Technical Field
[0001] The present invention relates to a fiber structure including elastic polyurethane
yarns, which has high water repellency and keeps a low water retention rate to resist
being wetted when immersed in water.
Background Art
[0002] Water and oil repellent agents containing fluorine-based compounds have been widely
used to impart water repellency and oil repellency to clothing materials and industrial
materials made from textiles.
[0003] However, such fluorine-based water and oil repellent agents are found to contain
compounds that may affect the living environment and living organisms, such as perfluorooctanoate
(hereinafter PFOA) and perfluorooctane sulfonate (hereinafter PFOS). Therefore, fluorine-based
water and oil repellent agents free of these compounds are demanded for textiles.
[0004] It is considered that a small amount of PFOA as an impurity is mixed in the fluorine-based
water repellent agents during the manufacturing process, but the mechanism is not
clarified. Since fluorine-based water repellent agents containing a polyfluoroalkyl
group with 8 or more carbon atoms are likely to generate PFOA when decomposed by some
influence, they are being replaced with those containing a polyfluoroalkyl group with
6 or less carbon atoms that generate no PFOA by decomposition. Patent Document 1 proposes
a water and oil repellent fabric obtained by applying a fluorine-based water repellent
agent free of PFOA and a crosslinker to a fabric and subjecting it to heat treatment.
Patent Document 2 proposes a fiber structure in which a fluorine-based water repellent
compound having a PFOA and/or PFOS concentration of less than 5 ng/g is fixed to monofilament
surfaces, on which a layer of the fluorine-based compound is further fixed to form
a two-layer structure. Both of the above, however, have lower water repellent performance
than the fluorine-based water repellent agents containing PFOA with 8 or more carbon
atoms.
[0005] To improve water repellent performance, Patent Document 3 proposes a method of fixing
a polymer containing a specific fluoroalkyl alcohol (meth)acrylic acid derivative
in a part, a melamine resin, and a water-dispersible polyfunctional isocyanate crosslinker
to fiber surfaces, through at least one of a sulfone group-containing compound or
a polyphenol compound fixed to the fiber surfaces. This method achieves a low water
retention rate, but the water repellent performance is lower than the fluorine-based
water repellent agents containing PFOA with 8 or more carbon atoms when immersed in
water for an extended time.
Prior Art Documents
Patent Documents
Disclosure of Invention
Problem to be Solved by the Invention
[0007] As described above, conventional techniques leave room for improvement of fiber structures
suitable for water repellent finishing, and there have been demands for fiber structures
having higher water repellency and lower water retention rate.
[0008] To solve the above conventional problem, the present invention provides a fiber structure
having improved water repellency and keeping a low water retention rate when immersed
in water for an extended time.
Means for Solving Problem
[0009] A fiber structure of the present invention is a fiber structure including an elastic
polyurethane yarn. The elastic polyurethane yarn contains: 0.5 to 10% by mass (mass%)
of a cationic high-molecular-weight compound A having a number-average molecular weight
of 2000 or more; and an inorganic chlorine deterioration inhibitor B. The mass ratio
of the cationic high-molecular-weight compound A to the inorganic chlorine deterioration
inhibitor B ranges from 0.3 to 3, and a silicone oil is applied to the elastic polyurethane
yarn. The fiber structure is treated with water repellent finishing.
Effect of the Invention
[0010] The present invention can provide a fiber structure having high water repellency
and keeping a low water retention rate when immersed in water for an extended time,
with the following configurations: the elastic polyurethane yarn contains 0.5 to 10%
by mass of a cationic high-molecular-weight compound A having a number-average molecular
weight of 2000 or more, and an inorganic chlorine deterioration inhibitor B; the mass
ratio of the cationic high-molecular-weight compound A to the inorganic chlorine deterioration
inhibitor B ranges from 0.3 to 3; a silicone oil is applied to the elastic polyurethane
yarn; and the fiber structure is treated with water repellent finishing. The fiber
structure of the present invention is particularly advantageous as a fabric for a
swimsuit.
Description of the Invention
[0011] To make fabrics such as swimwear fabrics water repellent, the present inventors have
focused on elastic polyurethane yarns, which have not received much attention, and
conducted various studies to improve the water repellency of the elastic polyurethane
yarns themselves. As a result of the studies, specific elastic polyurethane yarns
are found to be highly compatible with water repellent agents.
[0012] The elastic polyurethane yarn of the present invention contains: 0.5 to 10 mass%
of a cationic high-molecular-weight compound A having a number-average molecular weight
of 2000 or more; and an inorganic chlorine deterioration inhibitor B. The mass ratio
of the cationic high-molecular-weight compound A to the inorganic chlorine deterioration
inhibitor B ranges from 0.3 to 3, and a silicone oil is applied to the elastic polyurethane
yarn. By treating a fiber structure including the elastic polyurethane yarn with water
repellent finishing, it is possible to obtain a highly water and oil repellent fiber
structure having high water repellency and a low water retention rate to resist being
wetted when immersed in water for an extended time.
[0013] Any water repellent treatment finishing agent may be used in the present invention,
but it is preferable to use a treatment agent that makes the ratio of fluorine (F)
/ carbon (C) (hereinafter, referred to as a F/C ratio) on the elastic polyurethane
yarn satisfy 0.030 or more in the elemental mass concentration according to SEM-EDX.
In the elemental mass concentration according to SEM-EDX, the F/C ratio of 0.030 or
more on the elastic polyurethane fiber indicates that the adhesion amount of the fluorine-based
water repellent agent is large, whereas the F/C ratio of less than 0.03 indicates
that the adhesion amount of the fluorine-based water repellent agent is small, and
wettability is not lowered sufficiently. The F/C ratio is further preferably 0.045
or more.
