Composite spun yarn, fiber structure, and manufacturing method thereof

Abstract

To provide a composite spun yarn and a fiber structure, which can highly maintain moisture absorbing and heat generating property, and a manufacturing method thereof.SOLUTION: A composite spun yarn includes an animal hair fiber and a cellulosic fiber. The animal hair fiber is covered by a fiber including the cellulosic fiber. When the composite spun yarn is 100 mass%, sodium ratio is 0.5 mass% or more, consequently, the composite spun yarn has a moisture absorbing and heat generating property. A fiber structure of the present invention includes the composite spun yarn of the present invention. The composite spun yarn or the fiber structure is subjected to a sodium replacement processing after refining and bleach, dyeing and neutralization soaping steps so that the sodium ratio is 0.5 mass% or more.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a composite spun yarn containing animal hair fiber and cellulosic fiber, a fiber structure, and a method for producing the same. [Background technology]

[0002] Hygroscopic heat generation is the property of dry fibers that generates heat when they absorb moisture (water). For example, if you bring a futon that has been exposed to the sun during the day into a room, even if it has cooled to room temperature after a few hours, it will still feel warm when you put your skin against it. Animal hair has long been known as a fiber material characterized by its heat-generating and heat-retaining properties, and these properties are utilized in thermal clothing worn during cold seasons. Spun yarns have been proposed that absorb sweat and maintain a comfortable fit even in summer, even outside of cold seasons. Patent Document 1 proposes a core-sheath type moisture-absorbing and heat-generating composite spun yarn that absorbs and removes sweat, has excellent heat-generating and heat-retaining properties, and has the texture of natural fibers. The core component is made of animal hair fiber with an official moisture regain of 10 to 19% by weight and moisture-absorbing and heat-generating properties, and the sheath component is made of natural cellulosic fiber. Patent Documents 2 and 3 propose graft polymerization of a compound containing an ethylenically unsaturated double bond onto a cellulosic fiber. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-293235 [Patent Document 2] Re-tabled publication No. 2010-018792 [Patent Document 3] Patent Publication No. 2021-025135 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the moisture-absorbing heat-generating properties of the conventional composite spun yarns are insufficient, and there is a demand for even higher moisture-absorbing heat-generating properties.

[0005] In order to solve the above-mentioned problems of the prior art, the present invention provides a composite spun yarn, a fiber structure, and a method for manufacturing the same, which are capable of maintaining high moisture absorption and heat generation properties. [Means for solving the problem]

[0006] The present invention provides a composite spun yarn containing animal hair fibers and cellulosic fibers, The animal hair fiber has a compound containing an ethylenically unsaturated double bond chemically bonded to the surface of the fiber, The animal hair fiber further has sodium bonded to a carboxyl group or a sulfonic acid group, The ratio of the animal hair fiber and the cellulosic fiber is 5 to 50 mass% of the animal hair fiber and 50 to 95 mass% of the cellulosic fiber, The animal hair fiber is covered with the fiber containing the cellulosic fiber, When the spun yarn is taken as 100% by mass, the sodium content is 0.5% by mass or more, and the composite spun yarn has moisture-absorbing heat-generating properties.

[0007] The fiber structure of the present invention is a fiber structure made of a composite spun yarn containing animal hair fiber and cellulosic fiber, The animal hair fiber has a compound containing an ethylenically unsaturated double bond chemically bonded to the surface of the fiber, The animal hair fiber further has sodium bonded to a carboxyl group or a sulfonic acid group, The ratio of the animal hair fiber and the cellulosic fiber is 5 to 50 mass% of the animal hair fiber and 50 to 95 mass% of the cellulosic fiber, The animal hair fiber is covered with the fiber containing the cellulosic fiber, When the spun yarn is taken as 100% by mass, the sodium content is 0.5% by mass or more, and the fiber structure has moisture-absorbing and heat-generating properties.

