TWI345005B - Stitchbonded fabric and artificial leather and article of manufacture comprising the same and process for making the same - Google Patents
Stitchbonded fabric and artificial leather and article of manufacture comprising the same and process for making the same Download PDFInfo
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- TWI345005B TWI345005B TW93104636A TW93104636A TWI345005B TW I345005 B TWI345005 B TW I345005B TW 93104636 A TW93104636 A TW 93104636A TW 93104636 A TW93104636 A TW 93104636A TW I345005 B TWI345005 B TW I345005B
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- Prior art keywords
- yarn
- poly
- fabric
- group
- stitch
- Prior art date
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- 238000000034 method Methods 0.000 title claims description 17
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 239000002649 leather substitute Substances 0.000 title claims description 9
- -1 poly(ethylene terephthalate) Polymers 0.000 claims description 70
- 239000000835 fiber Substances 0.000 claims description 42
- 238000009940 knitting Methods 0.000 claims description 20
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- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 1
- 125000003258 trimethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- 150000003673 urethanes Chemical class 0.000 description 1
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- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 1
Classifications
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/45—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by forming intermeshing loops or stitches from some of the fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
- D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/52—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
- D04H3/115—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by applying or inserting filamentary binding elements
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using knitted fabrics
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/643—Including parallel strand or fiber material within the nonwoven fabric
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Knitting Of Fabric (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
Description
1345005 玖、發明說明: 【發明所屬之技術領域】 本發明係關於一種縫編(stitchbonded)不織物,尤其係其 中至少一紗之針紋包含聚(對苯二曱酸乙二酯)及聚(對苯二 甲酸丙二酯)之雙組分聚酯纖維之織物;此一織物之製法; 及包含此一織物之人工皮革及製造物件。 【先前技術】 縫編係可將不織物插於包含兩紗之經編針織物之沈圈 (sinker loops)與針圈之間的技術。舉例來說,美國專利US 470432 卜 US 4737394、US 4773238、US 4879169、US 4897297、 US 5041255、US 4876128、US 4998421、歐洲專利EP 476193 B1、及其之日本相對專利中揭示使用彈性纖維於製造縫編 不織物。然而,當將此種不織物浸泡聚胺基甲酸酯樹脂溶 液以製造人工皮革時,聚胺基甲酸酯樹脂之溶劑會使彈性 纖維降解,及製造條件和產物控制會變困難。 美國公開申請案US 2003/162454中揭示具有拉伸特性之 人工皮革。美國專利US 5932056中揭示層合天然皮革,但 其可能相當昂貴。 如於美國專利US 5922433及US 6668598、英國專利GB 1421694、美國公開申請案US 2003/0134094、及日本公開 申請案JP 2000-336581A中所揭示,將雙組分纖維使用於針 織物及不織物中。雖然可將針織物使用作為可拉伸人工皮 革之基礎織物,但必需修改此種織物,以限制織物在加工 過程在縱向中之伸長率。此外,需要使針織物起毛
O:\91\91534.DOC 1345005 (naPping)、將其妙磨(―)、或磨光(buffing)或經塗布樹 脂之粗纺織物(㈣稱為「奶㈣㈣咖⑽顧叫」), 以改良黏著’及在塗布聚胺基f酸g旨之前製備織物之表面。 所仍有需要-種適用於包括含具與天然:皮革類似之拉伸性 貝之人丨革之製造物件之不需額外製造步驟的不織物。 【發明内容】 本發明提供—種縫編不織物,其包括—不織網片、第一 紗之針紋、及第二紗之針紋’其令第一紗包括呈現潛在捲 曲且L S聚(對苯_甲酸乙二酷)及聚(對苯二甲酸丙二醋) 之聚醋雙組分纖維。本發明進一步提供此一織物,A中該 針紋係經編針織構造,該雙組分纖維呈現制捲曲,且具 有選自由並排及偏心皮芯所組成之群之形態,及其中第一 紗之針紋呈現二至七個針距(neecUe spaees)的下露(U油邮。 本發明亦提供-種製造縫編不織物之方法,其包括下列 步驟:a)提供-具有第—給紗棒(guideb㈣及第:給紗棒之 經編針織機器、一前身不織物網片、—包括具選自由並排 及偏心皮芯所組成之群之截面形態且包含聚(對笨二甲酸 乙二酯)及聚(對苯二甲酸丙二酯)之聚酯雙組分纖維之第一 、"及一第二紗;b)將第一紗供給通過第一給紗棒;c)將第 二紗供給通過第二給紗棒;d)將前身網片供給至針織機 器,以致於針織之後,其係在針織針紋的沈圈及針圈之間; 及e)經由使第一給紗棒及第二給紗棒各於複數個針距上往 復搖擺,而將第一紗及第二紗針織通過前身網片^亦提供 將縫編不織物在足以使聚酯雙組分纖維中之捲曲展開之溫
O:\91\91534.DOC 1345005 度下加熱足夠時間之非必需的方法步驟f)。 此外,本發明提供—種包括本發明織物之人卫皮革及製 造物件。 【實施方式】 現意料之外地發現其中編織至前身不織物中之至少一紗 包含聚醋雙组分纖維之缝編不織物具有當未經塗布及當經 塗布夺之间度期望的特性,諸如高拉伸,及典型上m 合塗層之良好黏著及優異視覺均勾度。雙組分纖維呈現可 於縫編之後經由暴露至熱而展開 :…纖維」係指切斷纖 =絲:紗」係指使用作為一軍元之複數個纖維;紗為 連續長絲較佳。 「雙組分纖維」係指呈現可自其展開有用捲曲之潛在捲 曲之聚醋切斷纖維及/或聚醋連續長絲,且其包 為第組分及聚(對苯二甲酸丙二_第二組 刀'、之重里比典型上係約70/30至30/70。 「單組分纖維」係指包含至少約85 八 物或共聚物,例如選自由聚(對苯之聚口 二歹酸丙H(對笨二甲酸丁二3旨)、:^)、聚(對苯 酿己二胺)、聚己内酿胺、…二:丙稀、聚(己二 維及/或連續長絲。 的切斷纖 「不織物」及「㈣㈣」係指經方 視需要經由摩擦、及/或内聚及,或黏著黏合之二二 絲、或絲線之紡織品結構,其係相對於規則圖案之機财
