Woven fabric and fiber product

Abstract

To provide a woven fabric and a fiber product with a high level of water repellency and softness.SOLUTION: A woven fabric includes a warp containing bulky polyester yarn having a single yarn fineness of 1.1 dtex or less, a weft containing polyester composite fiber having at least one component of polybutylene terephthalate having the single yarn fineness of 1.1 dtex or less, and a water repellent agent. A total fineness of the polyester bulky yarn is preferably 33 dtex or less, the total fineness of the polyester composite fiber is preferably 56 dtex or less, and a cover factor is preferably 2,000 or more.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to water-repellent textiles and textile products. [Background technology]

[0002] One known method for improving water repellency is to increase surface roughness. Based on this principle, water repellent materials have been proposed in which fine irregularities are formed by attaching fine particles to a substrate such as a film, thereby increasing the surface area (see, for example, Patent Document 1), and in which fine grooves are formed by deforming a smooth substrate such as a film, thereby increasing the surface area (see, for example, Patent Document 2).

[0003] As examples of applications to fibers, water-repellent fabrics have been proposed in which the surface roughness of the fabric is increased by using a blended yarn made by combining polyester filaments with a single yarn fineness of 1.0 dtex or more with polyester filaments with a single yarn fineness of 0.4 dtex or less (see, for example, Patent Document 3), and water-repellent materials have been proposed in which the ratio of the actual surface area to the apparent surface area is increased by using highly bulky composite fibers (see, for example, Patent Document 4). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-236955 [Patent Document 2] Japanese Patent Application Laid-Open No. 2003-147339 [Patent Document 3] Japanese Patent Application Laid-Open No. 2012-122144 [Patent Document 4] Japanese Patent Application Publication No. 2019-137945 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the method of attaching fine particles to the base material disclosed in Patent Document 1 uses a film or the like as the base material, and even if it is simply applied to a fabric, a practical fabric cannot be obtained. Similarly, even if the method disclosed in Patent Document 2 is simply applied, a practical fabric cannot be obtained.

[0006] Also, satisfactory water repellency has not been obtained by the method disclosed in Patent Document 3. Moreover, perhaps because water repellency was emphasized, the texture was hard. Furthermore, regarding the method disclosed in Patent Document 4, although it is excellent in initial water repellency, improvement in washing durability has been desired.

[0007] Therefore, an object of the present invention is to provide a fabric and a fiber product that have excellent initial water repellency without impairing flexibility and are also excellent in washing durability.

Means for Solving the Problems

[0008] In order to solve the above problems, the present invention employs the following means. (1) A fabric comprising a warp thread containing a polyester bulky yarn having a single-filament fineness of 1.1 dtex or less, a weft thread containing a polyester conjugate fiber having at least one component of polybutylene terephthalate and having a single-filament fineness of 1.1 dtex or less, and a water repellent. (2) The fabric according to (1) above, wherein the polyester bulky yarn is a polyethylene terephthalate bulky yarn. (3) The fabric according to (1) or (2) above, wherein the polyester conjugate fiber contains at least polybutylene terephthalate and polyethylene terephthalate. (4) The fabric according to any one of (1) to (3) above, wherein the polyester bulky yarn is an entangled yarn. (5) The fabric according to any one of (1) to (4) above, wherein the total fineness of the polyester bulky yarn is 33 dtex or less. (6) The fabric according to any one of (1) to (5) above, wherein the total fineness of the polyester conjugate fiber is 56 dtex or less. (7) The fabric according to any one of (1) to (6) above, wherein the cover factor of the fabric is 2,000 or more. (8) The fabric according to any one of (1) to (7) above, wherein the water repellent does not contain a fluorine element and contains at least one of a silicone-based water repellent and a hydrocarbon-based water repellent. (9) A fiber product containing at least a part of the fabric according to any one of (1) to (8) above.

Effect of the Invention

[0009] According to the present invention, it is possible to provide a fabric and a fiber product having a high level of water repellency and flexibility.

