Method for producing polyester fiber structure and method for producing medical uniform

Abstract

To provide a method for producing a polyester fiber structure excellent in antibacterial properties and washing durability.SOLUTION: A pre-heat treatment step of heat-treating a fiber base material containing polyester fibers having a single fiber fineness of 0. 3dtex or more and 5. 0dtex or less at an atmospheric temperature of 110 °C. or more and 210 °C. or less so that a rate of change in weave densities in a warp direction of the fiber base material containing the polyester fibers before and after the heat treatment is - 3.0% or more and 3.0% or less; 0.004, A method for producing a polyester fiber structure, comprising: a chemical solution treatment step of performing treatment by bath processing or pad processing; and a post-heat treatment step of performing dry heat treatment on a fiber base material containing the polyester fibers subjected to the chemical solution treatment.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a method for producing a polyester fiber structure having excellent antibacterial properties and washing durability, and a method for producing a medical uniform. [Background technology]

[0002] Hospital textile products, such as white coats worn by medical staff in hospitals, clinics, and other medical facilities, are required to have antibacterial properties that can withstand high-temperature washing, as they are sometimes subjected to repeated industrial washing in hot water at around 60 to 80 degrees Celsius for hygiene reasons.

[0003] From the viewpoint of productivity, the mainstream antibacterial processing technology for synthetic fiber products involves adding an antibacterial agent after the product has been made into a fabric or other product. However, this processing method generally has the problem of low antibacterial properties after washing, as the antibacterial agent is generally removed by washing.

[0004] To address this issue, studies have been conducted to improve antibacterial properties after washing. For example, Patent Document 1 proposes applying 2-pyridylthiol-1-oxide zinc (hereinafter referred to as zinc pyrithione), a type of pyridine antibacterial agent, to a textile structure by heat treatment at a specific temperature under normal or increased pressure. It is described that this method results in a textile structure with antibacterial properties that are highly durable against industrial washing at a temperature of 85°C.

[0005] Furthermore, Patent Document 2 proposes heat treating oxolinic acid under pressure in a treatment bath at a specific temperature, and describes that this can impart antibacterial properties. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-8275 [Patent Document 2] JP 2021-42498 A Summary of the Invention [Problem to be solved by the invention]

[0007] The method disclosed in Patent Document 1 has high antibacterial properties and washing durability, but has the problem that the antibacterial agent containing zinc ions is used, making it difficult to treat the wastewater generated after application of the antibacterial agent. Another problem is that the antibacterial agent may affect dyeability.

[0008] The method disclosed in Patent Document 2 uses oxolinic acid, an organic carboxylic acid compound, and therefore does not have the wastewater treatment problem that is the problem of Patent Document 1. However, according to the studies of the present inventors, it has been found that the antibacterial properties may be low depending on the processing steps and the composition of the base material used.

[0009] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a method for producing a polyester fiber structure that is excellent in antibacterial property and washing durability when antibacterial property is imparted to the polyester fiber structure without using an antibacterial agent containing zinc ions or the like. [Means for solving the problem]

[0010] As a result of intensive studies, the present inventors have found that a polyester fiber structure having excellent antibacterial properties and washing durability can be obtained by attaching a specific amount of a quinoline-based compound to a fiber substrate containing polyester fibers, using polyester fibers having a specific monofilament fineness, and heat-treating the fiber substrate containing polyester fibers at a specific temperature so that the weave density in the warp direction falls within a specific rate of change, followed by antibacterial treatment. In particular, the present inventors have newly discovered an effect that the antibacterial properties and washing durability are improved by controlling the weave density change rate in the warp direction within a specific range in the pre-heat treatment step before the antibacterial treatment.

[0011] That is, the present invention has the following configuration to solve the above problems. (1) a pre-heat treatment step of heat-treating a fiber substrate containing polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less at an atmospheric temperature of 110°C or more and 210°C or less so that the change rate of the weave density in the warp direction of the fiber substrate containing the polyester fibers before and after the heat treatment is -3.0% or more and 3.0% or less; a processing solution preparation step of preparing a processing solution containing 0.004% by mass or more of a quinoline-based compound relative to the mass of the processing solution; a chemical solution treatment step of immersing a fiber substrate containing the polyester fiber in the treatment solution and treating it by bath treatment or pad treatment; a post-heat treatment step of dry-heat treating the fiber substrate containing the chemically treated polyester fiber; A method for producing a polyester fiber structure, comprising: (2) The method for producing a polyester fiber structure according to (1), wherein the fibers constituting the fiber substrate containing the polyester fibers contain 40% by mass or more of polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less relative to the mass of the entire fiber substrate. (3) The method for producing a polyester fiber structure according to (1) or (2), wherein the quinoline compound is at least one compound selected from oxolinic acid, ciprofloxacin, levofloxacin, moxifloxacin, garenoxacin, and sitafloxacin. (4) The method for producing a polyester fiber structure according to (1) or (2), wherein the quinoline-based compound is oxolinic acid. (5) The method for producing a polyester fiber structure according to (1) or (2), wherein in the chemical treatment step in the bath treatment, the bath ratio of the treatment solution (mass of the fiber substrate including the polyester fiber:mass of the treatment solution) is 1:5 to 1:30. (6) A method for producing a medical uniform, comprising a step of sewing a medical uniform using a polyester fiber structure produced by the method for producing a polyester fiber structure according to (1) or (2). [Effects of the Invention]