O:\91\91534.DOC 1345005 互結合纖維;即其並非紡織或針織物。 本發明之縫編不織物包括—不織網片、1現潛在捲曲且 4含聚m苯二甲酸乙二0旨)及聚(對苯二甲酸丙二醋)之 “旨雙組分纖維之第一紗之針紋、及可與第一紗相同或不 7第v之針紋。雙組分纖維可呈現展開捲曲,典型上 係於熱處理之後。 縫編不織物可且古的,Λ se丄 /、有約10至150克/平方米之基重量,及約 18至22牛頓之橫向撕裂強度。 用織物I造人卫皮革時,於織物之表面上將第一紗 (:含,分纖維)設置於第二紗之外側,即第二紗係在第一 y和 '身不織網片之間較佳。織物可具有約10至50%(以約 至0%較佳)之橫向拉伸及約〇至(以約〇至7%較佳 縱向拉伸。 身不織網片可包含聚(對苯二甲酸乙二醋)、聚(對苯二 酿間丙稀、聚(對苯二醯對笨二胺)、聚(間苯二 )纖維素、叢絲(plexifilamentary)聚乙稀、其 共 物、及 #S /、*1/ '以物之纖維。不織織物及網片構造之例子 。括刀斷纖維及/或連續長絲之針刺、射流喷網 ed)、液壓針縫(hydraulically needled)、紡黏、梳理、 氣流鋪置(a i r 1 ·』\ 一 wwiaid)、及濕鋪(weMaid)構造。 " 針文為經編針織構造時,第一紗之針紋可呈現二 至七個針距夕 、 一 <下露,典型上係1-0/2-3至1-0/7_8之繞線 雜叩蝻選自由1_〇/4_5、1_〇/5_6、卜〇/6_7及Μ,7·8所組成之 之、'線更為典型。第二紗之針紋可呈現選自由1-0/0-1(有
O:\91\91534.DOC 1345005 時稱為「柱形針紋(pillar stitch)」)、ι_2/1_〇、2·3/1-〇 及 3·4/1-〇 所組成之群之繞線,1-2/1-0繞線更為典型。 組成雙組分纖維之聚酯的一或兩者可為共聚酯,及「聚 (對笨一甲酸乙二酯)」及「聚(對苯二甲酸丙二酯)」包括在 其思義内之此種共聚酯。舉例來說,可使用共聚(對苯二甲 酸乙二酯)’其中用於製造共聚酯之共單體係選自由下列所 組成之群:具4-12個碳原子之直鏈、環狀、及分支鏈脂族 二羧酸(例如,丁二酸、戊二酸、己二酸、壬二酸、癸二酸、 十二烷二酸、及1,4-環己烷二羧酸);具8_12個碳原子之除 對本一甲&外之方族一叛酸(例如,間苯二甲酸及2,6_萘_ 羧酸);具3-8個碳原子之直鏈、環狀、及分支鏈脂族二元醇 (例如,1,3-丙二醇、L2-丙二醇、!,4_丁二醇、^-戊二醇' 3 -甲基-1,5-戊二醇、2,2-二甲基- ΐ,3-丙二醇、2-曱基 ,二醇、帛己烧二甲醇、及M環己二醇);芳族二醇諸如 氫醌及雙酚A;羥基酸諸如對羥基苯甲酸及心己内酯;及具 4-10個碳原子之脂族及芳脂族醚二醇(例如,氫醌雙(2_羥乙 基)醚、或具低於約460之分子量的聚(伸乙基醚)二醇,包括 二伸乙基醚二醇)。共單體可以不會減損本發明之效益的量 值存在,例如,以全體聚合物成分計至多約2〇莫耳百分比 之1值,典型上係至多約1〇莫耳百分比。間苯二甲酸、戊 一酸、己二酸、1,3-丙二醇、及丨,4•丁二醇為較佳的共單體。 亦可將共聚酯製造為具有少量的其他共單體,其限制條 件為此種共單體不會對本發明之效益有不利影響。此種其 他共單體包括5-磺酸間苯二甲酸鈉、3_(2_磺酸乙基)己二酸
O:\91\91534.DOC 1345005 之納鹽、^其之二燒基酿,其可以全體聚酿計狀Μ莫耳 百刀比之里加人。為改良酸可染色性’亦可將(共)聚酿與聚
合第二胺添加劑,你丨S% i C ’及(6,6-亞咹基雙六亞甲基對苯二 曱醯胺)及其與六亞甲-脸 兄f 一fe之共聚醯胺,典型上係其之磷酸 及亞磷酸鹽混合。 對於高展開捲曲,雙組分纖維可具有並排或偏心皮怎截 面形態。對於雙Μ分纖維之外部截面並無特殊之限制,其 可為圓形、橢圓形、三角形、「雪人」、狀橢圓形」等等。 可將「雪人」截面描述為具有—長軸、—短轴及當對長轴 作圖時在短轴長度中之至少兩最大值的並排截面。「扇狀擴 圓形」截面具有在其表面中之複數個縱向溝槽,其可改良 聚酯雙組分之浸潤性質。 雙組分纖維中之聚(對笨二曱酸乙二酯)及聚(對苯二甲酸 丙一 Sb )典型上可具有不同的固有黏度,舉例來說,經由將 〇.1〇克之聚合物溶解於10毫升之鄰氣酚中,及使用奥斯瓦 爾德(Ostwald)黏度計在25°C下測量黏度進行測定,聚(對苯 二甲酸乙二酯)可具有約0.45至0.60分升(dl)/克之固有黏 度’及聚(對苯二甲酸丙二酯)可具有約1.0至12〇分升/克之 固有黏度β 使用於本發明中之個別的聚S旨雙組分纖維可具有每長絲 約0.4至25分得克斯(decitex)之纖度(titer)。