Polyester fiber structure and method for producing polyester fiber structure

Abstract

To provide a polyester-based fiber structure having antistaticity and water repellency with washing durability without using a fluorine-based water repellent, and to provide a method for producing the polyester-based fiber structure.SOLUTION: There are provided a polyester-based fiber structure in which a polymer of polyalkylene glycol diacrylic ester and a fluorine-free water repellent are attached to the surface of a polyester-based fiber dyed with a disperse dye, (A) both dry friction fastness and wet friction fastness are grade 3 or higher, and (B) initial water repellency is grade 3-4 or higher, and a method for producing the polyester-based fiber structure.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a polyester-based fiber structure and a method for producing a polyester-based fiber structure. [Background technology]

[0002] Polyester fibers have excellent mechanical strength and chemical stability, are durable, can be washed under strict conditions, and dry quickly. Taking advantage of their ease of handling, textile structures made from polyester fibers are widely used as materials for everyday items such as clothing, bedding, and furniture.

[0003] Furthermore, polyester fiber structures that have been given water repellency by applying a water repellent agent to the surface of polyester fiber, so that they repel water when exposed to rain, water work, or when water is spilled, are also widely used.

[0004] However, polyester fiber structures that have been given water repellency have the disadvantage that they are prone to become electrically charged due to their water-repellent properties, which can lead to static electricity causing repulsion between the fiber structures, clinging to the body, and discomfort from electric shocks when removing clothing or touching metal.

[0005] Therefore, for example, Patent Document 1 discloses a technology in which a polyester-based antistatic agent and a fluorine-based water-repellent agent are attached to the fiber surface and crosslinked with polyisocyanate to produce a polyester fabric with antistatic and water-repellent properties that are durable to washing. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-124879 Summary of the Invention [Problem to be solved by the invention]

[0007] On the other hand, in recent years, there has been a demand for technologies that avoid the use of fluorine-based chemicals in order to reduce the environmental impact. According to Patent Document 1, fiber fabrics having antistatic properties and water repellency that are durable to washing can be obtained, but this technology is premised on the use of a fluorine-based water repellent agent containing, for example, a perfluoroalkyl group as a main constituent. Polyester fiber structures obtained by a method similar to that of Patent Document 1 using a fluorine-free water repellent agent that has lower water repellency than fluorine-based water repellents have the problem that only products with significantly lower washing durability can be obtained due to the poor water repellency of the water repellent agent.

[0008] Therefore, an object of the present invention is to provide a polyester fiber structure that does not use a fluorine-based water repellent agent and has antistatic and water repellency properties that are durable to washing, and a method for producing the polyester fiber structure. [Means for solving the problem]

[0009] In order to solve the above problems, the polyester fiber structure according to the present invention has the following configuration. (1) A polyester fiber structure in which a polyalkylene glycol diacrylic ester polymer and a fluorine-free water repellent agent are adhered to the surface of a polyester fiber dyed with a disperse dye, and (A) both the dry and wet rubbing fastnesses are grade 3 or higher, and (B) the initial water repellency is grade 3-4 or higher. (2) The polyester fiber structure according to (1) above, further comprising: (C) water repellency of grade 2 or higher after 100 home washes; and (D) a frictional electrification voltage of 2000 V or less after 100 home washes. (3) The polyester fiber structure according to (1) or (2), further comprising at least one selected from the group consisting of a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, and an aziridine-based crosslinking agent, and an isocyanate-based crosslinking agent attached to the polyester fiber structure. (4) The polyester fiber structure according to (3) above, wherein the carbodiimide crosslinking agent, the oxazoline crosslinking agent, or the aziridine crosslinking agent is water-insoluble.

[0010] The method for producing a polyester fiber structure according to the present invention has the following features. (5) A method for producing a polyester fiber structure according to any one of (1) to (4), comprising the steps of (i) dyeing a polyester fiber structure with a disperse dye, (ii) polymerizing a polyalkylene glycol diacrylic ester on the fiber surface, and (iii) attaching a fluorine-free water repellent to the fiber surface, in this order, and not including a step of heating at a temperature of 160°C or higher after the step of polymerizing a polyalkylene glycol diacrylic ester on the fiber surface. (6) The method for producing a polyester fiber structure according to (5), further comprising (d) a curing step at a temperature of less than 160°C after the step (c) of attaching a fluorine-free water repellent agent to the fiber surface. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a polyester fiber structure that does not use a fluorine-based water repellent agent and has antistatic and water repellency properties that are durable to washing, and a method for producing the polyester fiber structure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of the present invention will be described. Note that each of the embodiments described below represents a preferred specific example of the present invention. Therefore, the numerical values, shapes, materials, components, etc. shown in the following embodiments are merely examples and are not intended to limit the present invention. Therefore, among the components in the following embodiments, components that are not described in the independent claims that represent the highest concept of the present invention will be described as optional components.