[0014] The water repellent finishing of the present invention preferably contains a water
repellent agent and a crosslinker. As the crosslinker, melamine resin, a water-dispersible
polyfunctional isocyanate crosslinker or the like is suitably used, and these may
be mixed together. Examples of the melamine resin include trimethylolmelamine and
hexamethylohnelamine. The water-dispersible polyfunctional isocyanate crosslinker
is not particularly limited as long as it is an organic compound containing two or
more isocyanate functional groups in the molecule. Examples of the same includes tolylene
diisocyanate, hexamethylene diisocyanate, diphenylmethane diisocyanate, hydrogenated
diphenylmethane diisocyanate, triphenyl triisocyanate, xylene diisocyanate, and diclohexylmethane
diisocyanate. More preferably, the water-dispersible polyfunctional isocyanate crosslinker
is a polyfunctional blocked isocyanate crosslinker obtained by reacting a trimethylolpropane
tolylene diisocyanate adduct, a friserin tolylene diisocyanate adduct or the like,
with a phenol that is a blocking compound (a compound that regenerates an isocyanate
group when heated to 70 to 200°C together with an isocyanate adduct), diethyl malonate,
methyl ethyl ketoxime, sodium bisulfite, ε-caprolactam, etc.
[0015] It is preferred that the melamine resin is mixed in a proportion of 1 to 40 mass%
based on the solid content of the water repellent agent, and the polyfunctional isocyanate
crosslinker is mixed in a proportion of 1 to 10 mass% based on the solid content of
the water repellent agent.
[0016] The fiber structure of the present invention includes the elastic polyurethane yarn
in an amount of preferably 1 to 99 mass%, more preferably 10 to 90 mass%, further
preferably 15 to 80 mass%, and particularly preferably 20 to 70 mass%, when the fiber
structure is assumed to be 100 mass%. With this configuration, the fiber structure
including the elastic polyurethane yarn can keep high water repellency and a low water
retention rate as a whole. In the case of using the fiber structure as a fabric for
a swimsuit, the fiber structure preferably includes the elastic polyurethane yarn
in an amount of 5 to 70 mass%, more preferably 5 to 60 mass%, further preferably 5
to 50 mass%, and particularly preferably 5 to 40 mass%. With this configuration, the
swimsuit including the elastic polyurethane yarn can keep high water repellency and
a low water retention rate as a whole. As other fiber yarns, synthetic fiber yarns
such as polyester yarns, nylon yarns, and polypropylene yarns can be appropriately
used.
[0017] The water repellency of the fiber structure of the present invention is preferably
grade 4 or higher, and more preferably grade 5 in the spray test according to JIS
L 1092. The fiber structure having a water repellency of grade 4 or higher is suitable
for, e.g., a swimsuit. The water retention rate of the fiber structure after 60 minutes
is preferably 50 mass% or less, more preferably 40 mass% or less, and further preferably
30 mass% or less of the mass of the fiber structure.
[0018] The elastic polyurethane yarn may be either a bare yarn or a yarn covered with another
synthetic fiber yarn. The covered yarn may be either a single covered yarn or a double
covered yarn. The swimsuit is preferably constituted by a woven fabric or knitted
fabric using an elastic polyurethane fiber yarn covered with another synthetic fiber
yarn. Examples of the synthetic fiber yarn include, but are not particularly limited
to, polyester synthetic fiber yarns typified by polyethylene terephthalate, polytrimethylene
terephthalate, polybutylene terephthalate, and copolymerized polyester fiber yarns
containing any of these as a main component; polyamide synthetic fiber yarns typified
by nylon 6 and nylon 6,6; and polypropylene synthetic fiber yarns. Among them, polyamide
synthetic fiber yarns and polyester synthetic fiber yarns are preferred. The polyamide
fibers are preferable from the viewpoint of strength and processability with the elastic
polyurethane yarn. The synthetic fibers may have any fiber form and any cross-sectional
shape, but it is preferable to subject them to false twisting by a known method to
impart crimps, in order to produce a highly stretchable woven fabric. To lower the
water retention rate, it is preferable to use straight yarns to minimize spaces between
yarns. It is more preferable to subject yarns to surface smoothing by a known method
to reduce spaces therebetween.
[0019] The tearing strength of the fiber structure is preferably 8 N or more, more preferably
10 N or more, and further preferably 12 N or more according to JIS L 1096. With this
configuration, it is possible to maintain a high tearing strength as a swimsuit. Moreover,
the bursting strength of the fiber structure is preferably 200 kPa or more, more preferably
300 kPa or more, and further preferably 400 kPa or more according to JIS L 1096. With
this configuration, it is possible to maintain a high bursting strength as a swimsuit.
[0020] The fiber structure is preferably at least one of a woven fabric or a knitted fabric.
In many cases, swimsuits for top swimmers are made from woven fabrics, and swimsuits
for general swimmers are made from knitted fabrics. The fiber structure of the present
invention is suitable as a fabric for a swimsuit. When the fiber structure is used
for a swimsuit, wettability in water is reduced during swimming. Particularly when
it is used for a competition swimsuit, wettability of the swimsuit during a race is
reduced and water resistance is also reduced.
[0021] The elastic polyurethane yarn of the present invention is mainly composed of polyurethane.
First, the polyurethane will be described.
[0022] The polyurethane used in the present invention is not particularly limited as long
as a polymer diol and a diisocyanate are used as starting materials. The synthesis
method is also not particularly limited. For example, the polyurethane may be a polyurethane
urea composed of a polymer diol, a diisocyanate and a low-molecular-weight diamine,
or a polyurethane urethane composed of a polymer diol, a diisocyanate and a low-molecular-weight
diol. Further, the polyurethane may be a polyurethane urea prepared using a compound
having a hydroxyl group and an amino group in the molecule as a chain extender. It
is also preferred that a polyfunctional glycol having trifunctionality or higher functionality,
isocyanate and the like are used within a range that does not impair the effect of
the present invention.
[0023] Preferable examples of the polymer diol include polyether diol, polyester diol, and
polycarbonate diol. Among these, a polyether diol is preferred particularly from the
viewpoint of imparting flexibility and elongation to the yarn.
[0024] Preferable examples of the polyether diol include polyethylene oxide, polyethylene
glycol, derivatives of polyethylene glycol, polypropylene glycol, polytetramethylene
ether glycol (hereinafter, abbreviated as PTMG), copolymers of tetrahydrofuran (THF)
and 3-methyltetrahydrofuran (modified PTMG), copolymers of THF and 2,3-dimethyl THF
(modified PTMG), polyols having side chains on both sides as disclosed in, e.g.,
Japanese Patent No. 2615131, and random copolymers in which THF and ethylene oxide and/or propylene oxide are
irregularly arranged. Such polyether diols may be used individually, or two or more
kinds of these may be mixed or copolymerized.