由此一纖維製得 之紗可具有約20至1,〇〇〇分得克斯之總纖度,典型上係約44 至156分得克斯。 當第二紗包含聚酯單組分纖維時,當聚合物為聚(對苯二 O:\91\9I534.DOC • 11 - 1345005 曱酸乙二酯)時,纖維可包含如於文中他處所說明之共聚 物,及當聚合物為聚(對苯二曱酸丙二酯)或聚(對笨二甲酸 丁二酯)時,更包含乙二醇為非必需之共單體。當第二紗包 含聚醯胺單組分纖維時,纖維可包含其中之共單體為對苯 一甲I、間笨二甲酸、己二酸、癸二酸、六亞曱二胺、己 内醯胺、2-甲基五亞甲二胺、雙(胺甲基)環己烷、聚(2_ 甲基五亞甲己二醯胺)等等之共聚物。 對於單組分纖維之外部截面並無特殊之限制,其可為圓 m 形、橢圓形、三角形、扇狀橢圓形或任何其他有用的截面。 當第二紗包含單組分纖維時,其經假拈,以賦予—些拉, 伸較佳。第二紗可具有約56至33()分得克斯之總纖度,典型 上係約44至156分得克斯。 ' 、7 矛一没、及不 織網片纖維之任何一者、兩者、或全部亦可包含習知之添 加劑諸如抗靜電劑、抗氧化劑諸如受阻紛、抗微生物劑、
防燃劑、染料及/或有色顏料、光安定劑、微細分割石夕石或 紹氧、及褪光劑諸如二氧化鈦’丨限制條件為其不會減損 本發明之效益。 包含本發明之縫編不織物的製造物件包括拉伸醫療綃帶 及衛生褲。亦可使林發明之織物於製造包括U皮革之 ::’其中皮革之基礎織物係本發明之織物。此種物件包 "類(例如’鞋子、鞋子、便鞋h住家及汽車裝飾、外 =如’夹克 '外套、褲子)、配件(例如,手提包、帽子、 、及仃李。人工皮革之拉伸特性應近似於天然皮革,
O:\9I\9I534.DOC -12- 1345005 上在第—方向中具有較在大致垂直於第—方向之第 ,方向中高之拉伸。舉例來說,鞋減用之天然皮革一般 仏裁切成「腳跟至腳指端緊(tight㈤t。㈣」,以致緊 又(民拉伸)線自聊跟朝腳指延伸。此使鞋鞋類具有縱向穩定 性,同時仍可橫向摺曲及拉伸,以提供耐用性及舒適1 本發明之縫編不織物可於縱向中具有低拉伸,及於橫向 中具相當高之拉伸,以致當經塗布聚胺基甲酸酉旨時,其可 模擬天然皮革的機械性質。此外,在織物之沈圈表面上之 雙組分纖維的小捲曲可使傳統的起毛步驟省略’而不會對 塗層黏著有不利影響,且可降低製造成本。 日 、對於使用於塗布本發明之縫編不織物的聚合物或塗布方 法並無特殊之限制。聚合物可為聚胺基甲酸_(較佳) 乙婦)、聚(乙稀縮丁路)、聚丙婦酸系、聚(胺基酸)、或聚石夕 氧,且其可以水性乳液(分散物)或以溶於有機溶劑中之溶液 塗布。視需要可將顏料、紫外吸收劑、阻燃劑、發泡劑、軟 化劑、染料、及/或抗氧化劑加至聚合物之溶液或分散物中: 供塗布或浸泡用之有用的聚胺基甲酸醋可經由使聚人二 元醇諸如聚醋二元醇、聚喊二元醇、及/或聚碳酸醋二元: 與二異氰酸酯反應,然後再利用至少一二胺、 醇使生成之「經封端二元醇」鏈增長而製得。 3 — 聚輯二元醇之例子包括聚(己二酸新戊二醋)二元醇、聚 (乙稀-共-己二酸丁二酯)二元醇、聚(十二燒二酸22_二甲基 丙二醋)二元醇、及聚(己二酸2,5_二乙基戍二酿)二元醇^ 醚二元醇之例子包括聚(四亞甲基醚)二元醇、聚(三亞甲基 O:\9I\91534.DOC •13· 1345005 醚)一元醇及聚(四亞甲基_共_2_甲基四亞甲基醚)二元醇。 聚碳酸酯二元醇之例子包括衍生自1,6-己二醇、i,5-戊二 醇、新戍一醇及3-甲基戊二醇之聚碳酸醋二元醇。 聚合二元醇可具有約500至3,5〇〇之數目平均分子量(典型上 係約 800-2500)。 可使-兀醇與選自由芳族、脂環族、及脂族二異氛酸醋 及其此口物所組成之群之二異氰酸酯反應。其例子包括 4,4,-二苯基f烷二異氰酸酯、2,4••二苯基甲烷二異氰酸 @曰、4_甲基-1,3-伸苯基二異氰酸酯、2,2•雙(4_異氰酸苯基) 丙烷、4,4’-亞甲基-雙(環己基異氰酸酯)、4,4,·二環己基甲 烷一異氰酸酯、3,3,5-三甲基_5_亞甲基環己基二異氰酸酯、 1,6-/、亞曱基一異氰酸酿、及其混合物。 可使視需要溶解於適當溶劑中之生成之「經封端二元醇」 與具有兩個以上之活性氫原子及不多於約3〇〇之分子量的 至少一低分子量化合物反應(「鏈增長」)。其例子包括乙二 醇(較佳)、丙二醇、1,3-丙二醇、込肛丁二醇、3_甲基 戊一醇、1,6-己一醇、二伸乙基趟二醇、二伸丙基醚二醇、 乙二胺、2-甲基-1,5-戊二胺、二伸乙三胺、1>3_二胺基環己 烷、1,4-二胺基環己烷、丨,3_二胺基戊烷、胺基_3,3,5_三 曱基-5-胺甲基環己烷、亞甲基雙苯胺、六氫吡^井、笨二胺、 己二醯肼、及異酞醯肼。當使用二醇鏈增長劑時,可加入 催化劑’例如有機錫化合物、有機鈦化合物、或第三胺。 