[0008] The method for producing a composite spun yarn or fiber structure of the present invention is characterized in that a sodium substitution treatment is carried out after the scouring, bleaching, dyeing and neutral soaping steps. [Effects of the Invention]

[0009] The present invention provides a composite spun yarn or fiber structure that can maintain high moisture absorption and heat generation properties by performing a sodium substitution treatment in the final step of a composite spun yarn or fiber structure containing animal hair fibers in which a compound containing an ethylenically unsaturated double bond is chemically bonded to the surface of the fiber, so that the sodium content is 0.5 mass% or more. Also, the present invention provides a moisture absorption and heat generation fabric and moisture absorption and heat generation clothing that are gentle on the skin and do not have the prickly feeling of animal hair fibers, because the animal hair fibers are covered with fibers containing the cellulosic fibers. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a process diagram showing a method for producing a composite spun yarn or a fiber structure according to one embodiment of the present invention. [Figure 2] FIG. 2 is a graph showing the results of a moisture absorption heat generation test for an example of the present invention and a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention provides a composite spun yarn containing animal hair fibers and cellulosic fibers, in which the animal hair fibers are covered with fibers containing the cellulosic fibers. This structure is obtained, for example, by arranging a sliver of cellulosic fibers and a sliver of animal hair fibers in a sheath-core structure when producing a sliver (fiber bundle) that is a precursor to the spun yarn, and then subjecting the sliver to a roving process and a fine spinning process to produce a sheath-core spun yarn.

[0012] The composite spun yarn contains sodium, and when the spun yarn is taken as 100% by mass, the sodium content is 0.5% by mass or more, giving the yarn moisture-absorbing heat-generating properties. This can be achieved by subjecting the composite spun yarn to a sodium substitution treatment in the final step of yarn dyeing. Similarly, the fiber structure of the present invention can be subjected to a sodium substitution treatment in the final step of fabric dyeing, thereby achieving a high sodium content and moisture-absorbing heat-generating properties. The preferred sodium content is 0.5 to 2.0% by mass, more preferably 0.5 to 1.5% by mass, and even more preferably 0.6 to 1.0% by mass.

[0013] The animal hair fibers are preferably prepared by adding active groups and / or generating radicals to the fiber surface, and chemically bonding a compound containing an ethylenically unsaturated double bond to the surface of the fiber. A method for adding active groups and / or generating radicals to the fiber surface and chemically bonding a compound containing an ethylenically unsaturated double bond to the surface of the fiber is graft bonding by electron beam irradiation. The graft bonding is carried out by irradiating an electron beam to generate radicals on the fiber surface, and then bonding the generated radicals to functional groups (-OH, -NH 2、 It is formed through various reactions, such as a reaction in which a compound having an ethylenically unsaturated double bond containing (e.g., -COOH, -SO3H) is brought into contact with the fiber to graft bond onto the surface of the fiber, or a reaction in which the functional group reacts with another functional group to form a covalent bond. The compound having an ethylenically unsaturated double bond is preferably added in an amount of 1 to 30% by mass, more preferably 5 to 25% by mass, based on the animal hair fiber. Within this range, the animal hair fiber can exhibit its moisture-absorbing and heat-generating function even when the outer surface is covered with cellulosic fibers.

[0014] The compound containing an ethylenically unsaturated double bond may be a compound having a functional group with moisture-absorbing heat-generating properties, such as a compound containing one ethylenically unsaturated double bond and one or two carboxyl groups. Specifically, it is preferably at least one carboxylic acid selected from acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid, or an ester or salt thereof. When acrylic acid or methacrylic acid is used as the compound containing an ethylenically unsaturated double bond, a carboxyl group is bonded. When a compound containing a sulfonic group is used as the compound containing an ethylenically unsaturated double bond, a sulfonic group is bonded. Chemically bonding these compounds to the fiber surface can impart moisture-absorbing heat-generating properties with washability.

