US20220316102A1

US20220316102A1 - Composite yarn, fabric, and fiber product

Info

Publication number: US20220316102A1
Application number: US17/608,792
Authority: US
Inventors: Sonomi SHIBATA; Nobuaki Ogata
Original assignee: Teijin Frontier Co Ltd
Current assignee: Teijin Frontier Co Ltd
Priority date: 2019-05-31
Filing date: 2020-05-18
Publication date: 2022-10-06
Also published as: EP3978663B1; KR102817484B1; KR20220015455A; JPWO2020241353A1; WO2020241353A1; CN113874563A; EP3978663A4; CA3139640A1; EP3978663A1; JP7284257B2; TWI871324B; TW202113179A

Abstract

A problem of the present invention is to provide a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties. The solution is to obtain a composite yarn using a thick and thin yarn and a crimped yarn and to obtain a fabric, if desired.

Description

TECHNICAL FIELD

The present invention relates to a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties.

BACKGROUND ART

Polyester filament fibers typified by polyethylene terephthalate (PET) are widely used for clothing, industrial materials, and the like. However, due to characteristics of a manufacturing method thereof, they involve such defects that as compared with natural fibers and spun yarns, the thickness unevenness is small, and the texture and the appearance change are poor.
In order to eliminate such defects, there is proposed a method for imparting thickness unevenness to a polyester fiber by controlling the length of an unstretched portion of a highly oriented polyester unstretched yarn, thereby imparting an arbitrary splashed pattern-like appearance to the fabric (see, for example, Patent Literature 1 and Patent Literature 2).
However, it could not be said that such a fabric is satisfactory in terms of cotton-like appearance, snagging resistance, and so on.

CITATION LIST

Patent Literature

Patent Literature 1: JP 60-199941 A
Patent Literature 2: JP 7-229030 A

SUMMARY OF INVENTION

Technical Problem

In view of the aforementioned background, the present invention has been made, and an object thereof is to provide a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties.

Solution to Problem

In order to achieve the aforementioned problem, the present inventors made extensive and intensive investigations, and as a result, they have led to accomplishment of the present invention.
Thus, in accordance with the present invention, a “composite yarn containing a thick and thin yarn and a crimped yarn” is provided.
On that occasion, it is preferred that the aforementioned thick and thin yarn is a non-crimped yarn.
In addition, it is preferred that the composite yarn contains the aforementioned thick and thin yarn in a ratio within a range of 30 to 852 by weight relative to the weight of the composite yarn. In addition, it is preferred that the composite yarn is interlaced such that an interlace number is 120 or less per meter. In addition, in the composite yarn, it is preferred that the thick and thin yarn and the crimped yarn are interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state. In addition, in the composite yarn, it is preferred that the non-aligned part is 40 to 95′ relative to the length of the composite yarn. In addition, in the composite yarn, it is preferred that the aligned part is 5 to 40% relative to the length of the composite yarn. In addition, it is preferred that a single fiber fineness of the thick and thin yarn is 1.5 dtex or more. In addition, it is preferred that a single fiber fineness of the crimped yarn is 1.0 dtex or less. In addition, it is preferred that the thick and thin yarn and/or the crimped yarn is made of a polyester fiber or a nylon fiber. In addition, it is preferred that the thick and thin yarn and/or the crimped yarn is made of a chemical or material recycled polymer. In addition, it is preferred that the thick and thin yarn and/or the crimped yarn is made of a cationic dyeable polyester. In addition, it is preferred that in the thick and thin yarn and/or the crimped yarn, the content of a matting agent is 0.1% by mass or more.
In accordance with the present invention, a fabric containing the aforementioned composite yarn is provided. On that occasion, it is preferred that the fabric is a knitted fabric having a density of 35 to 100 courses/2.54 cm and 30 to 100 wales/2.54 cm. In addition, it is preferred that a snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.
In addition, in accordance with the present invention, a fiber product made of the aforementioned composite yarn or fabric, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding, is provided.