如使用複數個聚合二醇及/或二異氰酸酯,則可使其個別反 應以製造許多預聚物’然後可將其混合及鏈增長,或可製 O:\91\9I534.DOC •14- 1345005 備具有混合成分之一預聚物,然後再鏈增長。 或者可使用「一歩(one_sh〇t)」方法,其中將所有原料混 合在一起及反應。 可利用浸泡、水平塗布、於夾輥之間擠壓、移轉塗布' 或類似方法,將不織物塗布或浸泡聚胺基甲酸酯溶液或分 散物。 者可將經^:泡之縫編不織物乾燥以移除溶劑,或可银 ,其浸泡於水中或水性有機溶劑溶液中,以使聚胺基甲酸酿 凝聚。舉例來說,可將不織物浸泡具1〇重量。4至的重量%之 聚胺基甲酸醋濃度的溶液,然後再在約2〇。。至7代之溫度 下…勺60/40至Ο"。。二甲基甲醯胺/水之溶液接觸。凝聚可 經由連續浸泡於複數個其之二甲基甲酿胺/水比及溫度不 同的水溶液中而進行。 ^^胺基甲酸醋溶液及皮把、,曰人& & 欣及水性/吧合物中之溶劑可為N,N,_二 甲基甲醢胺、二甲亞石風、NN, __ 兄風Ν,Ν -—甲基乙醯胺、N_f基吡洛 。定酮等等。亦可使用凝 之用疑聚調即劑,例如高碳醇或(陽離子〕 表面活性劑,例如二_十__ ,^ 十一基一甲銨、十二基三甲銨及氯化 或漠化十四基吡錠等等,1 .曲A 八例如係在母公升溶劑0.5至5克 之》辰度下。 在本發明之方法Φ交ώ 万去中將則身不織物網片、第一紗、及第 二紗供給至針織機器,例 』具有兩個以上(至少第一及第二) 之給紗棒的經編針織機 Λ/Γ ^ 渚如1^ RACOP 2K-V 或 Karl
Mayer RS2V。前身不織網 ^ ^ 、、,片了為如文中他處所說明。第一 、,:/具有選自由並排及偏心.+ 皮心所組成之群之截面,包括含聚
O:\91\91534.DOC -15· 1345005 酸乙二醋)及聚(對苯二甲酸丙二_)之聚醋雙組分 棒m 1供給通過第—給紗棒(其蘭織機11之前方給紗 車又佳)。當將第一紗供給 縫編織物中之第1、㈣" 棒時,其經設置於 第〜的外側’即遠離前身不織網片之表面。 〜可與第—紗相同’或可包含如文中他處所說明之單电 分纖維,例如假拈變形聚(對苯二甲酸乙二醋)纖維,且係供 ΐ通給紗棒(其係針織機器之後方給紗棒較佳)。當將 第-V供給通過後方給紗棒時,其經設置於縫編織物中 身不織網片之表面與第—紗之間。將前身網片供給至針織機 器’以致於針織之後,其係在針織針紋的沈圈和針圈之間。 由使第給紗棒及第二給紗棒各於複數個針距上往復搖 擺而將第一紗及第二紗針織通過前身網片。 為改良外觀及對聚合塗層之黏著,可選擇第一(例如,前 方)給紗棒之移動。可使前方給紗棒於複數個(以三至七個較 佳)針距上搖擺;L3至ro/W繞線為更佳;及選自由 ⑽4:5、m㈣6-7及m组成之群之前方棒針 、’文為最佳。可使後方給紗棒相對於前方棒於複數個針距上 搖擺,例如W-0/(M之繞線或選自Μ_2/ι·〇、“Μ及 3-4/Κ0所組成之群之繞、線。卜2/1趟線為較佳。 本發明之方法可進一步包括I縫編不織物暴露至足夠熱 足夠時間,以使雙組分纖維紗中之高捲曲程度展開之步 驟。熱可為乾或濕熱。舉例來說,可於約16〇至18〇七下進 行乾熱處理(其中未故意將水或水蒸氣加至熱處理環境)2〇 至60私可於约12〇至i45°c下進行,例如,制蒸汽或於
O:\91\91534.DOC -16· 1345005 例如可於染浴 染浴中之濕熱處理約3至40秒;較長的時間 中所達到者,並不會不利於捲曲展開。 在此舉出實施例作說㈣’但其並不_本發明。所使 狀不織物係㈣-以’ Ltd·製造之聚醋纺黏織物圖 型,其具有20克/平方米之基重量。所使用之聚g旨雙組分係 T⑽y Industries製造之「ΡΥ92」_聚(對苯二甲酸乙二酌及 聚(對苯二甲酸丙二醋)之56分得克斯/24長絲未糾^组 分;在縫編過程中,其之捲曲係潛在,且其要直至編縫不 織物:熱處理之後方才完全展開。所使用之聚(對苯二子酸 乙一酯)長絲係 T〇ray Industries, lnc.製造之「w〇〇ly Tet_」 • 8 3二分得克斯、3 6長絲假拈變形紗;其於表中指示為「资」。」 實施例中之織物的機械特性係利用以下之曰本標準協會 (Japanese Institute of Standards)方法測定: 斷裂強度: 斷裂伸長率: 自延伸之回復百分比 撕裂強度: JIS L-1018(條狀物方法) JIS L-1018(條狀物方法) JIS L-1096(A) JIS L-6772 拉伸百分比: 爆破強度:
JISL-1018(恒定負荷方法:22 a牛頓) JIS L-1018A 實施例 實施例1 使用在前方給紗棒上之聚(對苯二曱酸乙二酯)及聚(對笨 一甲酸丙二酯)之雙組分紗、在後方給紗棒上之主要為聚 笨二甲西参7 ~ 、丁 一 二酯)之假拈變形紗、及聚酯紡黏不織物,在表
