Spun yarns and textile products containing diatomaceous earth

Abstract

This invention provides diatomaceous earth-infused spun yarn for knitting textile products that possess water absorption, quick-drying, and temperature-regulating properties. [Solution] The spun yarn is a diatomaceous earth-infused spun yarn, which is produced by cutting yarn that has been spun by kneading diatomaceous earth using a melt-preventing method to provide at least one of water absorption and deodorizing properties, and the diatomaceous earth-infused spun yarn contains polyester and diatomaceous earth kneaded into the polyester, with a mass ratio of diatomaceous earth of 0.01% to 5% and a fineness of 30 to 90 cotton count, and textile products are manufactured by knitting with this diatomaceous earth-infused spun yarn.

Description

Technical Field

[0001] The present invention relates to a spun yarn having at least one of water absorption and deodorization properties, which is obtained by melt-spinning and spinning polyester including diatomaceous earth (the main component is silicon dioxide (SiO2), also called silicon dioxide (SiO2)), and a fiber product (such as socks, etc.) knitted from the spun yarn. Diatomaceous earth is a sediment (sedimentary rock) composed of fossils of the shells of diatoms, which are a type of algae. It is also called diatomite. The shell of diatoms is made of silicon dioxide (SiO2), and diatomaceous earth also has this as its main component.

Background Art

[0002] Among synthetic fibers (chemical fibers), polyester yarn is a fiber with high versatility and high usage frequency. This polyester yarn (itself or a fiber product mainly made of polyester) has the following characteristics: (1) The fiber is strong and not easily broken, so it is more durable than other fibers and hardly shrinks or loses its shape even after repeated washing; (2) Since it is derived from petroleum compared to natural fibers, it is less likely to be attacked by insects and is less affected by discoloration caused by insect repellents, and is easy to maintain; (3) It has the property of being difficult to wrinkle and maintaining its original shape, so it is not easily wrinkled even after washing. On the other hand, polyester is a material with low hygroscopicity, and it is difficult for moisture to enter the fiber, and it tends to be inferior in water absorption (as an advantage, when water or sweat touches the fabric, it is quickly diffused and evaporated).

[0003] When polyester having such characteristics is used in fiber products (clothes) that come into contact with the skin, such as socks and underwear, increasing the polyester mixing ratio has the problem of impairing the comfort (wearing comfort) of underwear and the like due to the above-mentioned inferior water absorption characteristics.

[0004] Diatomaceous earth (whose main component is silicon dioxide (SiO2)) is known as a material that enhances water absorption and / or deodorization. Solidified diatomaceous earth is often crushed to a degree that does not break the shells before use. The particle size of diatomaceous earth (the size of the diatom shells) is generally between 100 μm and 1 mm. The morphology of the particles varies depending on the type of diatom from which they originate, ranging from disc-shaped to spindle-shaped. Because diatom shells have numerous small pores, diatomaceous earth has a very low weight per unit volume, and it is said that the surface area of ​​the pores in 1 g of diatomaceous earth is equivalent to half a tennis court. In addition, diatomaceous earth can hold large amounts of moisture and oil. For this reason, it is used as a soil conditioner to improve dry soil and for the purpose of capturing spilled oil. Furthermore, because of its excellent fire resistance and heat insulation properties, it is used as a building material and heat insulation material, as it does not conduct electricity, it is used as an insulator, and as an abrasive due to its moderate hardness.

[0005] Such a technology for using diatomaceous earth in fibers (functional fibers) is disclosed in Japanese Patent Publication No. 4067547 (Patent Document 1). The functional fibers disclosed in Patent Document 1 are functional fibers that are provided with far-infrared radiation function, deodorizing properties, and antibacterial properties, and are characterized in that a fine powder containing one or more types of ceramics that emit far-infrared rays, diatomaceous earth, and tourmaline is attached to part or all of the fiber, and the mass ratio of diatomaceous earth contained in the total fine powder is 70% to 85%.