Mode for Carrying Out the Invention

[0010] The fabric of the present invention includes a warp containing a polyester bulky yarn and a weft containing a polyester composite fiber having at least one component of polybutylene terephthalate. Here, examples of the polyester in the polyester bulky yarn include aromatic polyesters such as polyethylene terephthalate, polytrimethylene terephthalate, and polybutylene terephthalate, and aliphatic polyesters such as polylactic acid, but are not limited thereto. These polyesters may contain a copolymerizable component in which a part of the diol component and the acid component forms other ester bonds at a ratio of 20 mol% or less, more preferably 10 mol% or less, based on 100 mol% of the total amount of all the diol components and acid components. Examples of copolymerizable compounds include dicarboxylic acids such as isophthalic acid, succinic acid, cyclohexanedicarboxylic acid, adipic acid, dimer acid, sebacic acid, and 5-sodium sulfoisophthalic acid, and diols such as ethylene glycol, diethylene glycol, butanediol, neopentyl glycol, cyclohexanedimethanol, polyethylene glycol, and polypropylene glycol. These may contain additives such as a matting agent, a flame retardant, an antistatic agent, and a pigment.

[0011] Also, as the polyester in the polyester composite fiber containing at least one component of polybutylene terephthalate, it can be the same polyester as above except that polybutylene terephthalate is essential. As the polybutylene terephthalate, it may also contain a copolymerization component as described above. The number of components is not particularly limited and can be, for example, 2 to 5 components, preferably 2 components. If the polyester composite fiber contains at least one component of polybutylene terephthalate, combinations of polybutylene terephthalates with different viscosities as other components, combinations with different polyesters, such as polyethylene terephthalate, polypropylene terephthalate, etc., may also be used. Those not containing polypropylene terephthalate are preferred, and polyester composite fibers containing at least polybutylene terephthalate and polyethylene terephthalate are more preferred, and polyester composite fibers composed of two components of polybutylene terephthalate and polyethylene terephthalate are even more preferred. By combining the polyester composite fiber containing at least one component of polybutylene terephthalate with the above-described polyester composite fiber, the water repellency of the fabric can be greatly improved.

[0012] Here, as the bulky yarn in the present invention, entangled yarns such as wooly yarn, brellia yarn, Italian yarn, knit denit yarn, pushed-in yarn, composite false twist yarn, taslan yarn, etc. are preferred. The manufacturing method is not particularly limited, and various entanglement processing treatments can be adopted. A larger crimp is preferred because the water repellency tends to improve due to the unevenness and internal voids of the fabric. Although the polyester composite fiber can also be made into a bulky yarn by the manifestation of crimp, in the present invention, using an entangled yarn as the bulky yarn and using the entangled yarn and the polyester composite fiber as the warp and weft is more preferred in that the water repellency can be greatly improved compared to using the polyester composite fiber for both the warp and weft. Also, as the bulky yarn, from the viewpoints of cost reduction and water repellency improvement, it is preferably an entangled yarn composed of a single-component fiber, and more preferably a polyethylene terephthalate bulky yarn.

[0013] The composite form of the polyester composite fiber in the present invention is not particularly limited, and it can be, for example, a side-by-side type polyester composite fiber, a core-sheath type polyester composite fiber, an eccentric core-sheath type polyester composite fiber, etc., but it is preferably a fiber having crimps or potentially expressing crimps, and side-by-side type polyester composite fibers and eccentric core-sheath type polyester composite fibers are preferred. Also, the method for producing the polyester composite fiber is not particularly limited, and examples include a method of composite two types of polymers in a side-by-side type using a die and a method of composite in an eccentric core-sheath type.

[0014] In terms of obtaining excellent water repellency and flexibility, the total fineness of the bulky polyester yarn is preferably 50 dtex or less, more preferably 33 dtex or less. The lower limit is not particularly limited, but is preferably 10 dtex or more in terms of ease of production. Also, the single fiber fineness is 1.1 dtex or less. By setting it to 1.1 dtex or less, it is estimated that the permeability of the water repellent to the bulky polyester yarn and the coating property of the water repellent on the single fiber surface are enhanced due to capillary action, and the flexibility and washing durability can be improved. The lower limit is not particularly limited, but is usually 0.001 dtex or more. For the same reason, the total fineness of the polyester composite fiber is preferably 70 dtex or less, more preferably 60 dtex or less, and even more preferably 56 dtex or less. The lower limit is not particularly limited, but is preferably 10 dtex or more in terms of ease of production. Also, the single fiber fineness is 1.1 dtex or less. By setting it to 1.1 dtex or less, it is estimated that the permeability of the water repellent to the polyester composite fiber and the coating property of the water repellent on the single fiber surface are enhanced due to capillary action, and thereby the flexibility and washing durability can be improved. The lower limit is not particularly limited, but is usually 0.001 dtex or more.