[0025] From the viewpoint of imparting wear resistance and light stability to the elastic
polyurethane yarn, polyester diols such as butylene adipate, polycaprolactone diol
and polyester polyol having a side chain as disclosed in, e.g.,
JP S61-26612 A, and polycarbonate diols as disclosed in, e.g.,
JP H2-289516 A are favorably used.
[0026] Such polymer diols may be used individually, or two or more kinds of these may be
mixed or copolymerized.
[0027] As the molecular weight of the polymer diol, the number-average molecular weight
is preferably 1000 or more and 8000 or less, and more preferably 1500 or more and
6000 or less, from the viewpoint of imparting elongation, strength, heat resistance
and the like to the yarn. The use of a polyol having a molecular weight of this range
makes it possible to easily obtain an elastic yarn excellent in elongation, strength,
elastic recovery, and heat resistance.
[0028] Next, as the diisocyanate, aromatic diisocyanates are particularly suitable for synthesizing
a polyurethane with high heat resistance and high strength, examples of which include
diphenylmethane diisocyanate (hereafter, abbreviated as MDI), tolylene diisocyanate,
benzene 1,4-diisocyanate, xylylene diisocyanate, and 2,6-naphthalene diisocyanate.
Further, preferable examples of alicyclic diisocyanates include methylenebis(cyclohexyl
isocyanate), isophorone diisocyanate, methylcyclohexane 2,4-diisocyanate, methylcyclohexane
2,6-diisocyanate, cyclohexane 1,4-diisocyanate, hexahydroxylylene diisocyanate, hexahydrotolylene
diisocyanate, and octahydro-1,5-naphthalene diisocyanate. Aliphatic diisocyanates
are particularly effective to prevent yellowing of the elastic polyurethane yarn.
Such diisocyanates may be used individually or in combinations of two or more kinds.
[0029] Next, the chain extender used in the synthesis of the polyurethane preferably contains
at least one of a low-molecular-weight diamine or a low-molecular-weight diol. The
chain extender also may be a compound having a hydroxyl group and an amino group in
the molecule such as ethanolamine.
[0030] Preferred examples of the low-molecular-weight diamine include ethylenediamine, 1,2-propanediamine,
1,3-propanediamine, hexamethylenediamine, p-phenylenediamine, p-xylylenediamine, m-xylylenediamine,
p,p'-methylenedianiline, 1,3-cyclohexyldiamine, hexahydro metaphenylenediamine, 2-methylpentamethylenediamine,
and bis(4-aminophenyl)phosphine oxide. It is preferable to use one or two or more
of the above. Ethylenediamine is particularly preferred. The use of ethylenediamine
makes it possible to easily obtain a yarn excellent in elongation, elastic recovery,
and heat resistance. A triamine compound capable of forming a crosslinking structure
with these chain extenders, such as diethylenetriamine, may be added within a range
that does not impair the effect.
[0031] Typical examples of the low-molecular-weight diol include ethylene glycol, 1,3-propanediol,
1,4-butanediol, bishydroxyethoxybenzene, bishydroxyethylene terephthalate, and 1-methyl-1,2-ethanediol.
It is preferable to use one or two or more of the above. Ethylene glycol, 1,3-propanediol,
and 1,4-butanediol are particularly preferred. The use of the above makes it possible
to obtain a yarn with further improved heat resistance as for polyurethane having
diol extension and further improved strength.
[0032] As the molecular weight of the polyurethane in the present invention, the number-average
molecular weight preferably ranges from 30000 to 150000, from the viewpoint of imparting
high durability and strength to the fibers. The molecular weight is measured by GPC
and converted by polystyrene.
[0033] One or a mixture of two or more kinds of end-capping agents are preferably used for
the polyurethane. Preferable examples of the end-capping agent include monoamines
such as dimethylamine, diisopropylamine, ethyl methylamine, diethylamine, methyl propylamine,
isopropyl methylamine, diisopropylamine, butyl methylamine, isobutyl methylamine,
isopentyl methylamine, dibutylamine and diamylamine, monools such as ethanol, propanol,
butanol, isopropanol, allyl alcohol and cyclopentanol, and monoisocyanates such as
phenylisocyanate.
[0034] In the present invention, when an elastic polyurethane yarn made from the polyurethane
having the above basic composition contains 0.5 to 10 mass% of a cationic high-molecular-weight
compound A having a number-average molecular weight of 2000 or more and an inorganic
chlorine deterioration inhibitor B, and the A/B mass ratio ranges from 0.3 to 3, a
large synergistic effect is produced, and an excellent effect of resisting chlorine
deterioration and excellent water repellent property are exhibited.
[0035] The cationic high-molecular-weight compound used in the present invention is not
particularly limited as long as it is a compound having an amino group in the structure.
From the viewpoint of preventing chlorine deterioration and yellowing of the elastic
polyurethane yarn, it is particularly preferable to use a compound having only a tertiary
amino group in the molecule among primary to tertiary amino groups.
[0036] If the number-average molecular weight of the cationic high-molecular-weight compound
is less than 2000, the water repellent property degrades due to falling off by rubbing
with a guide or a knitting needle during formation of the elastic polyurethane yarn,
or due to bleeding during processing such as dyeing in a bath. Therefore, the number-average
molecular weight needs to be 2000 or more. In terms of solubility in the polyurethane
spinning solution, the number-average molecular weight preferably ranges from 2000
to 10000. More preferably, it ranges from 2000 to 4000.
[0037] Containing the cationic high-molecular-weight compound can improve the water repellent
property of the elastic polyurethane yarn. The content of the cationic high-molecular-weight
compound is preferably more than 0.5 mass% and 10 mass% or less, and more preferably
more than 0.5 mass% and 4 mass% or less with respect to the fiber mass, from the viewpoint
of sufficiently producing this effect and not adversely affecting the physical properties
of the fibers.
[0038] Moreover, the polyurethane yarn of the present invention is to contain the inorganic
chlorine deterioration inhibitor, together with the cationic high-molecular-weight
compound.