[0012] According to the present invention, a method for producing a polyester fiber structure having excellent antibacterial properties and washing durability can be provided. DETAILED DESCRIPTION OF THE INVENTION

[0013] [Method for producing polyester fiber structure] The present invention will be described in detail below with reference to preferred embodiments, but is not limited to these. The method for producing a polyester fiber structure of the present invention includes a pre-heat treatment step of heat-treating a fiber substrate containing polyester fibers having a single fiber fineness of 0.3 dtex to 5.0 dtex at an ambient temperature of 110°C to 210°C so that the change rate of the weave density in the warp direction of the substrate containing the polyester fibers before and after the heat treatment is -3.0% to 3.0%; a processing solution preparation step of preparing a processing solution containing 0.004% by mass or more of a quinoline-based compound relative to the mass of the processing solution; a chemical solution treatment step of immersing a fiber substrate containing the polyester fiber in the treatment solution and treating it by bath treatment or pad treatment; and a post-heat treatment step of dry-heat treating the fiber substrate containing the polyester fiber that has been treated with the chemical solution.

[0014] <Pre-heat treatment process> (fiber substrate) As the fiber substrate constituting the polyester fiber structure, fabric-like materials such as woven fabrics, knitted fabrics, and nonwoven fabrics can be preferably used. The form of the fiber substrate may be either a filament yarn or a spun yarn, but is not limited to these. If necessary, synthetic fibers other than polyester fibers, such as acrylic and nylon, natural fibers such as cotton, wool, and silk, and semi-synthetic fibers such as rayon and acetate may be combined and used in the form of interwoven, interknitted, mixed woven, mixed spun, or mixed fibers.

[0015] The fiber substrate contains polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less. Furthermore, among the fibers constituting the fiber substrate, polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less preferably account for 40% by mass or more, more preferably 60% by mass or more, and even more preferably 75% by mass or more, of the total mass of the fiber substrate. By setting the content within the above range, the proportion of polyester fibers to which quinoline compounds are attached increases, resulting in higher antibacterial properties of the resulting polyester fiber structure. From the viewpoint of improving antibacterial properties, the higher the proportion of the polyester fibers, the better. The "proportion of polyester fibers relative to the total mass of the fiber substrate" may also be referred to as the "proportion of polyester fibers."

[0016] The polyester fiber is a fiber obtained by melt-spinning a polyester resin. The polyester used here is a common polyester produced by polymerizing terephthalic acid or its ester derivative as a carboxylic acid component with an alkylene glycol component such as ethylene glycol or trimethylene glycol, and any known polyester fiber can be used.

[0017] The single fiber fineness of the polyester fiber is 0.3 dtex or more, preferably 1.0 dtex or more. It is also 5.0 dtex or less, preferably 4.0 dtex or less, and more preferably 2.0 dtex or less. When the single fiber fineness is less than 0.3 dtex, antibacterial properties cannot be obtained. While the detailed mechanism is unknown, it is presumed that when the single fiber fineness is small, the polymer is oriented, making it difficult for the antibacterial agent to penetrate into the fiber interior, and the antibacterial agent attached to the surface falls off in subsequent processes, resulting in insufficient antibacterial properties. On the other hand, when the single fiber fineness is greater than 5.0 dtex, the fiber surface area per unit weight is reduced, resulting in a smaller contact area between the antibacterial agent and the fiber, and therefore insufficient antibacterial properties can be obtained as a polyester fiber structure.

[0018] (Weave density change rate in the vertical direction of the fiber base material) Before and after the pre-heat treatment described below, the weave density change rate in the warp direction of a fiber substrate containing the polyester fibers (hereinafter sometimes referred to as "polyester fiber substrate") is -3.0% or more, preferably -1.5% or more, and 3.0% or less, preferably 1.5% or less. Methods for adjusting the weave density change rate in the warp direction include adjusting the tension in the warp and weft directions during the pre-heat treatment, which can be adjusted taking into account the shrinkage characteristics of the polyester fiber substrate. Among these, the weave density change rate in the warp direction can be easily adjusted by adjusting the tension in the weft direction. For example, in the pre-heat treatment, tension is applied in the transverse direction (width direction) of the polyester fiber substrate using a pin tenter machine or the like to adjust the width of the polyester fiber substrate to a predetermined set width before treatment. In this case, if the heat treatment is performed with the set width of the pin tenter machine wider than the transverse length (width) of the polyester fiber substrate before the pre-heat treatment, the polyester fiber substrate is pulled in the weft direction, resulting in a sparse fiber density in the warp direction and a smaller weave density value in the warp direction. By utilizing this, the rate of change in weave density in the warp direction can be adjusted to a desired range, taking into consideration the shrinkage characteristics of the polyester fiber base material, etc. From this viewpoint, it is preferable to set the width of the pin tenter machine to be −3.0% or more and 3.0% or less with respect to the length (width) in the transverse direction of the polyester fiber base material before the pre-heat treatment.