[0013] (Polyester fiber structure) The polyester fiber structure of this embodiment comprises a polyester fiber dyed with a disperse dye, to the surface of which a polymer of polyalkylene glycol diacrylic ester and a fluorine-free water repellent agent are adhered, and the polyester fiber structure has (A) both dry and wet rubbing fastnesses of grade 3 or higher, and (B) initial water repellency of grade 3-4 or higher.

[0014] As with conventional technology, both a hydrophilic agent (corresponding to the polyalkylene glycol diacrylic ester in this embodiment) and a water-repellent agent are attached to the fiber surface, and the hydrophilic agent retains moisture in the fiber structure, preventing the fiber structure from becoming electrically charged, while the water-repellent agent repels large amounts of water from outside the fiber structure.

[0015] Generally, a water repellent cannot fully exhibit its water repellency simply by being attached to the fiber surface, and it is necessary to apply thermal energy sufficient to cause the hydrophobic segments of the water repellent attached to the fiber surface to undergo micro-Brownian motion at least once, so that the hydrophobic segments repel each other and form a forest covering the fiber surface. However, when a polyalkylene glycol diacrylic ester polymer is also attached to the fiber surface, heating (curing) to enhance the water repellency partially cleaves the polyalkylene glycol units, which are relatively sensitive to heat, leading to deterioration of the polyalkylene glycol diacrylic ester polymer itself and the dye in a chain reaction, causing a decrease in the washing durability of the antistatic property and the color fastness.

[0016] Therefore, the present inventors have discovered that, by suppressing degradation while creating a situation in which water repellency is high, for example by not heating a polyalkylene glycol diacrylic ester polymer to 160°C or higher, it is possible to suppress a decrease in washing durability even when using a fluorine-free water repellent agent that has lower water repellency than fluorine-based water repellents.

[0017] The polyester fiber structure of this embodiment has (A) both dry rubbing fastness and wet rubbing fastness of grade 3 or higher. This not only confirms that the polyester fiber structure is resistant to color fading and color transfer when rubbed, but also that degradation of the polyalkylene glycol diacrylic ester polymer, and therefore degradation of the dye, is suppressed.

[0018] The polyester fiber used in this embodiment is a fiber formed from a polyester resin such as polyethylene terephthalate (PET) obtained by condensation polymerization of a dicarboxylic acid such as terephthalic acid or naphthalenedicarboxylic acid with a diol such as ethylene glycol, propylene glycol, or butylene glycol, or a polyester resin obtained by condensation polymerization of a hydroxycarboxylic acid such as lactic acid, or a polyester resin obtained by polyaddition involving ring-opening of a lactone.

[0019] The polyester fiber may be either a long fiber or a short fiber. The yarn using the fiber may be any of raw silk, twisted yarn, and textured yarn. There are no particular limitations on the textured yarn, and it is possible to use false twist textured yarn, push textured yarn, shaped textured yarn, rub textured yarn, taslan textured yarn, long yarn parallel textured yarn, composite textured yarn, fluff textured yarn, entangled bundled yarn, etc. It is preferable to use textured yarn from the viewpoint that it is easy to attach a large amount of chemicals to the fiber surface and improve antistatic properties and water repellency.

[0020] Furthermore, the cross-sectional shape of the yarn using polyester fiber is not particularly limited, and may be, for example, round, triangular, star-shaped, C-shaped, hollow, well-shaped, dog-bone-shaped, or the like.

[0021] The fabric that serves as the base of the polyester fiber structure of this embodiment is not particularly limited in its weave. Specifically, it may be a plain weave, twill weave, or satin weave, or a plain knit or tricot knit, or a nonwoven fabric formed by a spunlace method or needle punch method. Furthermore, it may be a pile fabric formed by knitting loop yarns, or may be flocked.

