m/min, heat pin 100℃, stretching ratio
Normal drawing was carried out at a magnification of 3.4 times to obtain a drawn yarn of 82 denier 36 filaments (70 denier 108 filaments after alkali treatment). The peeling resistance of the drawn yarn is determined by 2310 times of ironing until fluffing occurs and 3560 times until yarn breakage, and the elution resistance of the polyester component is determined by the concentration of the alkaline aqueous solution.
The elution time when treated with alkali at 30 g of NaOH/100° C. was 3 minutes. This drawn yarn is used as warp yarn and weft yarn for plain fabric (warp yarn density 116
A book/2.54cm, weft yarn density of 93 pieces/2.54cm) was woven. The warp yarn breakage during weaving was as low as 0.6 times/10 ⁶ m, and the surface fuzz was at a level that did not cause any problems. After scouring this fabric in water at 98 to 100°C with Neugen and soda ash without causing wrinkles, its shape was fixed by moist heat setting at 120°C for 5 minutes while allowing free shrinkage. Ta. Then, 30
The polyester component was completely eluted by alkaline treatment with a NaOH aqueous solution of 100°C for 5 minutes, and the polyamide split threads were washed with water and air-dried. The resulting woven fabric was subjected to a dry heat finishing set at 150° C. for 5 minutes under substantially no tension. The obtained fabric was excellent in drapability, bulkiness, and soft feel and texture.

Example 2 Spinning, stretching, I did some weaving. The peeling resistance of the drawn yarn was determined by 1090 strokes before fluffing and 2100 strokes before yarn breakage, and the elution time of polyester was 45 minutes (alkaline aqueous solution concentration NaOH30).
g/, treatment temperature 100°C). The warp thread breakage during weaving was as low as 0.9 times/10 ⁶ m, and the surface fuzz was at a level that did not cause any problems. After scouring and fixing the shape of the fabric in accordance with Example 1, the fabric was treated with an alkali solution of 30 g/NaOH aqueous solution at 100° C. for 60 minutes to completely dissolve the polyester component, and washed with water and air-dried as polyamide split threads. The resulting woven fabric was subjected to a dry heat finishing set at 150° C. for 5 minutes under substantially no tension. The obtained woven fabric was a good woven fabric similar to that of Example 1.

Comparative Example 1 Spinning and stretching were carried out in the same manner as in Example 1, except that the polyester component in Example 1 was changed to ethylene 5-sodium sulfoisophthalate (2.0 mol%)/ethylene terephthalate (98.0 mol%) copolymer. , Weaving. The peeling resistance of the drawn yarn was poor, with 270 times of ironing before fluffing and 930 times before yarn breakage.
(30g of NaOH/treatment temperature: 100°C) was required for a long time. Warp yarn breaks during weaving: 2.7 times/10 ⁶ m
There was a lot of fluff on the surface, and the quality of the fabric was poor. Furthermore, in order to completely remove the polyester component from the fabric with a 30 g NaOH aqueous solution, an extremely long treatment time of 120 minutes was required.

[Brief explanation of the drawing]

Figures 1 a to e are cross-sectional views of various split yarns in the present invention, Figures 2 a to e are cross-sectional views of various split composite yarns for obtaining split yarns in the present invention, and Figure 3 is a cross-sectional view of various split yarns in the present invention. FIG. 4 is a schematic cross-sectional view of the vicinity of the discharge hole showing the spinning state of the splittable composite yarn for obtaining the splittable yarn in the present invention, and FIG. 4 is a schematic diagram of the flaking resistance measuring device. A: polyester component, B: polyamide component,
10; Sample yarn, 11, 16; Thread fixing terminal, 1
2-15; Rotation guide, 21-26; Vibration table, 3
0; Thread path regulation rotation guide, 41-45; Free rotating body, 50; Support body, 60; Load, 70; Twisting portion.

Claims (1)

[Claims] 1. A polyamide component is divided into a plurality of pieces by a polyester component that exists continuously in the yarn cross section, and the polyester component is composed of ethylene in 2.4 mol% or more and less than 20 mol% of the total structural units. 5-Sodium sulfoisophthalate, and 70 mol% or more is ethylene terephthalate, and has good peeling resistance.
A polyamide splitting method characterized in that a knitted fabric is made of a splittable composite yarn that has been used over 1000 times, is subjected to scouring and shape fixing treatment without causing wrinkles, and then treated with an alkaline aqueous solution to elute and split at least a part of the polyester component. A method of manufacturing yarn-based knitted fabrics. (However, the peeling resistance is determined by twisting the yarn 2.5 times, twisting angle 45°, yarn tension 0.2 g/d, and ironing frequency 100 times/min.) 2. The method for producing a knitted fabric using polyamide split yarn according to claim 1, wherein the constituent unit of the polyamide component in the splittable composite yarn is 1 denier or less.