[0019] By adjusting the tension so that the change in weave density in the warp direction is between -3.0% and 3.0% before and after the pre-heat treatment, antibacterial properties and washing durability can be achieved. While the exact reason for this is unclear, it is presumed that the above change in weave density in the warp direction places the crystallinity of the polyester fiber within an appropriate range, allowing a sufficient amount of antibacterial agent to remain even after washing, thereby exhibiting washing durability. That is, when the change in weave density in the warp direction is less than -3.0%, the tension in the transverse direction applied to the polyester fiber substrate is too high, reducing the amorphous region in the fiber and increasing the crystalline region, making it difficult for the antibacterial agent to be fixed inside the fiber. Therefore, it is thought that a sufficient amount of antibacterial agent does not remain after washing, resulting in reduced washing durability. On the other hand, when the change in weave density in the warp direction is greater than 3.0%, the tension in the transverse direction applied to the polyester fiber substrate is insufficient, reducing the crystallinity of the polyester fiber. Although more antibacterial agent is fixed inside the fiber, the crystalline structure is too loose and unable to firmly retain the antibacterial agent. This is thought to result in increased antibacterial agent loss during washing and reduced washing durability. The rate of change in weave density in the warp direction is measured by the method described in the examples.

[0020] (ambient temperature) The ambient temperature range during pre-heat treatment is 110°C or higher, preferably 170°C or higher, and more preferably 180°C or higher. It is also 210°C or lower, preferably 200°C or lower, and more preferably 190°C or lower. Dry heat treatment at an ambient temperature of 190°C is preferred because it minimizes the amount of antibacterial agent removed by washing. Pre-heat treatment at an ambient temperature lower than 110°C, or no pre-heat treatment, results in a large amount of antibacterial agent removed by washing, reducing antibacterial properties after washing, i.e., washing durability. Pre-heat treatment at an ambient temperature higher than 210°C also results in a large amount of antibacterial agent removed by washing, reducing antibacterial properties after washing, i.e., washing durability. In addition, the hardening of the polyester affects the texture, making it undesirable for use in textile products.

[0021] <Processing solution preparation process> The method for producing a polyester fiber structure of the present invention includes a treatment solution preparation step of preparing a treatment solution containing a predetermined amount of a quinoline-based compound. Since the antibacterial properties of the resulting polyester fiber structure are not affected even if a functional finishing agent is used in addition to the quinoline-based compound described below, the treatment solution may contain other agents such as dyes, water-absorbing agents, and fluorescent whitening agents in any amounts appropriate for the desired functions.

[0022] (Quinoline compounds) Examples of the quinoline compounds include oxolinic acid (5-ethyl-8-oxo-[1,3]dioxolo[4,5-g]quinoline-7-carboxylic acid), ciprofloxacin (1-cyclopropyl-1,4-dihydro-6-fluoro-4-oxo-7-(1-piperazinyl)-3-quinolinecarboxylic acid), levofloxacin ((3S)-9-fluoro-3-methyl-10-(4-methyl-1-piperazinyl)-7-oxo-2,3-dihydro-7H-pyrido[1,2,3-de][1,4]benzoxazine-6-carboxylic acid), moxifloxacin ((1S,6S)-1-cyclopropyl-7-(2,8-diazabicyclo[4.3.0]non-8-isopropyl) Preferably, the quinoline compound is at least one compound selected from the group consisting of 1-cyclopropyl-8-(difluoromethoxy)-7-[(1R)-1-methyl-2,3-dihydro-1H-isoindol-5-yl]-6-fluoro-8-methoxy-4-oxo-1,4-dihydroquinoline-3-carboxylic acid), garenoxacin (1-cyclopropyl-8-(difluoromethoxy)-7-[(1R)-1-methyl-2,3-dihydro-1H-isoindol-5-yl]-4-oxo-1,4-dihydroquinoline-3-carboxylic acid), and sitafloxacin (7-[(7S)-7-amino-5-azaspiro[2.4]heptan-5-yl]-8-chloro-6-fluoro-1-[(1R,2S)-2-fluorocyclopropyl]-4-oxo-1,4-dihydroquinoline-3-carboxylic acid). Among these, oxolinic acid is more preferred as the quinoline compound.

[0023] The quinoline compounds listed above may be in the form of metal salts such as alkali metal salts, such as sodium salts or potassium salts, alkaline earth metal salts, such as calcium salts or magnesium salts, aluminum salts, or iron salts.

[0024] The content of the quinoline compound in the treatment solution is 0.004% by mass or more, preferably 0.008% by mass or more, based on the mass of the treatment solution. When the content is 0.004% by mass or more, an antibacterial effect can be obtained. On the other hand, if the mass of the quinoline compound is too large, a large amount of the white quinoline compound adheres to the surface of the polyester fiber structure, which causes the polyester fiber structure to whiten (i.e., the brightness L * The concentration of the quinoline compound is preferably 0.030% by mass or less, more preferably 0.015% by mass or less, based on the mass of the treatment solution. By using the quinoline compound in the above range, good antibacterial properties can be obtained.

[0025] <Chemical treatment process> The method for producing a polyester fiber structure of the present invention includes a chemical treatment step in which a fiber substrate containing the polyester fibers is immersed in the treatment solution and treated by bath treatment or pad treatment.