[0022] The base fabric may contain fibers made of materials other than polyester-based fibers, as long as the invention is not deviated from the spirit of the invention. Specifically, the base fabric may contain a yarn in which the polyester-based fiber and a fiber made of another material are blended or interwoven into a single yarn, or may be a fabric made by interweaving or interknitting a yarn containing the polyester-based fiber with a yarn made of another material. From the viewpoint of easily achieving strong antistatic and water-repellent properties and high durability, the base fabric contains 50% by mass or more of polyester-based fibers, and preferably 80% by mass or more.

[0023] The polyester fiber structure of the present invention refers to the fabric itself obtained by the present invention, and to fiber products manufactured at least in part using the fabric obtained by the present invention. Examples of the fiber products include general clothing such as jackets, blouses, trousers, and underwear; work clothes for customer service in stores, factory work, and medical use including white coats; sportswear such as sports uniforms and windbreakers; fiber personal items such as gloves and hats; bedding such as sheets and futon covers; and furniture such as upholstery and curtains.

[0024] The polyester fiber structure of this embodiment is dyed with a disperse dye. The disperse dye used in this embodiment may be a known disperse dye, such as the "Kayalon Polyester" series and "Kayalon Microester" (registered trademark) series available from Nippon Kayaku Co., Ltd., the "KIWALON POLYESTER" series available from Kiwa Chemical Industry Co., Ltd., the "Sumikaron" (registered trademark) series available from Sumitomo Chemical Co., Ltd., the "TERASIL" (registered trademark) series available from Huntsman Japan, and the "Dianix" (registered trademark) series available from Dystar Japan.

[0025] In the polyester fiber structure of this embodiment, a polyalkylene glycol diacrylic ester polymer is attached to the surface of the polyester fiber. The polyalkylene glycol diacrylic ester polymer serves as a hydrophilic agent that imparts hydrophilicity and antistatic properties to the polyester fiber. In general, acrylic ester compounds are more likely to polymerize than other vinyl compounds, and even large monomers with long polyalkylene glycol units that impart hydrophilicity can be firmly attached to the fiber surface under mild conditions. On the other hand, polyalkylene glycol units are relatively sensitive to heat and tend to deteriorate not only themselves but also surrounding compounds.

[0026] The term "polyalkylene glycol diacrylic ester polymer" refers to a polymer obtained by polymerizing the vinyl group of a polyalkylene glycol diacrylic ester. The term "polyalkylene glycol diacrylic ester" refers to an ester compound of both terminal hydroxyl groups of a polyalkylene glycol with two molecules of acrylic acid or methacrylic acid. From the viewpoints of high hydrophilicity and economic efficiency, the polyalkylene glycol unit is preferably polyethylene glycol or polypropylene glycol, and the average degree of polymerization is preferably 9 or more, 15 or more, or 20 or more from the viewpoint of high hydrophilicity, and preferably 30 or less, or 25 or less from the viewpoints of economic efficiency and washing durability.

[0027] In the polyester fiber structure of this embodiment, a fluorine-free water repellent agent is attached to the surface of the polyester fiber. The hydrophobic segments in the water repellent agent stand in a forest so as to cover the fiber surface, thereby imparting water repellency to the fiber structure.

[0028] The fluorine-free water repellent used in this embodiment may be a known water repellent, and examples thereof include silicone-based water repellents, hydrocarbon-based water repellents, wax ester-based water repellents, acrylic-based water repellents, chlorine-based water repellents, or combinations of two or more of these. From the viewpoint of easily achieving high water repellency even at a relatively low curing temperature in the curing step described below, the fluorine-free water repellent preferably contains or is an acrylic water repellent.

[0029] To firmly attach the water repellent to the fiber surface, it is recommended to use a crosslinking agent in combination. The crosslinking agent is not particularly limited as long as it has two or more functional groups capable of reacting to form bonds with other compounds. However, from the viewpoints of not impairing the texture of the textile product and being easily applied to fibers together with the water repellent, it is preferable to use an isocyanate-based crosslinking agent, a melamine-based crosslinking agent, a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, an aziridine-based crosslinking agent, or a combination of two or more of these. From the viewpoint of easily imparting antistatic properties and water repellency durability to washing, it is more preferable to use a combination of at least one selected from the group consisting of a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, and an aziridine-based crosslinking agent with an isocyanate-based crosslinking agent. In the present invention, "adhering to a crosslinking agent" also includes a state in which the crosslinking agent reacts to form a bond with another compound.

[0030] When a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, or an aziridine-based crosslinking agent is used, the agent is preferably water-insoluble from the viewpoint of further enhancing hydrophobicity and improving water repellency. When the crosslinking agent has hydrophobicity to the extent that it is not miscible with water, it is easy to suppress a decrease in water repellency. When these crosslinking agents are applied to fibers, they may be used in a form dispersed or emulsified in water.