[0015] The weave of the fabric of the present invention is not particularly limited, and can be appropriately selected according to the use, such as plain weave, twill weave, damask weave, and multi-layer structured fabrics such as double weave. A normal weaving method can also be appropriately adopted as the manufacturing method. Here, in the fabric of the present invention, the warp contains the above-mentioned polyester bulky yarn, and the weft contains a polyester composite yarn containing at least one component of polybutylene terephthalate. Thereby, excellent flexibility and water repellency can be obtained. If the warp and weft are reversed respectively, the effects of the present invention cannot be obtained. The reason why the effects of the present invention can be obtained by using specific yarns for the warp and weft is not clear, but it is considered that unevenness is likely to appear on the fabric surface due to a specific yarn arrangement. Further, the mixing ratio is preferably 50% by mass or more, more preferably 80% by mass or more, and still more preferably 95% by mass or more with respect to the total mass of the warp or weft respectively.

[0016] The cover factor of the fabric is preferably 2,000 or more in terms of excellent water repellency. Generally, the higher the cover factor, the more excellent the water repellency tends to be, but on the other hand, the texture tends to become hard. However, in the present invention, by using the above-mentioned specific fabric, high water repellency can be obtained even with a relatively low cover factor. From this viewpoint, the cover factor is preferably 4,000 or less.

[0017] In the present invention, the cover factor is a numerical value representing the coarseness of the fabric, which is calculated by the following formula (i). In the formula (i), CF is the cover factor, T is the density of the warp constituting the fabric (ends / 2.54 cm), W is the density of the weft constituting the fabric (ends / 2.54 cm), DT is the fiber fineness (dtex) of the warp constituting the fabric, and "DW" is the fiber fineness (dtex) of the weft constituting the fabric. ·CF=T×(DT) 1 / 2 +W×(DW) 1 / 2 ···(i) The fabric of the present invention contains a water repellent. The water repellent is not particularly limited as long as the water repellency is improved depending on its presence or absence. The water repellent preferably exists in a state of being in contact with the fiber, adhered or coated. Specifically, the water repellent includes a fluorine-based water repellent having a perfluoroalkyl group with 7 or more carbon atoms, a fluorine-based water repellent having a perfluoroalkyl group with 6 or less carbon atoms, (for example, "Unidine" TG-5546, "Unidine" TG-5601 manufactured by Daikin Industries, Ltd., "Asahi Guard" AG-E061, "Asahi Guard" AG-E081 manufactured by Asahi Glass Co., Ltd.), a water repellent that does not contain fluorine element, etc. These can be used alone or in combination of two or more. In recent years, since perfluorooctanoic acid and perfluorooctanesulfonic acid tend to be avoided in use, those that do not contain fluorine element are preferred, and it is more preferred to contain at least one of a silicone-based water repellent and a hydrocarbon-based water repellent.

[0018] It is preferable that the fabric of the present invention contains a crosslinking agent together with the water repellent, as the washing durability is improved. From the viewpoint of safety, a blocked isocyanate that does not contain formaldehyde is preferred as the crosslinking agent.

[0019] The method for applying the water repellent to the fabric is not particularly limited, and examples include a padding method, a spraying method, an exhaustion method, etc. However, in order to penetrate the chemical agent to the inside of the multifilament, it is preferable to add a penetrant to the processing solution. As the penetrant, propanol, ethanol, etc. can be used.

[0020] The fabric of the present invention preferably has a contact angle of 140 degrees or more with respect to 4 μl of water. The contact angle is measured 3 seconds after dropping the water. When the angle is equal to or greater than the above value, water is easily repelled, and more excellent water repellency can be obtained. Further, the sliding angle is preferably 20 degrees or less. The sliding angle can be determined by the angle (sliding angle) when a 50 μl water droplet is placed on a sample placed on a horizontal surface and then the sample is tilted at a speed of 20 degrees per minute and the water droplet moves 1.0 mm. By setting the angle to be equal to or less than the above value, water is more likely to roll down, and more excellent water repellency can be obtained. The specific measurement method is as described in the examples. In order to obtain these characteristics, in the fabric of the present invention, it can be manufactured by making the fineness finer, applying more water repellent, etc.

[0021] The fiber product of the present invention contains at least a part of the fabric of the present invention. Since the fiber product of the present invention is excellent in water repellency, it can be preferably used for general clothing such as men's clothing, women's clothing, formal wear, school uniforms, work clothes, jackets, casual wear, raincoats and sportswear, as well as swimsuits, umbrellas, tents and the like.