[0039] The inorganic chlorine deterioration inhibitor used in the present invention is preferably
at least one of an oxide, a carbon oxide, a complex oxide or a solid solution of one
or more elements selected from the group consisting of Zn, Mg, Ca and Al. From the
viewpoint of durability against pool water and environment, carbon oxides CaCO
3, MgCO
3 and hydrotalcites composed of Mg and Al are particularly preferred.
[0040] The content of the inorganic chlorine deterioration inhibitor in the elastic polyurethane
yarn in the present invention preferably ranges from 0.5 mass% to 10 mass%, from the
viewpoint of durability against pool water and stability during production. The content
thereof more preferably ranges from 1 mass% to 5 mass%.
[0041] From the viewpoint of achieving both of durability against pool water and water repellent
property, the mass ratio (A)/(B) of the cationic high-molecular-weight compound (A)
to the inorganic chlorine deterioration inhibitor (B) in the elastic polyurethane
yarn ranges from 0.3 to 3, and more preferably 0.5 to 2.
[0042] The inorganic chlorine deterioration inhibitor, which is blended in the spinning
solution and spun, is preferably fine powder with an average particle diameter of
2 pm or less, and more preferably fine powder with an average particle diameter of
1 µm or less, from the viewpoint of spinning stability. Further, if the average primary
particle diameter is smaller than 0.01 pm, the cohesive force increases, which makes
the particles difficult to be uniformly mixed in the spinning solution. Therefore,
the average primary particle diameter is preferably 0.01 pm or more from the viewpoint
of dispersibility. As the average particle diameter, a 50% particle diameter is measured
by the laser diffracted light scattering method. The measuring device is, e.g., a
laser diffraction/scattering particle size distribution analyzer LA-950S2 manufactured
by HORIBA, Ltd.
[0043] To finely pulverize the inorganic chlorine deterioration inhibitor, it is preferable
to employ a method that includes: mixing the inorganic chlorine deterioration inhibitor
with a solvent such as N,N-dimethylacetamide (hereafter, abbreviated as DMAc), dimethylformamide
(hereafter, abbreviated as DMF), dimethylsulfoxide (hereafter, abbreviated as DMSO),
N-methylpyrrolidone (hereafter, abbreviated as NMP) or a solvent containing any of
these as a main component, and other additives such as a thickener to prepare a slurry;
and crushing the slurry by, e.g., a vertical or horizontal mill.
[0044] Further, for the purpose of improving the dispersibility of the inorganic chlorine
deterioration inhibitor into the yarn and stabilizing the spinning, it is also preferable
to use an inorganic chlorine deterioration inhibitor that has been surface-treated
with, e.g., an organic substance such as a fatty acid, a fatty acid ester, a phosphoric
acid ester or a polyol organic substance, a silane coupling agent, a titanate coupling
agent, water glass, a fatty acid metal salt, or a mixture of these.
[0045] Moreover, it is preferred that the elastic polyurethane yarn of the present invention
contains a partially hindered phenol compound, from the viewpoint of improving durability
against pool water. The partially hindered phenol compound preferably contains at
least two partially hindered hydroxyphenyl groups and has a skeleton selected from
bisester and alkylidene. It is more desirable that the alkyl group present in the
ring position adjacent to the hydroxyl group in the hydroxyphenyl group is a tertiary
butyl group, and it is further desirable that the equivalent of the hydroxyl group
is 600 or less.
[0046] A preferable example of such a partially hindered phenol compound is ethylene-1,2-bis(3,3-bis[3-t-butyl-4-hydroxyphenyflbutyrate)
having a structure in which a partially hindered hydroxyphenyl group is covalently
bonded to a bisester skeleton (Chemical Formula 1 below).

[0047] Containing the partially hindered phenol compound can increase the effect of resisting
chlorine deterioration. The content of the partially hindered phenol compound is preferably
0.15 to 4 mass%, and more preferably 0.5 to 3.5 mass% with respect to the elastic
polyurethane yarn, from the viewpoint of sufficiently producing this effect and not
adversely affecting the physical properties of the fibers.
[0048] As a treatment agent for the elastic polyurethane yarn in the present invention,
a specific amount of silicone, ranging from 0.5 mass% to 20 mass%, is applied to the
elastic fibers in the form of, e.g., an oil. The silicone is typically used to reduce
the tension fluctuation during unwinding of the elastic polyurethane yarn in the manufacture
of fabrics so that fine elastic fibers can be prevented from breaking due to the tension
fluctuation during unwinding. In the present case, the silicone greatly contributes
to an improvement in the water repellent property. The content of the silicone in
the treatment agent is 0.5 to 10 mass%, preferably 1 to 6 mass% in dry mass. Thus,
the affinity with the water repellent treatment agent can be improved. For example,
an oil containing silicone can reduce the surface energy of a fabric and remarkably
improve spreadability of a water repellent finishing agent when it is applied to the
fabric surface.
[0049] Examples of the silicone include polydimethylsiloxane having dimethylsiloxane units,
polydialkylsiloxanes having dimethylsiloxane units and dialkylsiloxane units containing
an alkyl group with 2 to 4 carbon atoms, and polysiloxanes having dimethylsiloxane
units and methylphenylsiloxane units, and these silicone oils are preferably used.
Further, it is preferred that the silicone has a viscosity at 25°C of 5 × 10
-6 to 50 × 10
-6 m
2 /s, from the viewpoint of handleability and reduction of running friction with guides
or the like. The viscosity can be measured by the method specified in JIS-K2283: "Crude
petroleum and petroleum products - Determination of kinematic viscosity and calculation
of viscosity index from kinematic viscosity".
