Island-in-sea single filament knitted fabric and method for manufacturing the same

Abstract

This invention relates to the field of island fiber technology, specifically to an island monofilament knitted fabric and its preparation method. The preparation method includes the following steps: knitting the fabric using island fibers to obtain the island monofilament knitted fabric; the island component of the island fiber is any one of TPEE, PA6, PA66, and PET with a viscosity greater than 0.9 dl / g; the sea component of the island fiber is PBT or PET with a viscosity of 0.5–0.75 dl / g. This preparation method uses island fibers to knit the fabric without alkali dissolution, and the finished product retains the monofilament state of the island fibers. The island component has a small fineness and good toughness, resulting in a soft and pliable fabric; the sea component has good abrasion resistance, which can improve the abrasion resistance of the knitted fabric.

Description

Technical Field

[0001] This invention relates to the field of island fiber technology, specifically to an island monofilament knitted fabric and its preparation method. Background Technology

[0002] Fibers prepared by dispersing one polymer in another are called island fibers. In island fibers, the dispersed phase is called the "island," and the parent phase is called the "sea." The "island" and "sea" components are continuously, densely, and uniformly distributed along the fiber's axial direction. Current technology typically uses island fibers for knitting, then completely dissolves the "sea" component through finishing processes to obtain ultrafine fibers with a single filament diameter of less than 3.0 μm. For example, Chinese invention patent application number 200410013813.0 discloses an island-type composite fiber, using thermoplastic resins such as PP (polypropylene) and PA6 (polyamide 6) as the "island" component and biodegradable polylactic acid or its copolymers as the "sea" component. A composite spinning method is used to obtain the island-type composite fiber. Treating this composite fiber or its fabric with alkaline water yields ultrafine fibers or fabrics. While this ultrafine fiber fabric is soft, has high elongation at break, and good flexural strength, its abrasion resistance is poor, which does not meet the requirements of the footwear industry. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a flexurally resistant and abrasion-resistant island monofilament knitted fabric and its preparation method.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a method for preparing island monofilament knitted fabric, comprising the following steps: knitting fabric using island fibers to obtain island monofilament knitted fabric;

[0005] The island component in the island fiber is any one of TPEE, PA6, PA66 and PET with a viscosity greater than 0.9 dl / g;

[0006] The marine component in the island fiber is PBT or PET with a viscosity of 0.5 to 0.75 dl / g.

[0007] Another technical solution adopted in this invention is: island monofilament knitted fabric prepared by the above preparation method.

[0008] The beneficial effects of this invention are as follows: the preparation method of this invention uses island-island fibers to weave knitted fabric without alkali dissolution, and the finished product retains the monofilament state of the island-island fibers. Among them, the island component has a small fineness and good toughness, and the prepared fabric is soft and resistant to bending; the sea component has good abrasion resistance, which can improve the abrasion resistance of the knitted fabric. Attached Figure Description

[0009] Figure 1The image shown is a cross-sectional view of the island monofilament before dissolution in Embodiment 1 of the present invention. Detailed Implementation

[0010] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0011] Reference Figure 1 A method for preparing a sea-island monofilament knitted fabric includes the following steps: knitting fabric using sea-island fibers to obtain sea-island monofilament knitted fabric;

[0012] The island component in the island fiber is any one of TPEE (thermoplastic polyester elastomer), PA6, PA66 (polyamide 66) and PET (polyethylene terephthalate) with a viscosity greater than 0.9 dl / g;

[0013] The marine component in the island fiber is PBT (polybutylene terephthalate) or PET with a viscosity of 0.5 to 0.75 dl / g.

[0014] As described above, conventional island-island fibers are alkali-dissolved and washed until only the island phase remains to prepare microfibers, which can improve the softness of the fabric. However, microfibers have poor abrasion resistance, which does not meet the requirements of footwear materials. This invention uses island-island fibers to weave knitted fabric without alkali dissolution, and the finished product retains the monofilament state of the island-island fibers. The island component has a small fineness and good toughness, resulting in a soft and pliable fabric; the sea component has good abrasion resistance, which can improve the abrasion resistance of the knitted fabric.

[0015] The island components are made from materials with excellent wear resistance and toughness. TPEE combines the excellent elasticity of rubber with the processability of thermoplastics, offering adjustable hardness and excellent resilience, toughness, and strength, with extremely high resistance to creep, impact, and flexural fatigue. PA6 and PA66 fibers have the highest wear resistance among textile fibers, high strength, and good resilience, resulting in fabrics with good wear resistance and strength—properties perfectly suited for footwear materials.

[0016] Furthermore, the knitted fabric is soaked in an alkaline solution to remove some of the sea components from the island fibers. The remaining sea components connect the island components and maintain the monofilament state of the island fibers, resulting in an island monofilament knitted fabric.