[0031] The isocyanate crosslinking agent may be a compound simply having an isocyanate group, or may be a polymer such as an adduct or isocyanurate, or may be a blocked isocyanate. When an isocyanate crosslinking agent in which the isocyanate group is protected is used, it is preferable that the protecting group can be deprotected at a relatively low temperature, and specifically, the dissociation temperature is preferably 150°C or lower, more preferably 130°C or lower.

[0032] The polyester fiber structure of this embodiment may contain various functional agents within the scope of the present invention. Specifically, the fiber structure of this embodiment may contain at least one of a polymerization initiator, a polymerization catalyst, a crosslinking agent different from the above, a flame retardant, a hydrophilic agent different from the above, an ultraviolet absorber, an infrared reflector, a softener, a heat storage agent, a deodorizer, organic or inorganic particles for changing the feel of the material, a colorant such as a dye or pigment different from the above, and an antibacterial agent.

[0033] In particular, when an antibacterial agent is attached to the fiber surface, it can inhibit the growth of bacteria on the surface of the fiber structure and suppress the generation of odors that can be problematic when the fabric is wet due to sweat or when it is half-dried when hung to dry indoors. Generally, silver-based compounds are excellent antibacterial agents that have high antibacterial activity and a broad antibacterial spectrum even in very small amounts, but they tend to be washed away by washing, making them difficult to apply to textile products that are washed frequently. However, the fiber structure of this embodiment can be firmly fixed to the fiber surface together with the hydrophilic agent, thereby imparting excellent antibacterial properties to textile products that are washed frequently.

[0034] Furthermore, the polyester-based fiber structure of this embodiment may be subjected to processing to change its design, such as calendaring, creasing, pleating, raising, and pattern printing.

[0035] The polyester fiber structure of this embodiment has (A) both dry and wet friction fastnesses of Grade 3 or higher. This not only confirms that the polyester fiber structure is resistant to color fading and color transfer when rubbed, but also indicates that the antistatic wash durability is maintained at a high level if the friction fastness remains high even after various processing steps have been completed. From the perspective of achieving higher wash durability, the polyester fiber structure preferably has a dry friction fastness of Grade 4 or higher, and more preferably both the dry and wet friction fastnesses of Grade 4 or higher. The dry and wet friction fastnesses are evaluated using the "dry test" and "wet test" methods using a friction tester type II (Gakushin type) as specified in JIS L 0849:2013.

[0036] The polyester fiber structure of this embodiment has (B) initial water repellency of grade 3-4 or higher. This not only confirms that the polyester fiber structure has high water repellency, but also demonstrates that, in addition to the high friction fastness, the water repellency is fully enhanced while suppressing the decrease in antistatic washing durability due to heating, etc. The initial water repellency of the polyester fiber structure is preferably grade 4 or higher. The water repellency is evaluated using the water repellency test (spray test) described in JIS L 1092:2020.

[0037] Furthermore, by having (A) both dry and wet rubbing fastnesses of Grade 3 or higher and (B) initial water repellency of Grade 3-4 or higher, the polyester fiber structure of this embodiment is likely to impart highly wash-durable antistatic and water repellency, such as (C) water repellency after 100 home washes of Grade 2 or higher and (D) a frictional electrification voltage of 2000 V or lower after 100 home washes. The water repellency after 100 home washes is preferably Grade 2-3 or higher, and the frictional electrification voltage after 100 home washes of 1500 V or lower, and it is more preferable for the structure to have both of these characteristics. Note that home washing refers to a washing treatment using the C4M method described in JIS L 1930:2014, and the frictional electrification voltage is evaluated using Method B (frictional electrification voltage measurement method) described in JIS L 1094:2020.

[0038] Furthermore, (E) the half-life after 100 home washes is preferably 60 seconds or less, more preferably 40 seconds or less. The half-life is evaluated by Method A (half-life measurement method) described in JIS L 1094:2020.

[0039] (Method of manufacturing polyester fiber structure) Next, the method for producing the polyester fiber structure of the present invention will be described, with the overlapping content already described being omitted where appropriate.