O:\9l\91534.DOC -17- 1345005 1所示之針織條件下製造原胚缝編不織物。 表1 縫編不織物針織條件 針織機器 LibaRACOP2: 12規, 130英吋 給紗棒 前方棒 後方棒 不織物進給器. 材料 PY92 WT Toyobo 6201 型 穿絲 全設 全設 構造 1-0/4-5 1-2/1-0 轉子長度(cm/搖針) 550 260 53 機器上之線套(線套/英吋) 23.7 有時將前方棒針紋稱為「絲絨(velvet)」針紋,及有時將 後方棒針紋稱為「假編(tricot)」針紋。然後使原胚織物接 受表2所示之條件,而產生本發明之缝編織物的一較佳具體 實施例,其中於缝編不織物之表面上,聚酯雙組分紗係設 置於聚(對笨二曱酸乙二酯)單組分紗之外側,即單組分紗係 在雙組分紗和前身不織網片之間。 表2 織物處理條件 操作 處理裝置 處理條件 原胚織物設定 綳架 150°C,20 m/分 染色 喷射染色機器 125°C,40分,分散染色(灰色) 完成織物設定 綳架 140°C,20 m/分 綳架之經加熱部分為21米長,及在該等溫度下之時間為 57秒。 圖1顯示實施例1之織物的横剖面示意圖。圖2A係實施例1 中之織物的簡化平面圖,及圖2B係相同織物之簡化横剖面 圖。在圖1及2中,1指示沈圈,及2指示針織圈(knit loop)。 1-1指示前方給紗棒沈圈,1-2指示後方給紗棒沈圈,2-1指 O:\91\91534.DOC -18- 1345005 示前方給紗棒針圈,其中紗係設置於後方給紗棒針圈2_2之 外側,及3指示不織物。圖3係於實施例丨中製得之經熱處理 織物在1.5X倍率下之顯微照片。 比較實施例1 使用在冑方及後方給紗棒兩者上之主要為聚(對苯二甲 酸乙二酯)之聚酯假拈變形紗及聚酯紡黏不織物,在表^所 示之針織條件下製造原胚縫編不織物。
線套(線套/英吋) 前方棒具有有時稱為「㈣」
稍高的縱向拉伸。有時將後方棒稱為「絲織」針紋:、亦將 =於表2之條件下處理得完成織物。圖4係於比較實施例丄 I侍之經熱處理織物在L5X倍率下之顯微照 見不期望的條紋。 史J 評估於實施例i及比較實施例i中製得之經熱處理 縫編織物的機械性質及外觀。結果記述於表4,其中「横向 =、_織物的横越方向(緯線),及「縱向」係指縫編;物」 的機裔方向(棱紋)。當於表面上沒有條 的外颧皙如η丄 叮相疋丨優良」 等級’及备表面上之條紋明顯時,指定
〇:\9l\9l534.D〇C 1345005 等級。 然後使用60份重量之SANPRENE LQ-620及40份重量之 SANPRENE LQ-660溶於1〇〇份重量之二甲基曱醯胺中之溶 液’將經熱處理之織物浸泡聚胺基曱酸酯。兩聚合物皆係 購自Sanyo Chemical Industries. Ltd.之聚酯胺基甲酸酯。溶 液之黏度為8000毫帕斯卡(11^&8(^1)_秒。其係使用刮刀(手 動形式的水平間隙塗布)在每平方米織物1000克溶液下利 手塗布至經熱處理之縫編不織物的沈圈表面。經由在2〇 °C下利用一田 於50°C水中浸泡2〇分鐘,及 J州一甲基甲醯胺/水混合物(13/87重量比)凝聚,然後 移除。
,及最終於120°C下乾燥,而將溶劑 之人工皮革的外觀記述於表4。當經塗布聚 物沒有殘留於表面上之環圈或條紋時,指 觀等級’及當有環圈或條紋殘留於表面上 -20- 1345005 表4 縫編不織物之性質及經塗布聚胺基甲酸酯之織物的外觀 實施例1 比較例1 缝編織物 線套密度(線套/英吋) 24.0 23.0 稜密度(棱/英吋) 23.0 22.0 基重量(g/m2) 125 114 斷裂強度(牛頓) 縱向 385 374 橫向 265 272 斷裂伸長率(%) 縱向 30.5 33.3 橫向 152 142 自延伸之回復(%) 縱向 95 93 橫向 94 92 撕裂強度(牛頓) 縱向 15.8 16.8 橫向 18.3 17.5 拉伸(%) 縱向 6.5 8.0 橫向 45.3 36.3 爆破強度(牛頓/m2) 6.84 6.22 外觀 優良 不良 經塗布織物 外觀 優良 不良 在實施例1之縫編織物中,即使沒有額外的起毛步驟,浮 現於原胚織物表面上之由前方給紗棒所形成之長沈圈產生 適用於較佳黏著之外觀,較於比較實施例1中更均勻之聚胺 基甲酸酯塗層。 在比較實施例1之縫編織物中,即使於塗布聚胺基曱酸酯 樹脂之薄塗層後,亦明顯可見出現於由後方給紗棒所形成 之長沈圈表面上之由前方給紗棒鏈針織之沈圈,且於織物 表面上產生條紋。 當觀察到所得織物之橫向撕裂強度對於人工皮革用途令 人無法接受地低(低於15牛頓)時,放棄使用彈性纖維製造類 O:\91\91534.DOC • 21 - 1345005 似縫編不織物的嘗試。 【圖式簡單說明】 圖1係本發明之缝編織物的横剖面示意圖。 圖2 A係本發明之缝編織物的簡化平面圖。 圖2B係本發明之縫編織物的簡化横剖面圖。 圖3係本發明之較佳織物的顯微照片。 圖4係非本發明之織物的顯微照片。 【圖式代表符號說明】 1 沈圈 2 針織圈 1-1 前方給紗棒沈圈 1-2 後方給紗棒沈圈 2-1 前方給紗棒針圈 2-2 後方給紗棒針圈 3 不織物 O:\9l\91534.DOC - 22 -