[0017] As can be seen from the above description, the beneficial effects of the present invention are as follows: by dissolving only a portion of the marine components of the island fibers, the technical effect of destroying but not completely removing the marine components is achieved, allowing the remaining marine components to still adhere to the island components and form a protective layer, thereby improving the abrasion resistance of the knitted fabric. Simultaneously, partial removal of the marine components can improve the flexural strength of the knitted fabric.

[0018] Furthermore, PET with a viscosity of 0.5 to 0.75 dl / g includes water-soluble PET.

[0019] As can be seen from the above description, marine components are selected from materials that are wear-resistant and easily soluble in a weakly alkaline environment.

[0020] Further, the specific steps for removing some marine components are as follows: soak the knitted fabric in an alkaline solution with a pH of 7 to 14 for 5 to 45 minutes.

[0021] As can be seen from the above description, partial dissolution of marine components can be achieved by controlling the pH value of the alkaline solution and the soaking time.

[0022] Furthermore, the alkali in the alkaline solution is KOH or NaOH.

[0023] Furthermore, when the marine component is PBT, the specific steps for removing part of the marine component are as follows: soak the knitted fabric in an alkaline solution with a pH of 7 to 10 for 5 to 10 minutes.

[0024] Furthermore, when the sea component is PET with a viscosity of 0.5 to 0.75 dl / g, the specific steps for removing part of the sea component are as follows: soak the knitted fabric in an alkaline solution with a pH of 7 to 12 for 5 to 30 minutes.

[0025] Furthermore, the specifications of the island fiber are 60-800D / 1F.

[0026] As can be seen from the above description, using coarse denier monofilaments to prepare knitted fabrics is more in line with the requirements of shoe materials for wear resistance and breathability.

[0027] Furthermore, before being woven into knitted fabric, the mass ratio of the sea component to the island component in the island fiber is 3–8.5:17.

[0028] Furthermore, the preparation method of island fiber is as follows: sea component slices and island component slices are respectively subjected to crystallization drying and melting, and the melted sea component and island component are combined and then spun, cooled, oiled, stretched and deformed and wound to obtain island fiber.

[0029] Furthermore, the temperature for crystallization drying is 80–160°C.

[0030] Furthermore, the melting temperature is 240–290°C.

[0031] Furthermore, the cooling system employs side-blowing cooling with a wind speed of 0.5–1.5 m / s.

[0032] Furthermore, the air duct for side-blowing cooling is ≥20m.

[0033] As can be seen from the above description, since the monofilaments prepared by this invention have a specification of 60-800D / 1F, which is relatively thick, the length of the air net needs to be increased to achieve complete cooling.

[0034] Furthermore, the oil content of the fiber after oiling is 0.4% to 1.0%.

[0035] Furthermore, the winding speed is 600–2000 m / min.

[0036] As can be seen from the above description, controlling the winding speed to 600–2000 m / min can ensure fiber stretching and orientation while maintaining production stability.

[0037] Furthermore, during the stretching deformation, the material passes through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 80–95°C, the stretching temperature of the second-stage hot roller is 120–140°C, and the stretching temperature of the third-stage hot roller is 180–220°C.

[0038] As can be seen from the above description, because the island fibers of the present invention have a larger diameter, multi-stage hot roller stretching and shaping is required. Multi-stage hot roller stretching deformation causes the fibers to form crystalline regions with regular and compact molecular chain segments, which improves the crystallinity and modulus of the fibers, resulting in fibers with higher strength and toughness.

[0039] Another technical solution adopted in this invention is: island monofilament knitted fabric prepared by the above preparation method.

[0040] As described above, the island-island monofilaments prepared using the method of this invention can achieve a strength of over 6.0 Cn / dtex and a breaking elongation of over 40%, exhibiting superior tensile properties. The resulting island-island monofilament knitted fabric achieved a flexural strength of 1.5 million flexural cycles without breaking, demonstrating excellent flexural resistance.

[0041] Embodiment 1 of the present invention is a method for preparing a sea-island monofilament knitted fabric, comprising the following steps:

[0042] S1: 15 kg of PET sea component chips with a viscosity of 0.5 dl / g and 85 kg of TPEE island component chips are crystallized, dried and melted in different metering and conveying systems. The melted sea component and island component are fused together at the spinneret and extruded to form nascent fibers. The crystallization and drying temperature of the sea component chips is 120℃ and the melting temperature is 250℃. The crystallization and drying temperature of the island component chips is 12℃ and the melting temperature is 270℃.