[0015] The animal hair fibers preferably have sodium bonded to the carboxyl or sulfonic acid groups. The carboxyl or sulfonic acid groups exist in the form of acids or sodium salts, but since blocking the acids or sodium salts with calcium, magnesium, or the like will eliminate the hygroscopic heat-generating properties, they are preferably substituted with sodium. When a compound having a carboxyl group is grafted, sodium substitution treatment can cause any portion of the grafted compound on the fiber surface to exist in the form of a carboxylic acid group (-COOH) or its sodium salt, thereby maintaining the hygroscopic heat-generating properties. Animal hair fibers in which a compound containing an ethylenically unsaturated double bond has been chemically bonded to the fiber surface by graft polymerization have a greater number of functional groups, such as carboxyl groups, than animal hair fibers that have not been graft-polymerized, and sodium substitution treatment results in a greater amount of sodium present than animal hair fibers that have not been graft-polymerized.

[0016] The ratio of animal hair fiber to cellulosic fiber is preferably 5 to 50 mass% animal hair fiber and 50 to 95 mass% cellulosic fiber, more preferably 10 to 45 mass% animal hair fiber and 55 to 90 mass% cellulosic fiber, and even more preferably 15 to 40 mass% animal hair fiber and 60 to 85 mass% cellulosic fiber.

[0017] The cellulose-based fibers of the present invention are preferably natural cellulose-based fibers, regenerated cellulose-based fibers, or blends thereof with synthetic fibers. Natural cellulose-based fibers include cotton and hemp. Regenerated cellulose-based fibers include ordinary rayon, cupra, and solvent-based rayon. Synthetic fibers include polyester, nylon, and acrylic fibers.

[0018] In the composite spun yarn, the animal hair fiber is preferably subjected to a moisture-absorbing and heat-generating treatment, and the cellulosic fiber is preferably not subjected to a moisture-absorbing and heat-generating treatment. By subjecting the animal hair fiber to a moisture-absorbing and heat-generating treatment, a composite spun yarn having good moisture-absorbing and heat-generating properties can be obtained without subjecting the cellulosic fiber covering the animal hair fiber to a moisture-absorbing and heat-generating treatment.

[0019] Animal hair fibers include wool, cashmere, mohair, etc., but wool is preferred. It is also preferred that the fiber covering the wool is cotton. If the fiber covering the wool is cotton, the prickly feeling of wool will not occur, and cotton is gentle on the skin, making for comfortable clothing.

[0020] The fiber structure of the present invention is a fiber structure containing the composite spun yarn of the present invention. When the fiber structure is subjected to a sodium substitution treatment in the final step of fabric dyeing, high moisture absorption and heat generation properties can be obtained. The fiber structure's form makes it easy to perform the sodium substitution treatment. By including the composite spun yarn in the fiber structure, a moisture absorption and heat generation fiber structure that is gentle on the skin and does not have the prickly feeling of animal hair fibers can be obtained.

[0021] The fiber structure is preferably a knitted fabric or a woven fabric. Knitted fabrics and woven fabrics are suitable for use as innerwear. Knitted fabrics are particularly stretchy and flexible, making them suitable for use as innerwear. Knitted fabrics include circular knitting, weft knitting, warp knitting (including tricot knitting and raschel knitting), pile knitting, etc., and may be of any weave such as plain knitting, jersey knitting, rib knitting, smooth knitting (double knitting), rib knitting, purl knitting, Denbigh knitting, cord knitting, atlas knitting, chain knitting, insertion knitting, and woven fabrics combining these. Various interlacing methods are used to produce knitted fabrics. Interlacing knitted fabrics may be warp knitting or weft knitting, for example, tricot, raschel knitting, circular knitting, etc. Furthermore, the knitting structure may be any knitting structure such as half knitting, reverse half knitting, double atlas knitting, double Denbigh knitting, and knitting combining these. Examples of woven fabrics include plain weave, twill weave, satin weave, varied plain weave, varied twill weave, varied satin weave, variegated weave, patterned weave, single-ply weave, double weave, multi-ply weave, warp pile weave, weft pile weave, leno weave, and combinations thereof. Among these, weft knitted fabrics including circular knitting, or warp knitted fabrics are preferred.

[0022] The mass per unit area of ​​the fabric is 80 to 300 g / m 2 is preferable, and more preferably 90 to 250 g / m 2 and more preferably 100 to 200 g / m 2If the thickness falls within the above range, it is suitable for use as innerwear.