[0050] The silicone oil is preferably mixed with a paraffinic hydrocarbon such as a mineral
oil, an antistatic agent, a dispersant, a metal soap, etc. The paraffinic hydrocarbon
such as a mineral oil preferably has a viscosity at 25°C of 5 × 10
-6 to 50 × 10
-6 m
2/s, from the viewpoint of handleability and reduction of running friction with guides
or the like. Preferable examples of the antistatic agent include anionic surfactants
such as alkyl sulfate, fatty acid soap, alkyl sulfonate, and alkyl phosphate. Preferable
examples of the dispersant include silicone resin, polyether-modified silicone, carbinol-modified
silicone, carboxyl-modified silicone, amino-modified silicone, amide-modified silicone,
carboxyamide-modified silicone, mercapto-modified silicone, and organic carboxylic
acid, and these may be used individually or as a mixture. Preferable examples of the
metal soap include magnesium stearate (hereafter, abbreviated as St-Mg) and calcium
stearate, and the average particle diameter is preferably 0.1 to 1.0 pm from the viewpoint
of improving handleability and dispersibility.
[0051] The silicone oil used in the present invention preferably contains components that
are typically used in treatment agents for synthetic fibers, including a binder, an
ultraviolet absorber, an antioxidant, a preservative, and a wettability modifier,
as needed. The contents of the paraffinic hydrocarbon such as a mineral oil, metal
soap, antistatic agent, dispersant, etc., are appropriately determined depending on
the intended purpose.
[0052] Further, the silicone oil is preferably blended with a stabilizer, a thermal conductivity
improver, and a pigment, within a range that does not impair the effect of the present
invention.
[0053] The elastic polyurethane yarn of the present invention may contain various stabilizers,
a pigment and the like, as needed. For example, as a light resistance agent, an antioxidant
and the like, the elastic polyurethane yarn may contain the following: a sterically
hindered phenol-based chemical agent typified by BHT or "SUMILIZER" (registered trademark)
GA-80 manufactured by Sumitomo Chemical Co., Ltd., a benzotriazole- or benzophenone-based
chemical agent such as "Tinuvin" (registered trademark) manufactured by Ciba-Geigy
Corporation, a phosphorus-based chemical agent such as "SUMILIZER" P-16 manufactured
by Sumitomo Chemical Co., Ltd., various hindered amine-based chemical agents, an inorganic
pigment such as titanium oxide or carbon black, a fluorine- or silicone-based resin
powder based on vinylidene polyfluoride or the like, a metal soap such as magnesium
stearate, a germicide containing silver, zinc or any of these compounds, a deodorant,
a lubricant such as silicone or mineral oil, barium sulfate, cerium oxide, an antistatic
agent such as betaine, a phosphoric acid compound or phosphoric acid ester compound.
These may be reacted with polymer to remain present. To further increase durability,
especially against light and nitrogen oxides, it is preferred that the elastic polyurethane
yarn also contains a nitrogen oxide scavenger such as HN-150 manufactured by Nippon
Hydrazine Co., Ltd., or "Hostanox" (registered trademark) SE10 manufactured by Clariant
Corporation, a thermo-oxidation stabilizer such as "SUMIUZER" GA-80 manufactured by
Sumitomo Chemical Co., Ltd., and a light stabilizer such as "SUMISORB" (registered
trademark) 300#622 manufactured by Sumitomo Chemical Co., Ltd.
[0054] Next, the method for producing the elastic polyurethane yarn of the present invention
will be described in detail.
[0055] The production method of the polyurethane may be either melt polymerization or solution
polymerization, or another method. However, solution polymerization is more preferred.
In the solution polymerization, foreign substances such as gel are less generated
in the polyurethane, spinning is easy, and an elastic polyurethane yarn of low fineness
is easily obtained. Obviously, solution polymerization is advantageous in that the
operation of preparing a solution can be omitted.
[0056] A polyurethane particularly suitable for the present invention is synthesized using
PTMG having a molecular weight of 1500 to 6000 as a polymer diol, MDI as a diisocyanate,
and at least one of ethylenediamine, 1,2-propanediamine, 1,3-propanediamine or hexamethylenediamine
as a chain extender.
[0057] The polyurethane is obtained, for example, by synthesizing the above raw materials
in a solvent such as DMAc, DMF, DMSO, NMP, or a solvent containing any of these as
a main component. For example, particularly suitable methods which may be employed
are: a one-shot method of throwing the raw materials into such a solvent to dissolve,
and heating and reacting them to form a polyurethane; and a method of first melting
and reacting a polymer diol and a diisocyanate, then dissolving the reaction product
in a solvent and reacting it with the chain extender to form a polyurethane.
[0058] In the case of using a diol as a chain extender, it is preferable to adjust the melting
point of the polyurethane on the high temperature side to a range from 200°C to 260°C,
from the viewpoint of obtaining a polyurethane having excellent heat resistance. A
typical method of achieving this adjustment is to control the type and ratio of the
polymer diol, MDI, and diol. In the case that the polymer diol has a low molecular
weight, increasing the relative proportion of MDI can yield a polyurethane having
a high melting point on the high temperature side. Similarly, in the case that the
diol has a low molecular weight, reducing the relative proportion of the polymer diol
can yield a polyurethane having a high melting point on the high temperature side.
[0059] In the case that the polymer diol has a molecular weight of 1800 or more, the polymerization
preferably takes place with a ratio of (the number of moles of MDI) / (the number
of moles of polymer diol) = 1.5 or more in order to make the melting point on the
high temperature side 200°C or higher.
[0060] One or a mixture of two or more kinds of catalysts such as an amine catalyst and
an organometallic catalyst are preferably used for the synthesis of the polyurethane.
[0061] Examples of the amine catalyst include N,N-dimethyl cyclohexylamine, N,N-dimethyl
benzylamine, triethylamine, N-methylmorpholine, N-ethylmorpholine, N,N,N',N'-tetramethyl
ethylenediamine, N,N,N',N'-tetramethyl-1,3-propanediamine, N,N,N',N'-tetramethyl hexanediamine,
bis-2-dimethylaminoethyl ether, N,N,N',N',N'-pentamethyl diethylenetriamine, tetramethylguanidine,
triethylenediamine, N,N'-dimethylpiperazine, N-methyl-N'-dimethylaminoethyl-piperazine,
N-(2-dimethylaminoethyl)morpholine, 1-methylimidazole, 1,2-dimethylimidazole, N,N-dimethylaminoethanol,
N,N,N'-trimethylaminoethyl ethanolamine, N-methyl-N'-(2-hydroxyethyDpiperazine, 2,4,6-tris(dimethylaminomethyl)phenol,
N,N-dimethylaminohexanol, and triethanolamine.