[0043] S2: Nascent fibers are cooled by side blowing, oiled with oil nozzles, stretched, set, and wound to obtain island-sea fibers with a specification of 100D / 1F. See Figure 1The side-blowing air velocity is 1 m / s, and the oil content of the fiber after oiling is 0.8%. During stretching deformation, the fiber passes through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 85℃, the stretching temperature of the second-stage hot roller is 130℃, and the stretching temperature of the third-stage hot roller is 200℃. The winding speed is 1000 m / min.

[0044] S3: Woven from island-sea fiber, 60 inches wide, 259g / m² 2 The knitted fabric is used to obtain the finished product.

[0045] Embodiment 2 of the present invention is a method for preparing a sea-island monofilament knitted fabric, the steps of which are as follows:

[0046] S1: 15 kg of PET sea component chips with a viscosity of 0.5 dl / g and 85 kg of TPEE island component chips are crystallized, dried and melted in different metering and conveying systems. The melted sea component and island component are fused together at the spinneret and extruded to form nascent fibers. The crystallization and drying temperature of the sea component chips is 120℃ and the melting temperature is 250℃. The crystallization and drying temperature of the island component chips is 12℃ and the melting temperature is 270℃.

[0047] S2: Nascent fibers are cooled by side blowing, oiled with oil nozzles, stretched and shaped, and wound to obtain island-island fibers with a specification of 100D / 1F; the wind speed of the side blowing is 1m / s, and the oil content of the fiber after oiling is 0.8%; during stretching and deformation, the fibers pass through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 85℃, the stretching temperature of the second-stage hot roller is 130℃, and the stretching temperature of the third-stage hot roller is 200℃; the winding speed is 1000m / min.

[0048] S3: Woven from island-sea fiber, 60 inches wide, 259g / m² 2 The knitted fabric was soaked in a NaOH solution with a pH of 12 for 5 minutes to remove some of the sea components of the island fibers. The remaining sea components connected the island components and maintained the monofilament state of the island fibers.

[0049] Example 3 of the present invention is a sea-island monofilament knitted fabric prepared using the preparation method of Example 1.

[0050] Embodiment four of the present invention is a method for preparing a sea-island monofilament knitted fabric, the steps of which are as follows:

[0051] S1: 15kg of water-soluble PET marine component chips and 85kg of PA6 island component chips are crystallized, dried and melted in different metering and conveying systems. The melted marine and island components are fused together at the spinneret and extruded to form nascent fibers. The crystallization and drying temperature of the marine component chips is 80℃ and the melting temperature is 240℃. The crystallization and drying temperature of the island component chips is 80℃ and the melting temperature is 290℃.

[0052] S2: Nascent fibers are cooled by side blowing, oiled with oil nozzles, stretched and set, and wound to obtain island-of-the-sea fibers with a specification of 800D / 1F. The side blowing speed is 1.5m / s, and the oil content of the fiber after oiling is 1.0%. During stretching and deformation, the fibers pass through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 95℃, the stretching temperature of the second-stage hot roller is 140℃, and the stretching temperature of the third-stage hot roller is 220℃. The winding speed is 2000m / min.

[0053] S3: Woven from island-sea fiber, 60 inches wide, 259g / m² 2 The knitted fabric was soaked in a KOH solution with a pH of 7 for 45 minutes to remove some of the marine components of the island fibers. The remaining marine components connected the island components and maintained the monofilament state of the island fibers.

[0054] Embodiment 5 of the present invention is a method for preparing a sea-island monofilament knitted fabric, the steps of which are as follows:

[0055] S1: 15kg of PBT marine component chips and 85kg of PA66 island component chips are crystallized, dried and melted in different metering and conveying systems. The melted marine and island components are fused together at the spinneret and extruded to form nascent fibers. The crystallization and drying temperature of the marine component chips is 160℃ and the melting temperature is 260℃. The crystallization and drying temperature of the island component chips is 160℃ and the melting temperature is 260℃.

[0056] S2: Nascent fibers are cooled by side blowing, oiled with oil nozzles, stretched and set, and wound to obtain island-of-the-sea fibers with a specification of 60D / 1F. The side blowing speed is 0.5m / s, and the oil content of the fibers after oiling is 0.4-1.0%. During stretching and deformation, the fibers pass through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 80℃, the stretching temperature of the second-stage hot roller is 120℃, and the stretching temperature of the third-stage hot roller is 180℃. The winding speed is 600m / min.

[0057] S3: Woven from island-sea fiber, 60 inches wide, 259g / m² 2 The knitted fabric was soaked in a KOH solution with a pH of 8 for 8 minutes. The remaining sea components connected the island components and maintained the monofilament state of the island fibers.

[0058] Embodiment six of the present invention is as follows:

[0059] The only difference between Example 6 and Example 1 is that the island component is PET with a viscosity of 2 dl / g.

[0060] Comparative Example 1 of the present invention is:

[0061] The only difference between Comparative Example 1 and Example 1 is that 100D / 1F PET fiber was used instead of island fiber, and the viscosity of PET was 0.5dl / g.