[0023] The fabric may contain at least one elastic yarn selected from polyurethane yarn and conjugate yarn obtained by conjugation spinning of at least two polymers with different shrinkage rates. For example, polyurethane elastic yarn may be any type, as long as it is made from polymer diol and diisocyanate as starting materials, and is not particularly limited. The conjugate yarn is a conjugate yarn obtained by conjugation spinning of at least two polymers with different shrinkage rates. It exhibits crimp (crimp) from the raw yarn stage, but upon application of heat, it exhibits even greater crimp (crimp). Specifically, conjugate yarn (bicomponent yarn) of polyethylene terephthalate (PET) and polytrimethylene terephthalate (PTT) is preferred. Examples of such latent crimp-type stretch yarns include "Lycra T400" manufactured by Toray Opelontex, "Spandy" manufactured by KB Seiren, and "Z10" manufactured by Unitika. The commonly used elastic yarn is polyurethane yarn.

[0024] For example, in the case of weft-knitted or circular-knitted fabrics, it is preferable to use bare spandex yarn as a plating yarn for loop yarns, while in the case of warp-knitted fabrics, bare spandex yarn is inserted by inserting the yarn into the weft or by weft insertion. For so-called innerwear, circular knitting is usually used, and elastic yarn, particularly polyurethane elastic yarn, is used as a plating yarn for loop yarns. Polyurethane elastic yarn is usually inserted as a plating yarn in a state where it is stretched about 2.5 times its original length, with a yarn size of 20 to 40 decitex.

[0025] Clothing sewn with the moisture-absorbing and heat-generating fabric of the present invention has elastic threads oriented in the circumferential direction of the body. So-called one-way stretch fabrics are preferred. The circumferential direction of the body refers to the circumferential direction of the torso and arms. This results in innerwear that is comfortable to wear and retains its shape even after repeated washing. The clothing is preferably a shirt or pants.

[0026] In the manufacturing method of the present invention, after the steps of scouring, bleaching, dyeing and neutral soaping, a sodium substitution treatment is carried out. The sodium substitution treatment preferably includes the steps of acid treatment, water washing, alkali treatment, water washing and drying.

[0027] FIG. 1 is a process diagram showing a method for producing a composite spun yarn or fiber structure in one embodiment of the present invention. First, the scouring / bleaching, dyeing, neutralizing soaping, and FIX processes are conventional processes. In the present invention, a sodium substitution process is then carried out. The sodium substitution process preferably includes the steps of acid treatment, water washing, alkali treatment, water washing, and drying. Conventionally, a sodium substitution process has not been carried out. Specific conditions for each process will be explained in the examples. After the sodium substitution process, a conventional finishing process is carried out. [Example]

[0028] The present invention will be described in more detail below with reference to examples, although the present invention is not limited to the following examples.