Claims (1)
1345005 年月日峰,X)正本 第093104636號專利申請案 中文申請專利範圍替換本(ldtr^r^ 拾、申請專利範圍: 1. 一種縫編非織造織物,其包括非織網片、第一紗之針紋、 及第一紗之針紋’其中該第一紗包括呈現潛在捲曲且包 含聚(對苯二甲酸乙二醋)及聚(對苯三甲酸丙二醋)之聚 醋雙組分纖維,及其中在織物之表面上,第一紗係設置 於第二紗外側。 2. 如申請專利範圍第!項之織物,其中該針紋係經編針織構 造,該雙組分纖維呈現展開捲曲,且具有選自由並排及 偏心皮芯所組成之群之形態’及其中該第一紗之針紋呈 現一至七個針距(needle spaces)的下露(underlap)。 3. 如申研專利乾圍第2項之織物,其具有丨〇%至5〇%之橫向 拉伸及0至10%之縱向拉伸。 4 ·如申呀專利範圍第2項之織物,其中該第一紗之針紋呈現 選自由1-0/4-5、1-0/5-6、1-0/6-7及1-0/7-8所組成之群之 繞線(lap),及該第二紗包括含選自由聚(對苯二曱酸乙二 酯)、聚(對苯二甲酸丙二酯)、聚(對苯二甲酸丁二酯)、聚 (己一醯己二胺)、聚己内醯胺、及其共聚物所組成之群之 聚合物之單組分纖維紗,及該第二紗之針紋呈現複數個 針距的下露。 5.如申請專利範圍第2項之織物,其具有18至22牛頓之橫向 撕裂強度、40至50%之橫向拉伸、及〇至7%之縱向拉伸, 其中該不織網片包括聚(對笨二曱酸乙二酯)之纖維,該縫 編不織物具有至150克/平方米之基重量,及該第二紗之 針紋呈現選自由1-2/1-0、1-〇/〇-1、2-3/1-0及3-4/1-〇所組 91534-1000407.doc '成之群之繞線。 6. -種製造縫編非織造織物之方法,其包括下列步驟: a) 提供具有第-給紗棒(guide㈣及第二給紗棒之經編 針織機器、前身非織織物網片、包括具選自由並排及偏 心皮芯所組成之群之截面形態且包含聚(對苯二甲酸乙二 S曰)及聚(對苯二曱酸丙二酯)之聚酯雙組分纖維之第一 紗、及第二紗; b) 將第一紗供給通過第一給紗棒; c) 將第二紗供給通過第二給紗棒; d) 將前身網片供給至針織機器,以致於針織之後,其係 在針織針紋的沈圈及針圈之間;及 e) 經由使第一給紗棒及第二給紗棒各於複數個針距上 在復搖擺’而將第一紗及第二紗針織通過前身網片。 如申明專利範圍第6項之方法,其進一步包括步驟f)將該 缝編非織織物在足以使聚酯雙組分纖維中之棬曲展開之 溫度下加熱足夠時間。 8’如申印專利範圍第7項之方法,其令該第一給紗棒係為前 方、’ π、’·/棒,5亥第一給紗棒係為後方給紗棒,及使該第一 給紗棒於三至七個針距上往復搖擺。 9.如申請專利範圍第6項之方法,其令該第一給紗棒針織選 自由1-0/4-5、1-0/5.6、卜〇/6_7、及N〇/7_8所組成之群之 繞線’該第二給紗棒針織選自由卜2/1_〇、1〇/〇_卜2_3/1·〇 及3-4/1-0所組成之群之繞線,及該第二紗包括選自由聚 (對苯二甲酸乙二酯)、聚(對苯二甲酸丙二酯)、聚丙烯、 91534-1000407.doc S -2 - 1345005 聚L己二醯己二胺)、聚己内醯胺、及其共聚物所組成之 之車組分纖維。 !〇. -種人工皮革’其包括利用如申請專利範圍第8 製得之如申請專利範圍第3項 物塗層。 ㈣且進步包含聚合 11. 一種製造物件, 、匕括如中請專㈣ϋ第2項之織物0 91534-1000407.doc
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| AU3004400A (en) * | 1999-02-22 | 2000-09-14 | Tietex International, Ltd. | Stitchbonded upholstery fabric and process for making same |
| JP3704536B2 (ja) | 1999-03-11 | 2005-10-12 | 帝人ファイバー株式会社 | 潜在捲縮性ポリエステル複合繊維 |
| JP2000336581A (ja) | 1999-05-28 | 2000-12-05 | Toray Ind Inc | 伸縮性皮革様物 |