[0006] This functional fiber allows for the attachment of a fine powder containing ceramics, diatomaceous earth, and tourmaline—one or more inorganic substances that emit far-infrared rays—to the fiber, thereby combining far-infrared emitting materials and attaching them to the fiber. This enables the high and stable emission of far-infrared rays in the 6μm to 12μm wavelength range, which humans perceive as warm, and also provides functional cotton and functional yarn with deodorizing and antibacterial properties. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Patent No. 4067547 [Overview of the project] [Problems that the invention aims to solve]

[0008] However, the functional fibers disclosed in Patent Document 1 are manufactured by simply attaching diatomaceous earth fine powder to the surface of short fibers before spinning them into yarn, and therefore cannot incorporate diatomaceous earth inside the short fibers. As a result, there is a problem in that the sufficient performance of diatomaceous earth (water absorption and / or deodorizing properties) cannot be expressed in either the short fiber state or the textile product state.

[0009] The present invention was developed in view of the above-mentioned problems of the prior art, and its objective is to provide a spun yarn having at least one of water absorption and deodorizing properties, which is spun by melt-spinning polyester with diatomaceous earth (whose main component is silicon dioxide (SiO2)) and a textile product (for example, socks) made from the spun yarn. [Means for solving the problem]

[0010] To achieve the above objective, the spun yarn according to the present invention employs the following technical means.

[0011] In other words, the spun yarn according to the aspect of the present invention is a spun yarn having at least one of water absorption and deodorizing properties, wherein the spun yarn contains polyester or nylon and diatomaceous earth, the mass ratio of the diatomaceous earth is 0.01% to 5%, and the fineness is 30 to 90 cotton count.

[0012] Furthermore, a spun yarn according to another aspect of the present invention is a textile product knitted with the above-mentioned spun yarn, and typical examples include socks, underwear, and the like. [Effects of the Invention]

[0013] The spun yarn and textile products according to the present invention provide a spun yarn having at least one of water absorption and deodorizing properties, which is spun by melt-spinning polyester with diatomaceous earth (whose main component is silicon dioxide (SiO2)) and a textile product (for example, socks) made by knitting the spun yarn. [Brief explanation of the drawing]

[0014] [Figure 1] This is a photograph in lieu of a drawing, showing a 1000x magnification of staple fibers (staples) constituting the spun yarn used to knit a textile product according to an embodiment of the present invention, processed by OSEM (ordered subsets-expectation maximization), where (A) is a polyester yarn mixed with diatomaceous earth, and (B) is a normal polyester yarn that does not contain any diatomaceous earth. [Figure 2] This figure shows the results of a quick-drying test (evaporation test) using knitted fabric made from spun yarn produced by spinning polyester staple fibers with 1.0% by mass of diatomaceous earth mixed in and regular polyester staple fibers without any diatomaceous earth in a 50:50 mass ratio. [Figure 3] This figure shows the results of a water absorption test using knitted fabric made from spun yarn produced by mixing 1.0% by mass of diatomaceous earth with polyester staple fibers and regular polyester staple fibers that do not contain any diatomaceous earth in a 50:50 mass ratio. [Modes for carrying out the invention]

[0015] Hereinafter, spun yarn according to embodiments of the present invention and textile products using the spun yarn will be described with reference to the drawings. In this invention, socks and underwear are given as examples of textile products. However, the fiber products using the spun yarn according to the present invention are not limited to these socks, underwear, and skin clothes. In the following description, although synthetic fibers are described as polyester, nylon as an alternative to polyester is not actively excluded (rather, as synthetic fibers in the present invention, it is preferable that they are polyester or nylon), and by changing polyester to nylon, the same effects as those of the present invention can be exhibited. Also, in order to clarify the difference from "short fibers with diatomaceous earth attached to the surface" in Patent Document 1, in the following description, the short fibers according to the present invention may be described as "short fibers with diatomaceous earth kneaded (contained) therein" and the like.

[0016] <Polyester short fiber with diatomaceous earth kneaded>

[0017] Using polyester and diatomaceous earth as raw materials, a polyester yarn with diatomaceous earth kneaded is produced by the melt prevention method. This polyester yarn containing diatomaceous earth is cut to obtain polyester short fibers (staples) with diatomaceous earth kneaded. A microscopic photograph of the polyester short fibers with diatomaceous earth kneaded is shown in Fig. 1(A), and a microscopic photograph of the polyester short fibers without diatomaceous earth kneaded is shown in Fig. 1(B).