[0040] The method for producing a polyester fiber structure of this embodiment includes, in this order, (i) a step of dyeing a polyester fiber structure with a disperse dye, (ii) a step of polymerizing a polyalkylene glycol diacrylic ester on the fiber surface, and (iii) a step of attaching a fluorine-free water repellent agent to the fiber surface, and does not include a step of heating at a temperature of 160°C or higher after the step of polymerizing the polyalkylene glycol diacrylic ester on the fiber surface.

[0041] The method for producing a polyester fiber structure in this embodiment uses a base fabric containing polyester fibers, the material of which and the composition of which are as described above.

[0042] The method for producing a fiber structure in this embodiment includes (i) a step of dyeing a polyester fiber structure with a disperse dye. If dyeing is performed while various chemicals are attached to the fiber surface, it becomes difficult to sufficiently dye the disperse dye into the polyester fiber, and various color fastnesses may be reduced. Therefore, it is preferable to perform dyeing before the step of attaching the chemicals described below to the fiber surface.

[0043] A known method can be used to dye a polyester fiber structure with a disperse dye. For example, a base fabric containing polyester fibers and an aqueous dispersion (dyeing solution) containing a disperse dye are prepared, and the base fabric is immersed in the dyeing solution or the dyeing solution is applied to the base fabric by coating or spraying, and then the disperse dye is dyed onto the polyester fibers in a high-temperature environment.

[0044] The preferred method for dyeing polyester fibers with disperse dyes is the in-bath exhaustion method, which allows the disperse dye to be absorbed (exhausted) into the gaps between the molecular chains that make up the polyester fibers, thereby improving various color fastnesses. Specifically, a high-pressure jet dyeing machine, high-pressure winch, high-pressure jigging machine, or high-pressure drum dyeing machine may be used to immerse the base fabric in a dye solution and heat it to 80°C to 140°C. To improve various color fastnesses, the dyeing temperature is preferably 95°C or higher, and more preferably 100°C or higher. From the standpoints of economy and preventing embrittlement of polyester fiber structures, the dyeing temperature is preferably 135°C or lower.

[0045] The dye solution may contain known dyeing auxiliaries. Examples of dyeing auxiliaries include acids, pH adjusters, chelating agents, leveling agents, retarders, dispersants, and carriers. In addition to the dyeing auxiliaries, functionality-imparting agents such as flame retardants, antibacterial agents, ultraviolet absorbers, water absorbents, and SR agents may also be added within the scope of the present invention.

[0046] The method for producing a polyester fiber structure of this embodiment includes the step of (i) dyeing a polyester fiber structure with a disperse dye, followed by the step of (ii) polymerizing a polyalkylene glycol diacrylic ester on the fiber surface. Polymerizing the polyalkylene glycol diacrylic ester on the fiber surface allows the fiber surface to be covered with a hydrophilic film.

[0047] To polymerize the polyalkylene glycol diacrylic ester (also referred to as the hydrophilic agent) on the fiber surface, the hydrophilic agent is first applied to the fabric after the dyeing process. The hydrophilic agent can be applied to the fabric by immersion, application, spraying, or other methods using an aqueous solution or aqueous dispersion (hydrophilic treatment liquid) containing the hydrophilic agent or an appropriate functional agent. To remove excess treatment liquid from the fabric, a process of squeezing the fabric with a mangle roll or blowing it off with an air blower may be added.

[0048] The concentration of the hydrophilic agent in the hydrophilic treatment solution is preferably 0.5% by mass or more, more preferably 1% by mass or more, from the viewpoint of imparting high antistatic properties to the polyester fiber structure, and is preferably 15% by mass or less, more preferably 10% by mass or less, from the viewpoint of suppressing hardening of the texture and the occurrence of chalk marks.

[0049] As the functional agent, those mentioned above can be used, but it is advisable to add an appropriate polymerization initiator or polymerization catalyst according to the polymerization mechanism of the subsequent polymerization step. For example, when the hydrophilic agent is polymerized by radical polymerization, an initiator such as an inorganic system such as hydrogen peroxide or ammonium persulfate, an organic peroxide such as benzoyl peroxide or methyl ethyl ketone peroxide, an azo compound such as azobisisobutyronitrile, an aromatic ketone such as benzophenone, or a redox initiator combining an oxidizing agent and a reducing agent can be used in a dissolved or emulsified state in water.

[0050] Subsequently, the hydrophilic agent is polymerized and fixed to the fiber surface. The polymerization mechanism is not particularly limited as long as it is a mechanism that activates the acryloyl group contained in the molecule of the hydrophilic agent and causes a chain addition reaction. Examples include radical polymerization, cationic polymerization, anionic polymerization, and coordination polymerization. Since it is difficult to control the deactivation of active species and catalysts in cationic polymerization, anionic polymerization, and coordination polymerization, it is preferable to polymerize the hydrophilic agent by radical polymerization, which allows for a simple polymerization reaction.