[0026] The chemical solution treatment is achieved by either bath processing or pad processing. The bath processing referred to here is a method in which a fibrous substrate containing polyester fibers is immersed in a bath containing the treatment solution and then heat-treated, thereby adhering the treatment solution to the fibrous substrate containing polyester fibers. The pad processing referred to here is a method in which a fibrous substrate containing polyester fibers is immersed in the treatment solution, squeezed with a mangle roller or the like so that a certain amount of the treatment solution adheres to the fibrous substrate containing polyester fibers, and then subjected to dry heat treatment in a dryer or wet heat treatment in saturated steam at 100°C, thereby adhering the treatment solution to the fibrous substrate containing polyester fibers.

[0027] In the bath treatment, the fibrous substrate containing the preheat-treated polyester fibers is placed in a treatment solution containing a quinoline-based compound at a bath ratio (mass of the fibrous substrate containing the polyester fibers:mass of the treatment solution) of 1:5 to 1:30, and then heat-treated in a sealed container under normal or increased pressure in a bath at a temperature of 90°C to 140°C, preferably 110°C to 140°C. By performing the chemical treatment at a bath ratio within this range, the quinoline-based compound and the fibrous substrate can come into efficient contact with each other, and a polyester fiber structure that retains antibacterial properties even after washing can be provided.

[0028] In padding, the fibrous substrate containing the preheat-treated polyester fiber is immersed in a treatment solution containing a quinoline compound and squeezed with a mangle roller to adhere the treatment solution. The fibrous substrate containing the polyester fiber is then set in a pin tenter and subjected to a wet heat treatment at 130°C for 2 minutes. When using a fibrous substrate containing dyed polyester fiber, the fibrous substrate containing the preheat-treated polyester fiber is placed in a treatment solution containing a dye at a bath ratio (mass of the fibrous substrate containing polyester fiber:mass of the treatment solution) of 1:5 to 1:30, and then heat-treated in a sealed container at a temperature of 90°C to 140°C under normal or increased pressure. Padding is then performed.

[0029] <Post-heat treatment process> The method for producing a polyester fiber structure of the present invention includes a post-heat treatment step of dry-heat treating the fiber substrate containing the chemically treated polyester fibers. In the post-heat treatment step, the fiber substrate containing the polyester fibers treated in the chemical treatment step is set in a pin tenter and dry-heat treated at an ambient temperature of 130°C to 190°C, preferably 150°C to 190°C, for 15 seconds to 5 minutes. This dry-heat treatment can improve antibacterial properties after washing, i.e., washing durability.

[0030] <Post-processing process> A polyester fiber structure is obtained through the post-heat treatment step, and like general polyester fiber structures, various further finishing steps can be carried out, such as calendaring, which improves the light reflection of the polyester fiber structure surface by compressing and smoothing the polyester fiber structure with a roller or the like to give it a glossy feel, and raising, which provides heat retention and flexibility by scratching or abrading the polyester fiber structure surface with a needle, an abrasive cloth, etc. Of course, polyester fiber structures obtained by carrying out these finishing steps are also included in the polyester fiber structures obtained by the polyester fiber structure manufacturing method of the present invention.

[0031] <Antibacterial properties of polyester fiber structures> The polyester fiber structure provided by the method for producing a polyester fiber structure of the present invention has an antibacterial activity value of A after 50 high-temperature accelerated washings in the antibacterial evaluation method described in the SEK Mark textile product certification standard established by the Japan Textile Evaluation Technology Council. 50 is greater than the standard fabric growth value F. In other words, it is possible to provide a polyester fiber structure with antibacterial properties that meet the evaluation criteria for "antibacterial processing (specific use: red)" of the SEK Mark textile product certification standard after 50 high-temperature accelerated washings. The high-temperature accelerated washing and antibacterial property tests are evaluated using the methods described below.

[0032] [Application] The polyester fiber structure provided by the method for producing a polyester fiber structure of the present invention can be used in various applications requiring high antibacterial properties, for example, as fabrics for clothing, bedding, towels, rugs, curtains, sheets, etc.

[0033] The polyester fiber structure can be used for general clothing, uniforms, formal and business clothing, workwear, sportswear, and medical uniforms such as white coats, scrubs, casey coats, doctor coats, nurse uniforms, and tunics worn by medical professionals. The polyester fiber structure provided by the method for producing a polyester fiber structure of the present invention is particularly preferably used in medical uniforms. [Example]

[0034] Next, the method for producing a polyester fiber structure of the present invention will be explained in more detail with reference to examples, but the method is not limited to these examples. The washing method and various test methods in the examples were as follows.

[0035] (Washing method) This was in accordance with the "SEK Mark Textile Product Washing Method," a certification standard of the Textile Evaluation Technology Council, a general incorporated association. That is, using a washing machine, 120 mL of "JAFET standard blend detergent" was added to 90 L of water to make the washing liquid. Next, the polyester fiber structure and, if necessary, a load cloth were added so that the liquor ratio of this washing liquid (mass of polyester fiber structure: mass of washing liquid) was 1:30, and the total mass of the polyester fiber structure and the load cloth was adjusted to 3 kg. After that, 1) Wash at 80°C for 120 minutes 2) Drainage The washing machine was then rinsed using a standard washing capacity and standard water volume household washing machine with a centrifugal wringer that conforms to the standard of JIS C 9606:2007 (electric washing machine) specified in "Appendix 1 Test Methods by Symbol - Washing Method (Water Washing), Number 103" in JIS L 0217:1995 "Display Symbols and Their Display Methods for Handling Textile Products." That is, 3) Thoroughly dehydrate the polyester fiber structure and the load fabric for 3 to 5 minutes. 4) 15-minute overflow rinse (aim for 3 to 5 times the amount of water replaced) 5) Dehydrate in the same way as 4). After that, steps 3) to 5) were repeated a total of four times, and then steps 1) to 5) were repeated a total of five times using a washing machine and a home washing machine. Finally, only the polyester fiber structure was taken out, 6) Rinse with overflow water for 5 minutes using a household washing machine (aim for 3 to 5 times the amount of water replaced). 7) Dehydrate in the same way as in 3). 8) Dry at a temperature of 80°C or less In step 8), the product was hung to dry or laid flat to dry in a place where it was not exposed to direct sunlight.