[0029] <Moisture absorption test> Drying process: Leave at 105°C for 2 hours. Moisture absorption conditions: (1) 20°C, 40% RH (2) 20°C, 65% RH (3) 20°C, 90% RH (4) 30°C, 90% RH The samples were left in the tank for 2 hours in the order of (1) to (4) above. 1. The sample was placed in a weighing bottle and dried in a dryer at 105°C for 2 hours. 2. After drying, the sample was returned to room temperature (25°C) in a desiccator. 3. The weight of the weighing bottle was measured and taken as the bone dry weight (W0). 4. The sample was left to stand in the thermo-hygrostat prepared as described in (1) above, and after 2 hours had passed, the sample was taken out and placed in a weighing bottle, and its weight (W1) was measured. 5. The samples were then left to stand in the thermo-hygrostat adjusted in the order of (2) to (4) above, and after 2 hours had passed, the samples were taken out and placed in weighing bottles, and their weights (W2 to W4) were measured. The sample shape was 12 cm long and 12 cm wide, and the weight was measured after drying or after each moisture absorption condition, and the moisture absorption rate was calculated using the following formula. Moisture absorption rate (%) = [(weight after moisture absorption (W1-4) - bone dry weight (W0)) / bone dry weight (W0)] × 100 <Hygroscopic heat generation> (1) The sample fabric (knitted fabric) was cut to a size of 20 cm lengthwise and 20 cm widthwise, then folded in half (to make a square of approximately 10 cm), and three edges were sewn with a sewing machine. (2) The sample was dried in a dryer for 2 hours, then placed in a desiccator and left overnight. (3) The temperature and humidity of the thermo-hygrostat were set to 20°C and 90%, respectively, and the test was allowed to stand for 30 minutes. (4) The temperature and humidity of the thermo-hygrostat were set to 20°C and 40%, and once the temperature and humidity inside the chamber reached the set state, samples were placed on each thermocouple sensor and left to stand for 50 minutes. (5) After waiting for 50 minutes, change the temperature and humidity inside the thermo-hygrostat to 20.0°C and 80%, and measure the temperature change every minute for 15 minutes. (6) The difference between the maximum temperature of the reference fabric and the maximum temperature of the example fabric during the 15-minute measurement was calculated as the maximum temperature difference (°C). <Elemental analysis> Elemental analysis was carried out using a wavelength dispersive X-ray analyzer (WDX).

[0030] Example 1 <Modifying wool> A sheet of cotton-like wool was impregnated with a 32% by mass aqueous solution of acrylic acid and squeezed with a mangle to a squeezing rate of 100% by mass (1000 g of the aqueous solution was applied to 1 kg of cotton). The wool was then irradiated with electron beams using an electron beam irradiation device, washed with water, and dried to obtain modified wool. The grafting rate was 20.4%. <Creating thread> Modified wool was used as the core component and cotton as the sheath component in a wool:cotton ratio of 20:80 (weight ratio), and a 40 count (cotton count) core-sheath type moisture-absorbing and heat-generating composite spun yarn was prepared as follows. The cotton that forms the sheath component is passed through the blending and carding processes, and the modified wool that forms the core component is drawn in a drawing process so that the specified blend ratio is achieved and the cotton slivers and wool slivers are arranged to form a core-sheath structure.Then, after passing through a roving process and a ring spinning process, a core-sheath type moisture-absorbing and heat-generating composite spun yarn is obtained. <Sample preparation> The obtained core-sheath type moisture-absorbing and heat-generating composite spun yarn was used to prepare a rib knitted fabric. As shown in Figure 1, the fabric was subjected to bleaching (refining and bleaching), dyeing, sodium substitution treatment, and finishing treatment to obtain the fabric of Example 1. The sodium substitution treatment was carried out to convert the carboxyl groups grafted onto the wool fibers into the sodium salt form. The specific conditions for the sodium substitution treatment shown in FIG. 1 will be explained. (1) In the acid treatment step, the sample was treated with an aqueous solution of citric acid (6 g / L, pH 5 or less) at 40° C. for 20 minutes. (2) The next washing step was carried out at room temperature (25°C) for 5 minutes. (3) The next alkaline treatment was carried out using an aqueous solution of sodium bicarbonate (NaHCO3) 9g / L, chelating agent 1g / L, and pH 7.5 or higher at 40°C for 20 minutes. (4) In the next water washing step, a 1 g / L aqueous solution of a chelating agent with a pH of 7.5 to 8 was used, and treatment was carried out twice at room temperature (25° C.) for 5 minutes. (5) Finally, the finishing process was carried out along with drying.

[0031] (Comparative Example 1) A composite spun yarn was made using unmodified wool in the same process, and then a rib knitted fabric was made. This fabric was then processed as shown in Figure 1. The above knitted fabrics were subjected to moisture absorption tests and moisture absorption heat generation tests. The results are shown in Tables 1 and 2 and Figure 2. The results of elemental analysis are shown in Table 3.

[0032] [Table 1]

[0033] [Table 2]

[0034] [Table 3]

[0035] As is clear from Tables 1 to 3 and FIG. 2, the knitted fabric of Example 1 had a high moisture absorption rate, a high moisture absorption heat generation temperature, and a high amount of sodium present.