[0062] Comparative Example 2 of the present invention is as follows:

[0063] The only difference between Comparative Example 2 and Example 1 is that 100D / 1F TPEE fiber is used instead of sea-island fiber.

[0064] Comparative Example 3 of the present invention is as follows:

[0065] The only difference between Comparative Example 3 and Example 1 is that the knitted fabric was soaked in a NaOH solution with a pH of 14 for 30 minutes until the marine components of the island fibers were completely dissolved.

[0066] The fibers and knitted fabrics prepared in Examples 1, 3, 4, and 5, and Comparative Examples 1 to 3 were tested, and the results are shown in Table 1. The flexural strength test was conducted using a GT-7071-B leather flexural strength tester. The test steps were as follows: 1. Fix the fabric sample on the upper and lower clamps; 2. Turn on the power switch, set the test speed, and check the machine angle (22.5 degrees, machine speed: 100±10 / minute); 3. Reset the counter to zero, turn on the motor switch, and observe the test status at a certain speed according to the brand requirements; 4. After the test, remove the fabric sample and observe the results.

[0067] Table 1

[0068]

[0069] As shown in Table 1, the knitted fabric with insoluble sea components has better flexural resistance than the knitted fabric with only partially dissolved sea components; the knitted fabric with only partially dissolved sea components has better flexural resistance than the knitted fabric with completely dissolved sea components, as well as the knitted fabric with ordinary monofilament.

[0070] In summary, the island-sea monofilament knitted fabric and its preparation method provided by this invention have the following advantages:

[0071] (1) The knitted fabric is made of island fiber without alkali dissolution. The finished product retains the monofilament state of the island fiber. The island component has small fineness and good toughness, and the fabric prepared is soft and resistant to bending. The sea component has good abrasion resistance, which can improve the abrasion resistance of the knitted fabric.

[0072] (2) The dissolved sea component can improve the bending resistance of the knitted fabric; the undissolved sea component connects the island component and maintains the monofilament state of the island fiber. The sea component still adheres to the island component to form a protective layer, which improves the abrasion resistance of the knitted fabric.

[0073] (3) Select materials with excellent wear resistance and toughness as island components to further improve the bending resistance and wear resistance of knitted fabrics.

[0074] (4) Use coarse denier monofilaments to prepare knitted fabrics to meet the requirements of shoe materials for wear resistance and breathability.

[0075] (5) Using multi-stage hot rollers for stretching and shaping improves the crystallinity and modulus of the fiber, thereby improving the strength and toughness of the fiber.

[0076] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for preparing a single-filament knitted fabric with island-shaped sea edges, characterized in that, Includes the following steps: A knitted fabric is made by weaving island fibers. The knitted fabric is soaked in an alkaline solution to remove some of the island components of the island fibers. The remaining island components connect the island components and maintain the monofilament state of the island fibers, thus obtaining an island monofilament knitted fabric. The specifications of the island fiber are 60-800D / 1F, and the alkali in the alkaline solution is KOH or NaOH; The island component of the island fiber is any one of TPEE, PA6, PA66 and PET with a viscosity greater than 0.9 dl / g; the sea component of the island fiber is PBT or water-soluble PET with a viscosity of 0.5~0.75 dl / g. When the marine component is PBT, the specific steps for removing part of the marine component are: soaking the knitted fabric in an alkaline solution with a pH of 7 to 10 for 5 to 10 minutes; When the marine component is water-soluble PET with a viscosity of 0.5 to 0.75 dl / g, the specific steps for removing part of the marine component are as follows: soak the knitted fabric in an alkaline solution with a pH of 7 to 12 for 5 to 30 minutes.

2. The method for preparing island-shaped monofilament knitted fabric according to claim 1, characterized in that, Before being woven into knitted fabric, the mass ratio of sea component to island component in the island fiber is 3~8.5:

17.

3. The method for preparing island monofilament knitted fabric according to claim 1, characterized in that, The method for preparing the island fiber is as follows: sea component slices and island component slices are respectively subjected to crystallization drying and melting. The melted sea component and island component are combined and then subjected to spinning, cooling, oiling, stretching deformation and winding to obtain island fiber.

4. The method for preparing island-shaped monofilament knitted fabric according to claim 3, characterized in that, During the stretching deformation, the material passes through a first-stage hot roller, a second-stage hot roller, and a third-stage hot roller in sequence. The stretching temperature of the first-stage hot roller is 80~95℃, the stretching temperature of the second-stage hot roller is 120~140℃, and the stretching temperature of the third-stage hot roller is 180~220℃.

5. The island-island monofilament knitted fabric prepared by the preparation method of any one of claims 1-4.

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