[0036] (Antibacterial test) 1) Test method: The test was carried out using the bacterial liquid absorption method based on JIS L 1902:2015 "Test methods for antibacterial properties and antibacterial effects of textile products." The test was carried out under the condition that the nonionic surfactant "Tween" (registered trademark) 80 was added to the test bacterial suspension in an amount of 0.050% by mass relative to the mass of the polyester fiber structure. 2) Test strain: Staphylococcus aureus 3) Evaluation method: The evaluation criteria for antibacterial processing (specific use: red) in "18.3 Evaluation criteria for bacterial liquid absorption method" of the "SEK Mark Textile Product Certification Standards" mentioned above were followed. That is, the antibacterial activity value of the polyester fiber structure after antibacterial processing after washing 50 times was evaluated as A. 50 , the growth value of the unwashed standard cloth is F, A 50 > F, that is, A 50 -If F>0.0, the antibacterial property is good, and A 50 If -F≦0.0, the antibacterial properties were judged to be poor. The standard cloth refers to a white cloth (cotton No. 3-1) attached to JIS L 0803, which is sold by the Japan Textile Evaluation Technology Council as a standard cloth (cotton) for antibacterial testing and is listed in the proviso of "3.1 Control specimen" in JIS L 1902:2015 "Antibacterial test method and antibacterial effect of textile products," and which has been washed with water.

[0037] Here, the antibacterial activity value A after n washings nThe growth value F of the standard cloth was calculated using the following formulas (2) and (3). A n =(log C t -log C o )-(log T t -log T o ) …(2) F=log C t -log C o …(3) log C o : Common logarithm of the arithmetic mean of the viable bacterial counts of three samples immediately after inoculation of the test bacteria on the standard cloth log C t : Common logarithm of the arithmetic mean of the viable bacterial counts of three samples after 18 hours of incubation of the standard cloth log T o : Common logarithm of the arithmetic mean of the number of viable bacteria in three samples immediately after inoculation of the test bacteria on the obtained fiber structure log T t : Common logarithm of the arithmetic mean of the number of viable bacteria in three samples after 18 hours of incubation on the obtained fiber structure The antibacterial activity value A0 of the polyester fiber structure before washing was also evaluated by the above method.

[0038] (Colorimetry) Using a spectrophotometer model CM-3700d (Konica Minolta, Inc.), the diffuse reflectance of polyester fiber structures was measured under a D65 light source and a 10-degree field of view, and the lightness L was calculated. * Here, the lightness L * JIS Z8781-4:2013 (Colorimetry - Part 4: CIE 1976 L * a * b * L defined in "3.3 CIE1976 Lightness Index" of the * It refers to the value.

[0039] (Pickup rate) The pickup rate is the ratio of the mass of the fiber substrate containing polyester fibers before immersion in the processing solution to the mass of the fiber substrate containing polyester fibers after immersion in the processing solution and squeezing with a mangle roller or the like, and is expressed by the following formula (3). Pick-up rate (%) = ((mass of fibrous substrate containing polyester fiber after immersion and wringing - mass of fibrous substrate containing polyester fiber before immersion) / mass of fibrous substrate containing polyester fiber before immersion) × 100 ... (3).

[0040] (Weave density change rate in the vertical direction of the fiber base material) The weave density in the warp direction of the polyester fiber substrate before and after the pre-heat treatment was measured using an automatic densimeter (manufactured by Tamamura Co., Ltd.) for the woven and knitted fabrics. The change in weave density before and after the pre-heat treatment was then calculated. The change in weave density in the warp direction of the fiber substrate was calculated using the following formula (4). Change rate of weave density in the longitudinal direction of the fiber base material (%)=((weave density in the longitudinal direction after heat treatment−weave density in the longitudinal direction before heat treatment) / weave density in the longitudinal direction before heat treatment)×100...(4).

[0041] [Example 1] (1) Pre-heat treatment process A 148 cm wide woven fabric using 167 dtex-48 filament (hereinafter sometimes referred to as 167T-48F, and the same applies hereinafter) polyester fiber (single fiber fineness: 3.5 dtex) as the warp and weft was heat-treated at an ambient temperature of 190°C for 1 minute at a set width of 148 cm under tension sufficient to remove wrinkles, to produce a fiber substrate containing polyester fiber.

[0042] (2) Processing solution preparation process A treatment solution containing a quinoline compound and a dyeing acid was prepared using the following chemicals, with the mass ratio of each chemical relative to the mass of the treatment solution being as follows: Quinoline compounds: oxolinic acid, 0.004% by mass Dyeing acid: 70% acetic acid / 30% sodium acetate mixed aqueous solution, 0.005% by mass In the production method column of Table 1, the "ratio of the mass of the quinoline-based compound to the mass of the treatment liquid" is expressed as "quinoline-based compound."