| US6593256B1 (en) * | 2000-03-29 | 2003-07-15 | Tietex International, Ltd | Fluid containment textile and incontinence pad formed therefrom |
| EP1403411B1 (en) | 2001-07-04 | 2008-02-27 | Asahi Kasei Fibers Corporation | Warp knitted fabric |
| CN1273659C (zh) * | 2001-09-18 | 2006-09-06 | 旭化成纤维株式会社 | 聚酯系复合纤维纬纱管及其制造方法 |
| JP4079884B2 (ja) * | 2001-11-06 | 2008-04-23 | 旭化成せんい株式会社 | ポリエステル系複合繊維パッケージ |
| US7201816B2 (en) | 2001-12-21 | 2007-04-10 | Invista North America S.A.R.L. | High bulk composite sheets and method for preparing |
| US6855392B2 (en) * | 2002-12-12 | 2005-02-15 | Tietex International, Ltd. | Patterned stitch bonded pile fabric |
| US7186451B2 (en) * | 2003-03-31 | 2007-03-06 | Xymid, Llc | Composite sheet suitable for use as artificial leather |
-
2003
- 2003-02-24 JP JP2003045307A patent/JP2004256923A/ja active Pending
-
2004
- 2004-02-20 BR BRPI0408037-8A patent/BRPI0408037B1/pt not_active IP Right Cessation
- 2004-02-20 US US10/546,351 patent/US8685521B2/en not_active Expired - Fee Related
- 2004-02-20 EP EP04713449.9A patent/EP1597419B1/en not_active Expired - Lifetime
- 2004-02-20 WO PCT/US2004/005322 patent/WO2004076733A1/en not_active Ceased
- 2004-02-20 CN CN2004800109352A patent/CN1777713B/zh not_active Expired - Fee Related
- 2004-02-20 KR KR1020057015541A patent/KR101092190B1/ko not_active Expired - Fee Related
- 2004-02-24 TW TW93104636A patent/TWI345005B/zh not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| EP1597419B1 (en) | 2013-04-24 |
| CN1777713B (zh) | 2010-06-02 |
| CN1777713A (zh) | 2006-05-24 |
| EP1597419A1 (en) | 2005-11-23 |
| US8685521B2 (en) | 2014-04-01 |
| TW200420775A (en) | 2004-10-16 |
| US20070015427A1 (en) | 2007-01-18 |
| BRPI0408037A (pt) | 2006-02-14 |
| WO2004076733A1 (en) | 2004-09-10 |
| JP2004256923A (ja) | 2004-09-16 |
| BRPI0408037B1 (pt) | 2015-05-12 |
| KR20050107444A (ko) | 2005-11-11 |
| KR101092190B1 (ko) | 2011-12-13 |
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| MM4A | Annulment or lapse of patent due to non-payment of fees |