[0018] These photographs are image-processed using the OSEM (ordered subsets-expectation maximization) method. The polyester short fibers with diatomaceous earth kneaded shown in Fig. 1(A) have diatomaceous earth kneaded into the interior of the fibers by the melt prevention method, and even when compared with the polyester short fibers without diatomaceous earth kneaded shown in Fig. 1(B), the surface is smooth and no deposits or contaminants can be identified (not protruding from the surface of the short fibers). Here, the mass ratio of polyester to diatomaceous earth is 99:1 (1.0 mass%).

[0019] In contrast, as shown in the cross-sectional view of the staple (short fiber) in FIG. 3 of Patent Document 1, it is merely the one in which diatomaceous earth 5b adheres to the outer surface of the short fiber 2a. In the technology disclosed in Patent Document 1, without adopting a melting prevention method, as described in Paragraph 0025 of Patent Document 1, "The functional cotton 1 is composed of functional short fibers 2 in which a far-infrared radiation substance is pulverized and this fine powder is adhered to the short fibers 2a (see FIG. 3) of the cotton 1a. As the fine powder 5 which is a far-infrared radiation substance, ceramics 5a, diatomaceous earth 5b, and tourmaline 5c are used, and a liquid mixture obtained by mixing this fine powder 5 with a binder liquid 4 is sprayed onto the entire surface of the cotton 2 and adhered to the short fibers 2a." Therefore, as described above, it is merely the one in which diatomaceous earth 5b adheres to the outer surface of the short fiber 2a. In this case, since it is merely manufacturing a spun yarn after adhering fine powder of diatomaceous earth to the surface of the short fiber, diatomaceous earth cannot be contained inside the short fiber. For this reason, there is a problem that sufficient performance (water absorption and / or deodorizing property) of diatomaceous earth cannot be exhibited either in the state of the short fiber or in the state of the fiber product.

[0020]

[0021] The spun yarn (blended yarn) according to this embodiment is manufactured by mixing and spinning the above-described diatomaceous earth-incorporated polyester short fibers and the diatomaceous earth-unincorporated polyester short fibers at a mass ratio of 1:1. As described above, since the mass ratio of polyester and diatomaceous earth in the diatomaceous earth-incorporated polyester short fibers is 99:1 (1.0% by mass), the diatomaceous earth content (mass ratio) of the spun yarn (blended yarn) is 0.5%. However, the mass ratio of diatomaceous earth in the spun yarn (blended yarn) according to the present invention is preferably 0.01% to 5%.

[0022] Also, the fineness of this spun yarn (blended yarn) is 30 count (single yarn) in cotton count, but the fineness of the spun yarn (blended yarn) according to the present invention is preferably 30 count to 90 count.

[0023] <A fiber product (here, socks)>

[0024] The socks were knitted using the aforementioned spun yarn (blended yarn: 0.5% by mass of diatomaceous earth, 30 count cotton yarn (single yarn)) for the outer yarn and covering yarn, which is polyurethane covered with nylon or the like, for the back yarn.

[0025] According to these socks, diatomaceous earth microparticles embedded in the fibers quickly remove sweat from the wearer's body surface (the diatomaceous earth microparticles attract water vapor and move it to the outside of the sock fabric), achieving high water absorption. Therefore, textile products using the spun yarn (blended yarn) according to the invention will have water absorption and quick-drying functions.

[0026] Furthermore, the diatomaceous earth, which is embedded in the fibers as microparticles (possessing far-infrared radiation properties), can quickly evaporate moisture (sweat) that has been moved to the outside of the sock fabric along with infrared rays emitted from the wearer's body, thereby achieving a comfortable temperature and humidity. For this reason, textile products using the spun yarn (blended yarn) according to the invention will have temperature and humidity control functions.

[0027] <Quick-drying test of textile products (test specimens)>

[0028] The results of a rapid drying test (evaporation test) conducted using the following two test specimens (Example 1, Comparative Example 1) are described below. Example 1: Blended yarn of 50% polyester by mass with 1.0% by mass of diatomaceous earth and 50% by mass of regular polyester (without any diatomaceous earth), 30 count single yarn (30 / 1) Comparative Example 1: A blended yarn of 65% by mass of polyester and 35% by mass of cotton (regular polyester containing no diatomaceous earth), 30 count single yarn (30 / 1).