[0043] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment at 130°C for 30 minutes under pressure in a bath processing machine. Thereafter, the fibrous substrate containing polyester fibers was removed from the bath processing machine and subjected to water washing and dehydration. Here, the following equipment was used for the bath processing machine, and the bath ratio was as follows. In-bath processing machine: 12-color rotary pot dyeing tester (MINI-COLOUR 12EL type: manufactured by Texam Giken Co., Ltd.) Liquor ratio (mass of textile substrate including polyester fiber: mass of treatment liquid): 1:10.

[0044] (4) Post-heat treatment process The fiber substrate containing the chemically treated polyester fibers was set in a pin tenter and heat set with dry heat at 130°C for 1 minute to obtain a polyester fiber structure.

[0045] [Example 2] The same procedure as in Example 1 was carried out except that the post-heat treatment step was carried out at an atmospheric temperature of 170° C. for 1 minute.

[0046] [Example 3] The same procedures as in Example 2 were carried out except that the oxolinic acid was 0.008% by mass, the pre-heat treatment step was carried out at an atmospheric temperature of 210°C for 1 minute with a set width of 150 cm.

[0047] [Example 4] The same procedure as in Example 3 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 190° C. for 1 minute with a set width of 148 cm.

[0048] [Example 5] The same procedure as in Example 3 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 170° C. for 1 minute with a set width of 147 cm.

[0049] [Example 6] The same procedure as in Example 3 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 150° C. for 1 minute with a set width of 146 cm.

[0050] [Example 7] The same procedure as in Example 3 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 130° C. for 1 minute with a set width of 145 cm.

[0051] [Comparative Example 1] The same procedure as in Example 1 was carried out except that the post-heat treatment was not carried out.

[0052] Comparative Example 2 The same procedure as in Example 2 was carried out except that the pre-heat treatment was not carried out.

[0053] Comparative Example 3 The same procedure as in Example 3 was carried out except that the pre-heat treatment was not carried out.

[0054] Comparative Example 4 The same procedure as in Example 3 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 100° C. for 1 minute with a set width of 144 cm.

[0055] Comparative Example 5 The same procedures as in Example 3 were carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 230° C. for 1 minute with a set width of 144 cm.

[0056] Comparative Example 6 The same procedure as in Example 4 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 190° C. for 1 minute with a set width of 143 cm.

[0057] Comparative Example 7 The same procedure as in Example 4 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 190° C. for 1 minute with a set width of 154 cm.

[0058] [Example 8] (1) Pre-heat treatment process A 148cm wide woven fabric using 167T-48F polyester fiber (single fiber fineness: 3.5 dtex) as the warp and weft was heat treated with dry heat at an ambient temperature of 210°C for 1 minute at a set width of 150cm to produce a fiber substrate containing polyester fiber (pickup rate: 70%).

[0059] (2) Processing solution preparation process A padding treatment liquid containing a quinoline-based compound was prepared, with the mass ratio of the quinoline-based compound to the mass of the treatment liquid being adjusted as follows: Quinoline compounds: oxolinic acid, 0.008% by weight.

[0060] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the pad processing treatment liquid prepared above, and squeezed with a mangle roller so that the treatment liquid adhered to the substrate. The fibrous substrate containing polyester fibers was then set in a pin tenter and subjected to a wet heat treatment at an ambient temperature of 130°C for 2 minutes.

[0061] (4) Post-heat treatment process The fiber substrate containing the chemically treated polyester fibers was set in a pin tenter and heat set with dry heat at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0062] [Example 9] The same procedure as in Example 8 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 190° C. for 1 minute with a set width of 148 cm.

[0063] [Example 10] The same procedure as in Example 8 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 170° C. for 1 minute with a set width of 147 cm.

[0064] [Example 11] The same procedure as in Example 8 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 150° C. for 1 minute with a set width of 146 cm.

[0065] [Comparative Example 8] The same procedure as in Example 8 was carried out except that the pre-heat treatment was not carried out.

[0066] Comparative Example 9 The same procedure as in Example 8 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 100° C. for 1 minute with a set width of 144 cm.

[0067] [Comparative Example 10] The same procedure as in Example 8 was carried out except that the pre-heat treatment step was carried out at an atmospheric temperature of 230° C. for 1 minute with a set width of 144 cm.

[0068] [Table 1]

[0069] As shown in Table 1, in Examples 1 to 11 in which pre-heat treatment was performed before the chemical treatment step, the antibacterial activity value before washing (A0-F) and the antibacterial activity value after 50 high-temperature accelerated washings (A 50 In contrast, Comparative Example 1, in which no post-heat treatment was performed, Comparative Examples 2, 3, and 8, in which no pre-heat treatment was performed, Comparative Examples 4 and 9, in which pre-heat treatment was performed at 100°C, Comparative Examples 5 and 10, in which pre-heat treatment was performed at 230°C, and Comparative Examples 6 and 7, in which the change in weave density in the warp direction was less than -3.0% or more than 3.0%, had good antibacterial properties before washing but poor washing durability.