[0062] Examples of the organometallic catalyst include tin octanoate, dibutyltin dilaurate,
and lead dibutyl octanoate.
[0063] Typically, the concentration of the polyurethane in the polyurethane solution thus
obtained preferably ranges from 30 mass% to 80 mass%.
[0064] In the present invention, the polyurethane solution contains the cationic high-molecular-weight
compound having a number-average molecular weight of 2000 or more and the inorganic
chlorine deterioration inhibitor to improve durability against chlorine in pool water
and the water repellent property. As a method for incorporating the cationic high-molecular-weight
compound into the spinning solution, it may be solely mixed with the spinning solution,
or it may be mixed with the inorganic chlorine deterioration inhibitor beforehand.
As a method for evenly dispersing the cationic high-molecular-weight compound and
the inorganic chlorine deterioration inhibitor in the polyurethane spinning solution
before spinning, it is preferred that they are added to a polyurethane spinning solution
containing N,N-dimethylformamide or N,N-dimethylacetamide as a solvent, and then stirred
and mixed evenly. Specifically, it is preferred that the cationic high-molecular-weight
compound and the inorganic chlorine deterioration inhibitor are dissolved or dispersed
in a solvent such as N,N-dimethylformamide or N,N-dimethylacetamide beforehand, and
the solution or dispersion is mixed with the polyurethane spinning solution. Here,
the solvent for the cationic high-molecular-weight compound and the inorganic chlorine
deterioration inhibitor to be added is preferably the same as the solvent for the
polyurethane solution, from the viewpoint of adding them evenly in the polyurethane
solution. The chemical agents such as a light resistance agent and an antioxidant
and the pigment described above may be added simultaneously with the cationic high-molecular-weight
compound and the inorganic chlorine deterioration inhibitor. Any method can be adopted
to add the cationic high-molecular-weight compound and the inorganic chlorine deterioration
inhibitor into the polyurethane solution. Various typical methods may be adopted,
including a method using a static mixer, a method using stirring, a method using a
homomixer, and a method using a biaxial extruder.
[0065] To improve durability against chlorine in pool water, the elastic polyurethane yarn
preferably contains a partially hindered phenol compound having at least one partially
hindered hydroxyphenyl group and having a molecular weight of 300 or more, in an amount
of, e.g., 0.15 mass% or more and 4.0 mass% or less. Any method can be adopted to incorporate
the partially hindered phenol compound into the spinning solution, and it may be solely
mixed with the spinning solution, or it may be mixed with the above solution or dispersion
beforehand.
[0066] The polyurethane yarn of the present invention can be obtained by subjecting the
spinning solution prepared as described above to dry spinning, wet spinning or melt
spinning, followed by winding, for example. Among them, dry spinning is preferred
because it enables stable spinning in any fineness from thin to thick.
[0067] The elastic polyurethane yarn of the present invention may have any fineness and
any cross-sectional shape. For example, the cross-sectional shape of the yarn may
be circular or elliptical.
[0068] The dry spinning method is also not specifically limited, and suitable spinning conditions
are to be selected depending on the desired characteristics, spinning equipment, etc.
[0069] The spinning speed is preferably 250 m/min or greater from the viewpoint of improving
the strength of the elastic polyurethane yarn to be obtained.
[0070] The knitted fabric including the elastic polyurethane yarn may be any of a circular
knitted fabric, a weft knitted fabric, or a warp knitted fabric (e.g., a tricot knitted
fabric, a raschel knitted fabric). The knitted structure may be pile stitch, flat
stitch, plain stitch, rib stitch, smooth stitch (interlock stitch), rib stitch, pearl
stitch, denbigh stitch, double denbigh stitch, cord stitch, half stitch, back half
stitch, atlas stitch, double atlas stitch, chain stitch, inlay stitch, or any combination
of the above.
[0071] The woven fabric including the elastic polyurethane yarn and other fibers is woven
by a general method. Examples of the woven fabric structure include plain weave, twill
weave, sateen weave, variegated plain weave, variegated twill weave, variegated sateen
weave, fancy weave, brocade, single texture, double texture, multiple texture, warp
pile weave, weft pile weave, interweave, and any combination of the above. The woven
fabric may be either a one-way stretch fabric in which the polyurethane yarn is used
for warp or weft, or a two-way stretch fabric in which the polyurethane yarn is used
for both warp and weft.
[0072] The fabric including the elastic polyurethane yarn and other fibers is scoured, relaxed,
and set under normal conditions. The fabric is usually dyed with a dye and conditions
that are suitable for other fibers mixed at a high ratio in the fabric. The dye may
be a disperse dye, an acid dye, a metal complexed dye, or a conventional dye. The
fabric may be subjected to a fixing treatment for dye fixing, an antibiotic treatment,
a softening treatment, etc., as needed.
[0073] The following describes the water repellent finishing method of the present invention.
The water repellent finishing of the present invention is preferably imparted by dry
heat treatment. The dry heat treatment may be performed by applying a treatment liquid
containing a water repellent agent to a fiber structure with a device such as a mangle,
followed by drying and heat treatment. As a device for applying the treatment liquid
containing a water repellent agent to a fiber structure, a device that can uniformly
apply the liquid to the fiber structure is preferred, and a normal mangle is suitable
as a liquid applying device. The treatment liquid also can be applied by a foam processing
machine, or a method such as printing, inkjet, spraying or coating method. The drying
temperature is preferably 80°C to 150°C. The treatment time is preferably 15 seconds
to 5 minutes, more preferably 30 seconds to 3 minutes at 100°C to 140°C. The heat
treatment temperature after drying is preferably 80 to 200°C. The treatment time is
preferably 15 seconds to 8 minutes, more preferably 30 seconds to 5 minutes at 130°C
to 190°C. When the treatment temperature is low, the reaction will not occur sufficiently,
which lowers water repellency.
Examples
[0074] Hereinafter, the present invention will be described further specifically by way
of examples. However, the present invention is not limited to the following examples.
Further, in the following examples, the weight ratio simply expressed by % indicates
mass%.
[0075] Various characteristics of woven fabrics were measured in the following manner.