[0029] Test items Fast drying test (ISO 17617-2014 Method A-11 - Vertical drying)

[0030] Test method 1. Measure the mass of the test specimen (20cm x 20cm, made by circular knitting each blended yarn) and the hanger, which were humidified under standard conditions (20℃ x 65%RH) (M W ) 2. Drop water onto the test specimen (with the absorbent surface facing the back) (0.3 ml) and measure the mass (M0). 3. With the test specimen suspended, measure the mass at specified time intervals (t) (M t (Prescribed time: every 5 minutes until 60 minutes have passed, or until the residual moisture content is 10% or less) Transpiration rate L t (%)=[(M0-M t ) / (M0-M W )] × 100

[0031] Calculation method 1. Determine the regression line for the evaporative rate over the most recent time period from immediately after dripping until the evaporative rate reaches 90%. Regression line: y = ax + b ... (Equation 1) [y:transpiration rate L t (%), a: slope, x: time, b: intercept] 2. Calculate the value of 'a' obtained from (Equation 1) for the drying rate. Drying speed (% / min): a=(yb) / x) 3. Substitute 100 for y in (Equation 1) to calculate the value of x, which is the drying time (time when the evaporation rate is 100%). Drying time (100%):x=(100y-b) / a

[0032] Figure 2 shows the results of this rapid drying test (evaporation test). It can be seen that the water dropped in Example 1 evaporated (dried) considerably faster than in Comparative Example 1. The drying rate was 2.8% / min, and the drying time (100%) was 35.7 minutes.

[0033] <Water absorption test of textile products (test specimens)>

[0034] The results of the water absorption test conducted using the test specimens from Example 1 and Comparative Example 2 below will be explained. Comparative Example 2: 100% polyester spun yarn (without any diatomaceous earth), 30 count single yarn (30 / 1)

[0035] Test items Water absorption test (ISO 1907 drop method, reverse side)

[0036] Test method 1. Take five test specimens (20cm x 20cm, each made from a circular knit of spun yarn) that have been conditioned under standard conditions (20℃ x 65%RH), mount them in a specimen holder, place it between the light source and the observer, and adjust the height so that the distance from the surface of the test specimen to the tip of the burette is 10mm. 2. Drop one drop of water from the burette and measure the time to the nearest second using a stopwatch, from the moment the water droplet reaches the surface of the specimen until the specular reflection disappears as the specimen absorbs the water droplet, leaving only wetness.

[0037] Calculation method The average value of the five test specimens shall be rounded to an integer according to Rule B (rounding method) of JIS Z 8401. However, if one or more test specimens do not absorb water even after 60 seconds or more, the test report shall be noted as "60 seconds or more".

[0038] Figure 3 shows the results of this water absorption test. It can be seen that while Comparative Example 2 does not absorb water (for 60 seconds or more), Example 1 does absorb water.

[0039] As described above, the spun yarn and textile products according to this embodiment provide a spun yarn having at least one of water absorption and deodorizing properties, which is spun by melt-spinning polyester with diatomaceous earth (main component is silicon dioxide (SiO2)), and a textile product (in this case, socks) that has water absorption, quick-drying, and temperature and humidity control functions when the spun yarn is knitted.

[0040] It should be noted that the embodiments disclosed herein are illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims rather than by the foregoing description, and all modifications within the meaning and scope equivalent to the claims are intended to be included. [Industrial applicability]

[0041] The present invention relates to a spun yarn having at least one of water absorption and deodorizing properties, and is preferred for spun yarn spun by melt-spinning polyester including diatomaceous earth, and for textile products (such as socks) made from the spun yarn, and is particularly preferred in that it can realize textile products having water absorption, quick-drying, and temperature and humidity control functions. [Explanation of symbols]

[0042] 100 Diatomaceous earth-infused polyester yarn manufactured by melt spinning method 200 Regular polyester yarn that does not contain any diatomaceous earth, manufactured by the melt spinning method.

Claims

1. A spun yarn having at least one of water absorption and deodorizing properties, The aforementioned spun yarn comprises polyester or nylon and diatomaceous earth. The mass percentage of the diatomaceous earth is 0.01% to 5%, A spun yarn containing diatomaceous earth, characterized by a fineness of 30 to 90 cotton count.

2. A textile product knitted with the spun yarn described in claim 1.

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