[0070] [Example 12] (1) Pre-heat treatment process A 142 cm wide woven fabric using polyester fibers with a single fiber fineness of 0.3 dtex as the warp and weft was heat treated at an ambient temperature of 190°C for 1 minute at a set width of 142 cm under tension sufficient to remove wrinkles, to produce a fiber substrate containing polyester fibers.

[0071] (2) Processing solution preparation process A treatment solution containing a quinoline compound and a dyeing acid was prepared using the following chemicals, with the mass ratio of each chemical relative to the mass of the treatment solution being as follows: Quinoline compounds: oxolinic acid, 0.015% by mass Dyeing acid: 70% acetic acid / 30% sodium acetate mixed aqueous solution, 0.005% by mass In the production method column of Table 2, the "ratio of the mass of the quinoline-based compound to the mass of the treatment liquid" is expressed as "quinoline-based compound."

[0072] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment at 130°C for 30 minutes under pressure in a bath processing machine. Thereafter, the fibrous substrate containing polyester fibers was removed from the bath processing machine and subjected to water washing and dehydration. Here, the following equipment was used for the bath processing machine, and the bath ratio was as follows. In-bath processing machine: 12-color rotary pot dyeing tester (MINI-COLOUR 12EL type: manufactured by Texam Giken Co., Ltd.) Liquor ratio (mass of textile substrate including polyester fiber: mass of treatment liquid): 1:10.

[0073] (4) Post-heat treatment process The fiber substrate containing the chemically treated polyester fibers was set in a pin tenter and heat set with dry heat at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0074] [Example 13] The same procedure as in Example 12 was carried out except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 0.7 dtex were used for the warp and weft.

[0075] [Example 14] The same procedure as in Example 12 was carried out except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 1.4 dtex were used for the warp and weft.

[0076] [Example 15] The same procedure as in Example 12 was carried out except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 1.8 dtex were used for the warp and weft.

[0077] [Example 16] The same procedure as in Example 12 was carried out, except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 3.7 dtex were used for the warp and weft.

[0078] [Comparative Example 11] The same procedure as in Example 12 was carried out except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 0.1 dtex were used for the warp and weft.

[0079] Comparative Example 12 The same procedure as in Example 12 was carried out except that a 142 cm wide woven fabric was used in which polyester fibers having a single fiber fineness of 5.5 dtex were used for the warp and weft.

[0080] [Example 17] The same procedure as in Example 14 was carried out except that the amount of oxolinic acid was changed to 0.012% by mass.

[0081] [Example 18] The same procedure as in Example 14 was carried out, except that the amount of oxolinic acid was changed to 0.009% by mass.

[0082] [Example 19] The same procedure as in Example 14 was carried out, except that the amount of oxolinic acid was changed to 0.006% by mass.

[0083] [Comparative Example 13] The same procedure as in Example 14 was carried out, except that the amount of oxolinic acid was changed to 0.003% by mass.

[0084] [Example 20] The same procedure as in Example 14 was carried out, except that the fabric used was changed to a 142 cm wide woven fabric made of polyester / cotton blended fibers (polyester fiber: 86% by mass, cotton fiber: 14% by mass, single fiber fineness of blended fibers: 2.1 dtex).

[0085] [Example 21] The same procedure as in Example 14 was carried out, except that the fabric used was changed to a 142 cm wide woven fabric made of polyester / cotton blended fibers (polyester fiber: 78% by mass, cotton fiber: 22% by mass, single fiber fineness of blended fibers: 2.3 dtex).

[0086] [Example 22] The same procedure as in Example 14 was carried out, except that the fabric used was a 142 cm wide woven fabric made of polyester / cotton blended fibers (polyester fiber: 65% by mass, cotton fiber: 35% by mass, single fiber fineness of blended fibers: 1.1 dtex).

[0087] [Example 23] The same procedure as in Example 14 was carried out, except that the fabric used was a 142 cm wide woven fabric made of polyester / cotton blended fibers (polyester fiber: 55% by mass, cotton fiber: 45% by mass, single fiber fineness of blended fibers: 1.1 dtex).

[0088] [Example 24] The same procedure as in Example 14 was carried out, except that the fabric used was changed to a 142 cm wide woven fabric made of polyester / cotton blended fibers (polyester fiber: 40% by mass, cotton fiber: 60% by mass, single fiber fineness of blended fibers: 1.1 dtex).

[0089] [Table 2]

[0090] As shown in Table 2, when the single fiber fineness is 0.3 to 5.0 dtex, the antibacterial activity value before washing (A0-F) and after 50 high-temperature accelerated washings (A 50In all cases, the values ​​were greater than 0.0, indicating good antibacterial properties. On the other hand, when a fiber substrate with a single fiber fineness as thin as 0.1 dtex or a fiber substrate with a single fiber fineness as thick as 5.5 dtex was used, the antibacterial properties were poor. Furthermore, when the mass ratio of the quinoline compound to the mass of the treatment solution was 0.004 mass% or more, the antibacterial properties were good, but when it was less than 0.004 mass%, the antibacterial properties were poor. Furthermore, it was confirmed that the antibacterial properties decreased as the proportion of polyester fiber contained in the polyester fiber structure decreased, and it was confirmed that the antibacterial properties were good up to a polyester fiber proportion of 40 mass%.