[0051] The method for initiating and promoting polymerization may be appropriately selected depending on the selected polymerization mechanism. When polymerization is carried out by a radical chain reaction, the initiation and propagation reaction may be promoted by applying dry heat or moist heat to the fabric to which the hydrophilic agent has been applied, irradiating it with active energy rays such as ultraviolet rays or electron beams, or a combination of these. From the viewpoint of polymerization efficiency and processing stability, polymerization is preferably carried out under moist heat conditions. Specifically, moist heat processing conditions include processing for 1 to 20 minutes in a chamber filled with steam at 80°C to 180°C, preferably 100°C to 150°C, or in a chamber equipped with a steam-spraying nozzle.

[0052] The method for producing a polyester-based fiber structure of this embodiment includes the step (c) of attaching a fluorine-free water repellent agent to the fiber surface after the step (b) of polymerizing a polyalkylene glycol diacrylic ester on the fiber surface. Because it is difficult to apply a separate agent to fibers to which a water repellent agent has been attached, and because the water repellent agent is present on the outermost surface of the fiber (outside the polymer coating of the polyalkylene glycol diacrylic ester), it is easy to impart high water repellency to the polyester-based fiber structure, it is preferable that the step of attaching the water repellent agent be performed last among the steps of attaching agents to the fiber.

[0053] In order to adhere the fluorine-free water repellent agent to the fiber surface, the water repellent agent is first applied to the fabric after the polymerization treatment. The method for applying the water repellent agent to the fabric is the same as the above-mentioned process for applying the hydrophilic agent, in which an aqueous solution or aqueous dispersion (water repellent treatment liquid) containing the fluorine-free water repellent agent and an appropriate functional agent is applied.

[0054] The concentration of the fluorine-free water repellent agent in the water repellent treatment solution is preferably 0.5% by mass or more, more preferably 1% by mass or more, from the viewpoint of imparting high water repellency to the polyester fiber structure, and is preferably 10% by mass or less, more preferably 6% by mass or less, from the viewpoint of suppressing adverse effects on hardening of texture and antistatic properties.

[0055] As the functional agent, it is preferable to use an appropriate crosslinking agent from the viewpoint of improving the washing durability of water repellency. As the types and characteristics of the crosslinking agent are as described above, it is preferable to use an isocyanate-based crosslinking agent, a melamine-based crosslinking agent, a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, an aziridine-based crosslinking agent, or a combination of two or more of these. It is preferable to use a combination of at least one selected from the group consisting of a carbodiimide-based crosslinking agent, an oxazoline-based crosslinking agent, and an aziridine-based crosslinking agent with an isocyanate-based crosslinking agent, and it is particularly preferable that the carbodiimide-based crosslinking agent, the oxazoline-based crosslinking agent, and the aziridine-based crosslinking agent are water-insoluble.

[0056] In the process of applying the various chemicals described above, if any chemicals remain on the fabric in each process that have not dyed or fixed thereto, this may cause defects in the next process or problems such as a decrease in the color fastness of the final fiber structure, yellowing, or embrittlement. Therefore, a cleaning treatment may be carried out between each process using water or a cleaning solution containing an appropriate soaping agent or surfactant.

[0057] Before and after each step, heating steps such as a drying step and a heat-setting step for adjusting the properties of the base fabric may be included as necessary. In particular, after the step (c) of attaching a fluorine-free water repellent agent to the fiber surface, a curing step is preferably performed to apply sufficient thermal energy to the hydrophobic segments of the water repellent agent to induce micro-Brownian motion, thereby forming a forest of hydrophobic segments that repel each other and cover the fiber surface, thereby enhancing water repellency. However, to prevent deterioration of the polyalkylene glycol diacrylic ester polymer, the method does not include a step of heating at a temperature of 160°C or higher after the step (b) of polymerizing the polyalkylene glycol diacrylic ester on the fiber surface. Therefore, the temperature of the curing step is preferably below 160°C, and more preferably below 150°C. The curing step may be performed simultaneously with the drying step and the heat-setting step. [Example]

[0058] The present embodiment will be described in detail below with reference to examples, but the present invention is not limited to the following description. In the present invention, various physical properties were measured and evaluated by the following methods: "% omf" means the mass % of the dye relative to the mass of the fabric.