Examples

[0022] Hereinafter, the present invention will be described in detail with reference to examples, but the present invention is not limited thereto. In addition, the quality evaluation in the examples was carried out using the following method for samples that had been subjected to 20 washes (HL20) and 40 washes (HL40) by hanging dry according to the JIS L-1930 C4G method (2014) for the original fabric after processing.

[0023] (Denier per filament, total denier) The total denier was measured according to JIS L 1013 (2021) 8.4 Test method for chemical fiber filament yarns. The denier per filament was calculated by dividing the total denier by the number of filaments.

[0024] (Contact angle) The angle formed between the fabric and water when water was dropped on the sample was measured. ·Testing equipment: DSA25S (manufactured by KRUSS) ·Calculation method: Young Laplace · Test solution: High-purity purified water (manufactured by Furukawa Pharmaceutical Co., Ltd.) · Drop volume: 4 μl · Measurement: Measured 3 seconds after dropping.

[0025] (Sliding angle) While dropping water droplets on the sample, the stage was tilted, and the tilt angle when the water moved 1.0 mm was measured. · Test equipment: DSA25S (manufactured by KRUSS) · Calculation method: Tilt angle when the contact point (upper part) measured by the Tangent method moved 1.0 mm · Test solution: High-purity purified water (manufactured by Furukawa Pharmaceutical Co., Ltd.) · Drop volume: 50 μl · Tilt speed: 20 degrees / min.

[0026] (Water repellency) JIS L 1092(2020)7.2 (spray test) was performed and graded.

[0027] [Example 1] A plain fabric was woven using a false-twisted yarn of polyethylene terephthalate (PET) with 33 dtex and 36 filaments for the warp, and an eccentric core-sheath composite yarn of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) with 56 dtex and 72 filaments for the weft. The warp density of the gray fabric was 154 threads / 2.54 cm, and the weft density was 106 threads / 2.54 cm. The fabric thus obtained was scoured at 95 °C in a continuous scouring machine according to a conventional method, washed with hot water, set in a pin tenter at 190 °C, dyed in a liquid flow dyeing machine according to a conventional method, and dried in a pin tenter at 130 °C. Subsequently, the fabric obtained by impregnating with the following water repellent treatment liquid at a pickup rate of 60% and finishing in a pin tenter at 150 °C had a warp density of 219 threads / 2.54 cm, a weft density of 142 threads / 2.54 cm, and a cover factor of 2,321. The results of the contact angle, sliding angle, and water repellency are shown in Table 1. The contact angle of the original fabric after processing was 151 degrees, the sliding angle was 13 degrees, and the water repellency was grade 5, indicating excellent water repellency. Also, the results after 20 washes (HL20) and 40 washes (HL40) were as follows: the contact angle was 146 degrees (HL20), 144 degrees (HL40), the sliding angle was 14 degrees (HL20), 17 degrees (HL40), and the water repellency was grade 5 (HL20), grade 3 (HL40), showing excellent softness and washing durability. (Water repellent treatment liquid) Silicone-based water repellent agent without fluorine element "Neo Seed" NR-8800 (manufactured by Nichiwa Chemical Co., Ltd.) 30 g / l "Neo Seed" NR-7090 (manufactured by Nichiwa Chemical Co., Ltd.) 10 g / l Other chemicals "NK Assist" FU (manufactured by Nichiwa Chemical Co., Ltd.) 4 g / l "Textport" BG-2 (manufactured by Nichiwa Chemical Co., Ltd.) 10 g / l.

[0028] [Example 2] A water-repellent fabric was obtained in the same manner as in Example 1, except that the warp density of the finished fabric was 211 threads / 2.54 cm, the weft density was 120 threads / 2.54 cm, and the cover factor was 2,110. The results of the contact angle, sliding angle, and water repellency are shown in Table 1. The contact angle of the original fabric after processing was 150 degrees, the sliding angle was 10 degrees, and the water repellency was grade 5, indicating excellent water repellency. Also, the results after 20 washes and 40 washes were as follows: the contact angle was 149 degrees (HL20), 148 degrees (HL40), the sliding angle was 14 degrees (HL20), 16 degrees (HL40), and the water repellency was grade 5 (HL20), grade 3 (HL40), showing excellent softness and washing durability.