[0091] [Example 25] (1) Pre-heat treatment process A 142 cm wide woven fabric using polyester fibers with a single fiber fineness of 1.4 dtex as the warp and weft was heat treated at an ambient temperature of 190°C for 1 minute at a set width of 142 cm under tension sufficient to remove wrinkles, to produce a fiber substrate containing polyester fibers.

[0092] (2) Processing solution preparation process A treatment liquid containing a quinoline compound, a disperse dye, a dyeing acid, and a leveling agent was prepared. The following chemicals were used, and the mass ratio of each chemical to the mass of the treatment liquid was adjusted as follows: Quinoline compounds: oxolinic acid, 0.008% by mass Disperse dye (Dianix Black CC-Rnew (Dystar Co., Ltd.)), 0.5% by mass Dyeing acid: 70% acetic acid / 30% sodium acetate mixed aqueous solution, 0.050% by mass Leveling agent: "IONET" (registered trademark) RAP-250 (Sanyo Chemical Industry Co., Ltd.), 0.050% by mass In the production method column of Table 3, the "ratio of the mass of the quinoline-based compound to the mass of the treatment liquid" is expressed as "quinoline-based compound."

[0093] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment in a bath processing machine under pressure at an atmospheric temperature of 130°C for 30 minutes. Thereafter, the fibrous substrate containing polyester fibers was removed from the bath processing machine and washed with water. Here, the following equipment was used as the bath processing machine, and the bath ratio was as follows. In-bath processing machine: 12-color rotary pot dyeing tester (MINI-COLOUR 12EL type: manufactured by Texam Giken Co., Ltd.) Liquor ratio (mass of textile substrate including polyester fiber: mass of treatment liquid): 1:10 Thereafter, the fiber substrate containing polyester fiber was immersed in a treatment solution prepared with a reduction cleaning agent and subjected to reduction cleaning treatment in a bath processing machine at normal pressure and 80°C for 20 minutes. Here, the following bath processing machine was used, and the bath ratio was as follows. In-bath processing machine: 12-color rotary pot dyeing tester (MINI-COLOUR 12EL type: manufactured by Texam Giken Co., Ltd.) Reduction cleaning chemicals: sodium hydroxide (Nacalai Tesque, Inc.), 0.007% by mass, sodium hydrosulfite (Nacalai Tesque, Inc.), 0.020% by mass, "Gran Up" (registered trademark) US-20 (Meisei Chemical Industry Co., Ltd.), 0.005% by mass - Liquor ratio (mass of textile substrate including polyester fiber: mass of treatment liquid): 1:20.

[0094] (4) Post-heat treatment process The fiber substrate containing the chemically treated polyester fibers was set in a pin tenter and heat set with dry heat at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0095] [Example 26] Example 25 was repeated except that the amount of oxolinic acid was changed to 0.015% by mass.

[0096] [Example 27] The same procedure as in Example 25 was carried out except that the amount of oxolinic acid was changed to 0.030% by mass.

[0097] [Example 28] Example 25 was repeated except that the amount of oxolinic acid was changed to 0.045% by mass.

[0098] [Table 3]

[0099] As shown in Table 3, when the amount of oxolinic acid was 0.030% by mass, the antibacterial properties were good both before washing and after 50 high-temperature accelerated washings. * Furthermore, when the oxolinic acid content was increased to 0.045 mass%, the lightness L * rose significantly. [Industrial Applicability]

[0100] The polyester fiber structure provided by the method for producing a polyester fiber structure of the present invention has excellent antibacterial properties and washing durability. Such polyester fiber structure can be used in various applications requiring high antibacterial properties, such as fabrics for clothing, bedding, towels, rugs, curtains, sheets, etc., and is also suitable for use in medical uniforms.

Claims

1. a pre-heat treatment step of heat-treating a fiber substrate containing polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less at an atmospheric temperature of 110°C or more and 210°C or less so that the change rate of the weave density in the warp direction of the fiber substrate containing the polyester fibers before and after the heat treatment is -3.0% or more and 3.0% or less; a treatment liquid preparation step of preparing a treatment liquid containing 0.004% by mass or more of a quinoline-based compound relative to the mass of the treatment liquid; a chemical solution treatment step of immersing a fiber substrate containing the polyester fiber in the treatment solution and treating it by bath treatment or pad treatment; a post-heat treatment step of dry-heat treating the fiber substrate containing the chemically treated polyester fiber; A method for producing a polyester fiber structure, comprising:

2. 2. The method for producing a polyester fiber structure according to claim 1, wherein the fibers constituting the fiber substrate containing the polyester fibers comprise polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less in an amount of 40 mass% or more relative to the mass of the entire fiber substrate.

3. 3. The method for producing a polyester fiber structure according to claim 1, wherein the quinoline compound is at least one compound selected from the group consisting of oxolinic acid, ciprofloxacin, levofloxacin, moxifloxacin, garenoxacin, and sitafloxacin.

4. The method for producing a polyester fiber structure according to claim 1 or 2, wherein the quinoline-based compound is oxolinic acid.

5. 3. The method for producing a polyester fiber structure according to claim 1, wherein in the chemical solution treatment step in the bath treatment, a bath ratio of the treatment solution (mass of the fiber substrate containing the polyester fibers:mass of the treatment solution) is 1:5 to 1:

30.

6. A method for producing a medical uniform, comprising a step of sewing a medical uniform using the polyester fiber structure produced by the method for producing a polyester fiber structure according to claim 1 or 2.

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