[0059] (1) Dry and wet rubbing fastness Evaluation was carried out in accordance with the friction tester type II (Gakushin type) method described in JIS L 0849:2013.

[0060] (2) Home laundry Washing was carried out in accordance with the C4M method described in JIS L 1930:2014. Drying after washing was carried out using Method A (hang-drying). Note that 100 home washes will be referred to as "100HL" below.

[0061] (3) Water repellency Using the initial samples and samples after 100HL, evaluation was performed in accordance with the water repellency test (spray test) described in JIS L 1092:2020.

[0062] (4) Frictional electrification voltage The initial samples and samples after 100 HL were evaluated in accordance with Method B (frictional electrification voltage measurement method) described in JIS L 1094:2020.

[0063] (5) Half-life The initial and 100HL samples were evaluated in accordance with Method A (half-life measurement method) described in JIS L 1094:2020.

[0064] Example 1 (Base fabric) First, both the warp and weft yarns were plain woven using yarns with a fineness of 83 dtex, which consisted solely of general-purpose polyethylene terephthalate (PET) fibers, to obtain a plain woven fabric with a weave density of 141 threads / 2.54 cm x 111 threads / 2.54 cm.

[0065] <Dyeing process> The plain woven fabric was immersed in the following dyeing solution using a high-pressure jet dyeing machine (bath ratio (mass ratio) plain woven fabric: aqueous dispersion = 1:15), and the aqueous dispersion was heated at a rate of 2°C / min and maintained at 130°C for 30 minutes, thereby carrying out a dyeing process.

[0066] (staining solution) Dianix Yellow ACE new...0.03%omf (Disperse dye manufactured by Dystar Japan Co., Ltd.) Dianix Red ACE 01...0.03%omf (Disperse dye manufactured by Dystar Japan Co., Ltd.) Acetic acid: 0.2 g / L Nikka Sunsalt SN-550 1.0g / L (Nicca Chemical Co., Ltd. cleaning, dispersing and leveling agent) water...remainder

[0067] Next, the fabric was washed with water at 70°C, dried at 120°C, and then heat-set at 170°C to obtain a fabric dyed orange with a disperse dye.

[0068] <Polymerization process> Next, the following hydrophilic treatment liquid was applied to the dyed fabric by padding.

[0069] (hydrophilic treatment liquid) NK Ester 23G...4% by mass (Shinnakamura Chemical Co., Ltd., polyethylene glycol diacrylate with an average degree of polymerization of ethylene glycol units of 23) Ammonium persulfate: 0.1% by mass (Radical polymerization initiator) water...remainder

[0070] The fabric was then subjected to a wet heat treatment in a normal pressure steamer at 105°C for 20 minutes to polymerize the water-soaking agent on the surface of the PET fibers. The fabric was then washed with water at 70°C and dried at 120°C to obtain a fabric with a polyethylene glycol diacrylic ester polymer attached to the surface of the PET fibers.

[0071] <Water-repellent process> Next, the following water-repellent treatment liquid 1 was applied to the polymerized fabric by padding without including a step of heating at a temperature of 160°C or higher after the polymerization step.

[0072] (Water repellent treatment liquid 1) Unidyne XF-5003: 8% by mass (Acrylic water repellent manufactured by Daikin Industries, Ltd. Solid content: 30% by mass. Registered trademark) Amidia M-3: 0.5% by mass (Melamine-based crosslinking agent manufactured by DIC Kitanihon Polymer Co., Ltd., registered trademark) Catalyst ACX: 0.1% by mass (DIC Kitanihon Polymer Co., Ltd., melamine crosslinking agent catalyst: amino alcohol hydrochloride) water...remainder

[0073] Subsequently, the fabric was dried at 120°C to obtain a fabric with an acrylic water repellent agent attached to the fiber surface.