[0036] (Comparative Example 2) Next, fabric was made without sodium substitution treatment using the knitted fabric of Example 1. Specifically, fabric was made by scouring, bleaching, dyeing, neutral soaping, and FIX treatment as shown in Figure 1, followed by a finishing process. This fabric was used for a moisture absorption and heat generation test, and the results are shown in Table 4. The results of elemental analysis are shown in Table 5.

[0037] [Table 4]

[0038] [Table 5]

[0039] As is clear from Tables 4 and 5, the knitted fabric of Example 1 had a high moisture absorption heat generation temperature and a high amount of sodium. In particular, the amount of Na in Example 1 in Table 5 was 9.3 times that of Comparative Example 2, and the amount of Ca was 1 / 3.5. This is the effect of the sodium substitution treatment. In other words, even if an alkali metal is bonded to the carboxyl group of a graft-polymerized compound, the calcium contained in the water will replace the alkali metal during the scouring, bleaching, dyeing, neutralizing soaping, etc. processes, and the moisture-absorbing heat-generating properties will decrease. As described above, it was confirmed that the moisture absorption and heat generation properties can be maintained at a high level when the sodium substitution treatment is carried out. [Industrial Applicability]

[0040] The moisture-absorbing and heat-generating fabric of the present invention and moisture-absorbing and heat-generating clothing using the same are suitable for innerwear such as shirts and pants. Furthermore, because they are gentle on the skin, they are also suitable for T-shirts and the like.

Claims

1. A composite spun yarn containing animal hair fibers and cellulosic fibers, The animal hair fiber has a compound containing an ethylenically unsaturated double bond chemically bonded to the surface of the fiber, The animal hair fiber further has sodium bonded to a carboxyl group or a sulfonic acid group, The ratio of the animal hair fiber to the cellulosic fiber is 5 to 50 mass% of the animal hair fiber and 50 to 95 mass% of the cellulosic fiber, The animal hair fiber is covered with the fiber containing the cellulosic fiber, The composite spun yarn has a sodium content of 0.5% by mass or more when the spun yarn is taken as 100% by mass, and has moisture-absorbing heat-generating properties.

2. The composite spun yarn according to claim 1, wherein the animal hair fibers are subjected to a moisture-absorbing and heat-generating treatment, and the cellulosic fibers are not subjected to a moisture-absorbing and heat-generating treatment.

3. 3. The composite spun yarn according to claim 1, wherein the animal hair fiber is wool and the fiber covering the wool is cotton.

4. A fiber structure made of a composite spun yarn containing animal hair fiber and cellulosic fiber, The animal hair fiber has a compound containing an ethylenically unsaturated double bond chemically bonded to the surface of the fiber, The animal hair fiber further has sodium bonded to a carboxyl group or a sulfonic acid group, The ratio of the animal hair fiber to the cellulosic fiber is 5 to 50 mass% of the animal hair fiber and 50 to 95 mass% of the cellulosic fiber, The animal hair fiber is covered with the fiber containing the cellulosic fiber, A fiber structure having hygroscopic heat-generating properties, wherein the sodium content is 0.5% by mass or more when the spun yarn is taken as 100% by mass.

5. The fiber structure according to claim 4, wherein the animal hair fibers are subjected to a moisture-absorbing and heat-generating treatment, and the cellulosic fibers are not subjected to a moisture-absorbing and heat-generating treatment.

6. 6. The fiber structure according to claim 4, wherein the animal fiber of the composite spun yarn is wool, and the fiber covering the wool is cotton.

7. The fiber structure according to any one of claims 4 to 6, which is a knitted or woven fabric.

8. A method for producing the conjugated spun yarn according to any one of claims 1 to 3 or the fiber structure according to any one of claims 4 to 7, characterized in that a sodium substitution treatment is carried out after the scouring / bleaching, dyeing, and neutral soaping steps.

9. The method for producing a composite spun yarn or a fiber structure according to claim 8, wherein the sodium substitution treatment includes the steps of an acid treatment, water washing, an alkali treatment, water washing, and drying.

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