(Elemental Mass Concentration)
[0076] The elemental mass concentration was measured according to SEM-EDX under the conditions
below, using elastic polyurethane yarns that appeared on the surface of a dismantled
fiber structure or elastic polyurethane fibers taken out from unraveled yarns. The
F/C ratio was calculated from the obtained elemental mass concentration. A SEM (S-3400N
manufactured by Hitachi, Ltd.) and an EDX detector (EMAX x-act manufactured by HORIBA,
Ltd.) were used as the measuring devices.
<Measurement Conditions>
[0077]
Acceleration voltage: 5 kV
Resolution: 1024 × 768
Probe current: 50 mA
Live time: 120 sec
Vacuum: 30 Pa
Process time: mode: 4
WD: 10 mm
Spectral range: 0 to 20 keV
Magnification: 2000 times
Number of channels: 2K
(Water Repellency)
[0078] The water repellency was evaluated and classified according to the spray method specified
in JIS L 1092: "Testing methods for water resistance of textiles" (1998).
(Water Retention Rate)
[0079] A circle of diameter 11.2 cm was drawn in the middle of each fiber structure that
was cut in 20 cm long and 20 cm wide, and the fiber structure was stretched to extend
the circled area by 80%, to which a specimen holding frame for a water repellency
test (JIS L 1092) was attached. After the spray test (JIS L 1092), the fiber structure
was removed from the holding frame and air-dried in an environment of 20°C × 53% RH.
Ten pieces of the same fiber structure were prepared, and each was weighed as a "weight
before treatment".
[0080] 30 L of water (water temperature: 25 to 29°C) was filled in a washing machine (JIS
C 9606), into which the 10 pieces of the fiber structure were immersed. They were
rotated for a predetermined period of time (10 minutes, 60 minutes, 120 minutes) under
"strong conditions" and taken out from water one by one. They were inclined about
15 degrees in a spread state for 10 seconds to remove water droplets from the fiber
structure, and each was weighed as a "weight after treatment" to measure the water
retention rate by Formula below.

<Tearing Strength>
[0081] The tearing strength was evaluated according to the pendulum method specified in
JIS L 1096: "Testing methods for woven and knitted fabrics" (1999).
<Bursting Strength>
[0082] The bursting strength was evaluated according to the Mullen method specified in JIS
L 1096: "Testing methods for woven and knitted fabrics" (1999).
<Elongation Rate>
[0083] The elongation rate was measured according to the cut strip method specified in JIS
L 1096 A: "Testing methods for woven and knitted fabrics" (1999). A test piece was
5 cm wide, and a clamp interval was 20 cm. An initial load was set at a load corresponding
to a gravity applied to 1 m (length) of the test piece. A tensile speed was set at
20 cm/min. An elongation rate (%) under a load of 17.7 N (1.8 kg) was measured. The
elongation rate represents stretchability.
<Stress at 30% Elongation>
[0084] The stress (N) at 30% elongation during measurement of the elongation rate in warp
and weft directions was measured, and the value obtained was converted into per centimeter
and expressed by N/cm. The stress at 30% elongation can be a criterion for evaluating
the compression (wearing pressure) function of the sample.
(Preparation of Yarn A)
[0085] PTMG having a number-average molecular weight of 1800 and MDI were placed in a container
at a molar ratio of MDI/PTMG = 1.58/1 and reacted at 90°C, and the resulting reaction
product was dissolved in N,N-dimethylacetamide (DMAc). Next, a DMAc solution containing
ethylenediamine and diethylamine was added to the solution in which the reaction product
was dissolved to prepare a polyurethane urea solution having a solid content of 35
mass% in polymer.
[0086] A condensation polymer of p-cresol and divinylbenzene ("Methacrol" (registered trademark)
2390 manufactured by DuPont), as an antioxidant, and 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)phenyl
("Cyasorb" (registered trademark) 1164 manufactured by Cytech Inc.), as an ultraviolet
absorber, were mixed at a ratio (mass ratio) of 3/2 to prepare a DMAc solution (concentration:
35 mass%) as an additive solution (35 mass%).
[0087] The polyurethane urea solution and the additive solution were mixed at a ratio of
98 mass% and 2 mass% to prepare a polymer solution (X1).
[0088] As a cationic high-molecular-weight compound, a cationic high-molecular-weight compound
having a number-average molecular weight of 2600 was prepared by reacting t-butyldiethanolamine
with methylene-bis- (4-cyclohexyl isocyanate). The cationic high-molecular-weight
compound thus obtained was dissolved in DMAc to prepare a solution (A1) with a concentration
of 35 mass%.
[0089] Calcium carbonate HakuenkaA (CaCO
3, average primary particle diameter: 1.0 µm) manufactured by Shiraishi Kogyo Kaisha,
Ltd., was used as a chlorine deterioration inhibitor to prepare a 35 mass% DMAc dispersion.
For this preparation, a horizontal mill DYNO-MIL KDL manufactured by Willy A. Bachofen
AG was used, and 85% zirconia beads were filled therein to finely and evenly disperse
them at a flow rate of 80 g/min to prepare a DMAc dispersion B1 of synthetic carbonate
(35 mass%).
[0090] As a partially hindered phenol compound, ethylene-1,2-bis(3,3-bis[3-t-butyl-4-hydroxyphenyl]butyrate
("Hostanox" (registered trademark) 03 manufactured by Clariant Corporation) was dissolved
in DMAc to prepare a solution (C1) with a concentration of 35 mass%.
[0091] The polymer solutions X1, A1, B1 and C1 were mixed at a ratio of 97 mass%, 1 mass%,
3 mass% and 1 mass%, respectively, to prepare a spinning solution Y1. The spinning
solution Y1 was dry-spun at a winding speed of 580 m/min to produce an elastic polyurethane
yarn (78 decitex) (Z1). A silicone oil as a treatment agent was applied thereto while
winding. As the silicone oil, a treatment agent (oil) containing 96% of silicone (polydimethylsiloxane),
3% of St-Mg and 1% of dispersant was applied in an amount of 6% in dry weight.