[0074] <Curing process> Next, the water-repellent treated fabric was heated at 150°C for 1 minute using a tenter machine while adjusting properties such as weave density to obtain a polyester fiber structure. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0075] (Comparative Example 1) A polyester fiber structure was obtained in the same manner as in Example 1, except that the curing temperature in the curing step was changed to 170° C. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0076] (Comparative Example 2) A polyester fiber structure was obtained in the same manner as in Example 1, except that the water-repellent treatment agent was changed to the following water-repellent treatment liquid 2. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0077] (Water repellent treatment liquid 2) Neoseed NR-8000: 8% by mass (Silicone-based water repellent manufactured by Nicca Chemical Co., Ltd. Solid content: 30% by mass. Registered trademark) Amidia M-3: 0.5% by mass Catalyst ACX: 0.1% by mass water...remainder

[0078] Example 2 A polyester fiber structure was obtained in the same manner as in Example 1, except that the water-repellent treatment agent was changed to the following water-repellent treatment liquid 3. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0079] (Water repellent treatment liquid 3) Unidyne XF-5003: 8% by mass Carbodilite V―02-L2···0.5% by mass (Water-soluble carbodiimide crosslinking agent manufactured by Nisshinbo Chemical Inc., registered trademark) Meykanate CX 0.5% by mass (Blocked isocyanate crosslinking agent manufactured by Meisei Chemical Industry Co., Ltd. Dissociation temperature: approximately 120°C. Registered trademark) water...remainder

[0080] Example 3 A polyester fiber structure was obtained in the same manner as in Example 1, except that the water-repellent treatment agent was changed to the following water-repellent treatment liquid 4. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0081] (Water repellent treatment liquid 4) Unidyne XF-5003: 8% by mass Carbodilite E-05: 0.5% by mass (Nisshinbo Chemical Inc., non-water-soluble (emulsion type) carbodiimide crosslinking agent) Meykanate CX 0.5% by mass water...remainder

[0082] Example 4 A polyester fiber structure was obtained in the same manner as in Example 1, except that the water-repellent treatment agent was changed to the following water-repellent treatment liquid 5. Various properties of the obtained polyester fiber structure are shown in Table 1.

[0083] (Water repellent treatment liquid 5) Neoseed NR-8000: 8% by mass Carbodilite E-05: 0.5% by mass Meykanate CX 0.5% by mass water...remainder

[0084] [Table 1]

[0085] Referring to Table 1, it can be seen that the wet rubbing fastness of the polyester fiber structure of Comparative Example 1 was Grade 2-3, and the frictional electrification voltage and half-life after 100 HL were significantly worse than those at the initial stage. Also, it can be seen that the water repellency of the polyester fiber structure of Comparative Example 2 was Grade 3 at the initial stage, and after 100 HL, it had decreased to Grade 1, which is considered to have no water repellency.

[0086] In contrast, the polyester fiber structures of Examples 1 to 4 have both dry and wet rubbing fastnesses of Grade 3 or higher, and initial water repellency of Grade 3 or higher, so that they maintain relatively high antistatic properties and water repellency even after 100 hours of use. In particular, the polyester fiber structure of Example 3, which combines a water-insoluble carbodiimide crosslinking agent and an isocyanate crosslinking agent as crosslinking agents, exhibits the highest performance in terms of dry and wet rubbing fastness, initial water repellency, and water repellency after 100 hours of use.

Claims

1. A polyester fiber structure in which a polyalkylene glycol diacrylic ester polymer and a fluorine-free water repellent agent are adhered to the surface of a polyester fiber dyed with a disperse dye, and (A) both the dry and wet rubbing fastnesses are grade 3 or higher, and (B) the initial water repellency is grade 3-4 or higher.

2. 2. The polyester fiber structure according to claim 1, further comprising: (C) water repellency of grade 2 or higher after 100 home washes; and (D) a frictional electrification voltage of 2000 V or less after 100 home washes.

3. 3. The polyester fiber structure according to claim 1, further comprising at least one crosslinking agent selected from the group consisting of a carbodiimide crosslinking agent, an oxazoline crosslinking agent, and an aziridine crosslinking agent, and an isocyanate crosslinking agent attached to the polyester fiber structure.

4. The polyester fiber structure according to claim 3 , wherein the carbodiimide crosslinking agent, the oxazoline crosslinking agent, or the aziridine crosslinking agent is water-insoluble.

5. 3. A method for producing a polyester fiber structure according to claim 1 or 2, comprising the steps of: (i) dyeing a polyester fiber structure with a disperse dye; (ii) polymerizing a polyalkylene glycol diacrylic ester on the fiber surface; and (iii) attaching a fluorine-free water repellent to the fiber surface, in this order; and not including a step of heating at a temperature of 160°C or higher after the step of polymerizing the polyalkylene glycol diacrylic ester on the fiber surface.

6. The method for producing a polyester fiber structure according to claim 5, further comprising (d) a curing step at a temperature of less than 160°C after the step (c) of adhering a fluorine-free water repellent agent to the fiber surface.

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