[0029] [Example 3] A water-repellent fabric was obtained in the same manner as in Example 1, except that the warp density of the finished fabric was 211 threads / 2.54 cm, the weft density was 142 threads / 2.54 cm, and the cover factor was 2,275. The results of the contact angle, sliding angle, and water repellency are shown in Table 1. The contact angle of the as-processed original fabric was 147 degrees, the sliding angle was 11 degrees, and the water repellency was grade 5, indicating excellent water repellency. Also, the results after 20 and 40 washes were that the contact angle was 144 degrees (HL20), 144 degrees (HL40), the sliding angle was 16 degrees (HL20), 22 degrees (HL40), and the water repellency was grade 4 (HL20), grade 3 (HL40), showing excellent softness and washing durability.

[0030] [Comparative Example 1] A water-repellent fabric was obtained in the same manner as in Example 1, except that a bimetal composite yarn of 56 dtex and 72 filaments of polytrimethylene terephthalate (PTT) and polyethylene terephthalate (PET) was used for the weft yarn, and the warp density of the as-processed original fabric was 217 threads / 2.54 cm and the cover factor was 2,309. The results of the contact angle, sliding angle, and water repellency are shown in Table 1. The contact angle of the as-processed original fabric was 138 degrees, the sliding angle was 24 degrees, and the water repellency was grade 5, but satisfactory water repellency was not obtained. Also, the results after 20 and 40 washes were that the contact angle was 135 degrees (HL20), 131 degrees (HL40), the sliding angle was 25 degrees (HL20), 32 degrees (HL40), and the water repellency was grade 3 (HL20), grade 2 (HL40), and the washing durability was also significantly inferior to that of the product of the present invention.

[0031] [Comparative Example 2] A water-repellent fabric was obtained in the same manner as in Example 1, except that a false-twisted yarn of 56 dtex and 18 filaments of polyethylene terephthalate (PET) was used for the warp yarn, a bimetal composite yarn of 56 dtex and 72 filaments of polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) was used for the weft yarn, the warp density of the loom state was 121 threads / 2.54 cm, the weft density was 106 threads / 2.54 cm, the warp density of the as-processed original fabric was 166 threads / 2.54 cm, the weft density was 142 threads / 2.54 cm, and the cover factor was 2,305. The results of the contact angle, sliding angle, and water repellency are shown in Table 1. The contact angle of the as-processed base fabric was 137 degrees, the sliding angle was 23 degrees, and the water repellency was grade 5, but satisfactory water repellency was not obtained. Also, the results after 20 and 40 washes were that the contact angle was 130 degrees (HL20), 128 degrees (HL40), the sliding angle was 32 degrees (HL20), 40 degrees (HL40), and the water repellency was grade 2 (HL20), grade 1 (HL40), and the washing durability was also significantly inferior to that of the product of the present invention.

[0032] [Table 1]

Industrial Applicability

[0033] When the fabric of the present invention is used for textile products, because of its excellent water repellency, it can be preferably used for general clothing such as men's clothing, women's clothing, formal wear, school uniforms, work clothes, jackets, casual wear, raincoats, and sportswear, and textile products such as swimsuits, umbrellas, and tents.

Claims

1. A fabric comprising a warp thread containing a polyester bulky yarn having a single filament fineness of 1.1 dtex or less, a weft thread containing a polyester composite fiber having at least one component of polybutylene terephthalate with a single filament fineness of 1.1 dtex or less, and a water repellent agent.

2. The fabric according to Claim 1, wherein the polyester bulky yarn is a polyethylene terephthalate bulky yarn.

3. The fabric according to Claim 1 or 2, wherein the polyester composite fiber contains at least polybutylene terephthalate and polyethylene terephthalate.

4. The fabric according to Claim 1 or 2, wherein the polyester bulky yarn is an interlaced yarn.

5. The fabric according to Claim 1 or 2, wherein the total fineness of the polyester bulky yarn is 33 dtex or less.

6. The fabric according to Claim 1 or 2, wherein the total fineness of the polyester composite fiber is 56 dtex or less.

7. The fabric according to Claim 1 or 2, wherein the cover factor of the fabric is 2,000 or more.

8. The fabric according to Claim 1 or 2, wherein the water repellent agent does not contain a fluorine element and contains at least one of a silicone-based water repellent agent and a hydrocarbon-based water repellent agent.

9. A fiber product comprising at least a part of the fabric according to Claim 1 or 2.

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