[0092] The elastic polyurethane yarn obtained in the above-described manner was covered
with a nylon 66 yarn. The nylon 66 yarn used was 33 decitex, 10 filaments. The covering
was 1400 T/m, single covering. Thus, a yarn A was obtained.
(Preparation of Yarn B)
[0093] A yarn B was produced in the same manner as the yarn A except that an elastic polyurethane
yarn was produced in 55 decitex.
(Preparation of Yarn C)
[0094] A yarn C was produced in the same manner as the yarn A except that an elastic polyurethane
yarn was produced in 44 decitex and covered with a nylon 66 yarn of 33 decitex, 10
filaments.
(Preparation of Yarn D)
[0095] An elastic polyurethane yarn of 78 decitex (Type 176E, manufactured by TORAY OPELONTEX
CO., LTD.) was covered with a nylon 66 yarn of 33 decitex, 10 filaments, to produce
a yarn D.
(Preparation of Yarn E)
[0096] An elastic polyurethane yarn of 55 decitex (Type 254E, manufactured by TORAY OPELONTEX
CO., LTD.) was covered with a nylon 66 yarn of 33 decitex, 10 filaments, to produce
a yarn E.
(Preparation of Yarn F)
[0097] An elastic polyurethane yarn of 44 decitex (Type 254T, manufactured by TORAY OPELONTEX
CO., LTD.) was covered with a nylon 66 yarn of 33 decitex, 48 filaments, to produce
a yarn F.
(Example 1)
[0098] The yarn A was used as a warp yarn, and the yarn B and the yarn C were used as weft
yarns to produce a plain woven fabric. The obtained woven fabric was 66% of nylon
and 34% of polyurethane. The woven fabric was subjected to scouring, intermediate
setting, dyeing, and drying according to ordinary methods. The obtained woven fabric
was immersed in a water repellent preparation below, squeezed with a pickup of 50%,
and then dried in a pin tenter set at a temperature of 130°C. Then, the woven fabric
was subjected to dry heat treatment for 1 minute in the pin tenter at 170°C to obtain
a processed woven fabric (fiber structure) of Example 1. Regarding the finished density
of the woven fabric, the warp density was 185 yarns/2.54 cm, the weft density was
201 yarns/2.54 cm, and the mass per unit area was 146 g/m
2. The obtained processed fabric was a highly water repellent fiber structure having
a high water repellent degree and a low water retention rate.
- FX-ML (fluorine-based water repellent agent manufactured by Kyokenkasei): 100 g/L
- BECKAMINE M-3 (melamine resin manufactured by DIC Corporation): 3 g/L
- BECKAMINE ACX (catalyst manufactured by DIC Corporation): 2 g/L
- Super Fresh JB7200 (water-dispersible polyfunctional isocyanate crosslinker manufactured
by Kyokenkasei): 5 g/L
(Example 2)
[0099] A processed woven fabric (fiber structure) of Example 2 was obtained in the same
manner as in Example 1, except that the yarn A and the yarn B were used as a warp
yarn and a weft yarn, respectively, and the woven fabric was constituted by 66% of
nylon and 34% of polyurethane. Regarding the finished density of the woven fabric,
the warp density was 184 yarns/2.54 cm, the weft density was 178 yarns/2.54 cm, and
the mass per unit area was 129 g/m
2. The obtained processed fabric was a highly water repellent fiber structure having
a high water repellent degree and a low water retention rate.
(Comparative Example 1)
[0100] A processed woven fabric (fiber structure) of Comparative Example 1 was obtained
in the same manner as in Example 1, except that the yarn D was used as a warp yarn,
and the yarn E and the yarn F were used as weft yarns, and the woven fabric was constituted
by 66% of nylon and 34% of polyurethane. The obtained processed fabric had a high
water repellent degree but also a high water retention rate, which was unsatisfactory.
(Comparative Example 2)
[0101] A processed woven fabric (fiber structure) of Comparative Example 2 was obtained
in the same manner as in Example 1, except that the yarn D was used as a warp yarn,
and the yarn E was used as a weft yarn, and the woven fabric was constituted by 66%
of nylon and 34% of polyurethane. The obtained processed fabric had high a water repellent
degree but also a high water retention rate, which was unsatisfactory. Table 1 summarizes
the results.
[Table 1]
| |
Example 1 |
Example 2 |
Comparative Example 1 |
Comparative Example 2 |
| Mass (g/m2) |
146 |
129 |
136 |
126 |
| Tearing strength (N) |
Warp |
15.4 |
16.3 |
18.4 |
18.9 |
| Weft |
15.8 |
12.9 |
19.0 |
15.2 |
| Bursting strength (kPa) |
490 |
518 |
615 |
600 |
| SEM-EDX analysis value (F/C ratio) |
0.059 |
0.045 |
0.023 |
0.029 |
| Elongation rate (%) |
Warp direction |
55.1 |
38.7 |
54.7 |
43.4 |
| Weft direction |
31.8 |
34.4 |
37.6 |
33.7 |
| Stress at 30% elongation (N/cm) |
Warp direction |
1.61 |
2.57 |
1.27 |
2.14 |
| Weft direction |
3.27 |
3.00 |
2.61 |
3.00 |
| Water repellency (grade) |
5 |
5 |
5 |
5 |
| Water retention rate (%) |
After 10 minutes |
3.7 |
6.9 |
8.1 |
8.3 |
| After 60 minutes |
10.2 |
12.1 |
63.3 |
35.1 |
| After 120 minutes |
17.3 |
29.0 |
70.3 |
51.5 |
[0102] Table 1 shows that the fiber structures of Examples 1 and 2 were high in water repellency
and low in water retention rate, particularly they were low in water retention to
resist being wetted when immersed in water for an extended time.
Industrial Applicability
[0103] The fiber structure including the elastic polyurethane yarn of the present invention
can be applied to various stretch foundations of sports clothing, swimwear, girdles,
brassieres, intimate products and underwear, sock cuffs, tights, pantyhose, waistbands,
body suits, spats, stretch sportswear, stretch outerwear, bandages, supporters, medical
wear, stretch liners, and disposable diapers, for example. The fiber structure is
particularly suitable as a fabric for a swimsuit used in pools. A swimsuit obtained
therefrom can be excellent in water repellency and water retention rate.