Advantageous Effects of Invention

In accordance with the present invention, a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties are obtained.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present invention are hereunder described in detail. First, the composite yarn of the present invention is a composite yarn containing a thick and thin yarn and a crimped yarn.
Here, it is preferred that the composite yarn contains the thick and thin yarn in a ratio within a range of 30 to 85% by weight (more preferably 51 to 80% by weight) relative to the weight of the composite yarn. In addition, it is preferred that a weight ratio of the crimped yarn (relative to the weight of the composite yarn) is within a range of 15 to 70% by weight (more preferably 30 to 48% by weight). In the case where the weight ratio of the thick and thin yarn (relative to the weight of the composite yarn) is smaller than the foregoing range, there is a concern that the excellent cotton-like appearance is not obtained. In addition, in the case where the weight ratio of the thick and thin yarn is larger than the foregoing range, there is a concern that the snagging resistance of the fabric is lowered.
Here, though the thick and thin yarn may be a crimped yarn, it is preferably a non-crimped yarn. When the thick and thin yarn is a non-crimped yarn, in view of the fact that a difference in crimp between the thick and thin yarn and the crimped yarn is large, the thickness unevenness in the composite yarn becomes large, and excellent cotton-like appearance and texture are developed. In addition, in the case where the non-crimped yarn is disposed in a core of the composite yarn, and the crimped yarn is disposed in a sheath of the composite yarn, the water absorbing and quick drying properties are improved due to capillary phenomenon.
Examples of the thick and thin yarn include a thick and thin yarn having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers as described in JP 2000-234232 A; and a thick and thin yarn obtained by non-homogeneous stretching using a frictional resistor as described in JP 7-324237 A.
On the other hand, though the crimped yarn may be a crimped yarn in which latent crimp of side-by-side type conjugate fiber is visualized, it is preferably a false-twist crimped textured yarn.
The type of the polymer forming the thick and thin yarn and/or the crimped yarn is preferably a polyester or an aliphatic polyamide (e.g., nylon 6 and nylon 66). Above all, there are more preferably exemplified polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polylactic acid, and a polyester resulting from copolymerization with a third component. Such a polyester may also be a material recycled or chemical recycled polyester. Furthermore, the polyester may also be a polyester obtained by using a catalyst containing specified phosphorus compound and titanium compound as described in JP 2004-270097 A and JP 2004-211268 A. If desired, the polyester polymer may contain therein one or more of a micropore forming agent, a cationic dye dyeable agent, a coloring inhibitor, a thermal stabilizer, a fluorescent brightening agent, a matting agent, a coloring agent, a moisture absorbent, and inorganic fine particles within a range where the object of the present invention is not hindered. In particular, when the matting agent is contained in a ratio of 0.1, by weight or more (more preferably 0.3 to 2.0V by weight) relative to the weight of the polymer, the see-through-preventing properties are improved, and hence, such is preferred. Specifically, a semi dull polyester and a full dull polyester are preferred. In addition, when the cationic dye dyeable agent (e.g., a polyester-forming sulfonic acid metal salt compound is contained), antibacterial and deodorization properties are added by performing an acid treatment as described in WO 2011/048888 A, and hence, such is preferred.
In the thick and thin yarn, a total fineness thereof is preferably 22 to 400 dtex (more preferably 30 to 60 dtex). In addition, a single fiber fineness of the thick and thin yarn is preferably 1.5 dtex or more (more preferably 1.5 to 3.0 dtex). In addition, a filament number of the thick and thin yarn is preferably 12 to 200 (more preferably 20 to 60).
In the crimped yarn, from the standpoint of obtaining the excellent cotton-like appearance and snagging resistance, a total fineness thereof is preferably smaller than that of the thick and thin yarn. In particular, the total fineness of the crimped yarn is preferably 18 to 333 dtex (more preferably 20 to 50 dtex). In addition, a single fiber fineness of the crimped yarn is preferably 1.0 dtex or less (more preferably 0.1 to 1.0 dtex). In addition, a filament number of the crimped yarn is preferably 12 to 200 (more preferably 20 to 60). In addition, a crimp degree of the crimped yarn is preferably within a range of 2 to 40% (more preferably 5 to 35%).
Although the composite yarn of the present invention is preferably constituted of only the thick and thin yarn and the crimped yarn, it may contain other fibers. In addition, although the composite method is not particularly limited, it is preferred that the thick and thin yarn and the crimped yarn are aligned and interlaced (air-mixed).
On that occasion, an interlace number is preferably within a range of 200 or less per meter (more preferably 120 or less per meter, and especially preferably 20 to 120 per meter).
In the composite yarn, it is preferred that the thick and thin yarn and the crimped yarn are interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state. Such a composite yarn is, for example, obtained by obtaining a thick and thin yarn having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers according to the method as described in Example 1 of JP 2000-234232 A, followed by aligning the thick and thin yarn and the crimped yarn and interlacing.
Here, in the composite yarn, it is preferred that the non-aligned part is 40 to 95% relative to the length of the composite yarn. In addition, in the composite yarn, it is preferred that the aligned part is 5 to 40, relative to the length of the composite yarn. However, it is to be noted that each of those ratios is one obtained by extracting 10 composite yarns (20 cm) from the fabric, calculating each of the ratios relative to the composite yarn (20 cm), and then determining an average of the 10 yarns.
The fabric of the present invention contains the aforementioned composite yarn. In such a fabric, the structure of the fabric is not limited, and may be one obtained by knitting and weaving by a usual method.
Examples of the weave structure include three foundation weaves, such as plain weave, twill weave, and satin woven fabric; modified weaves; modified weaves, such as modified twill weave; one-side backed weaves, such as warp-backed weave and weft-backed weave; and warp velvet. In addition, examples of the knitted fabric include jersey stitch and half textures, half-base textures, or satin textures obtained using 2 reeds or 3 reeds. In particular, a knitted fabric having a density of 35 to 100 courses/2.54 cm and 30 to 100 wales/2.54 cm is preferred from the standpoint of water absorbing and quick drying properties.
A basis weight of the fabric is preferably within a range of 70 to 130 g/m².
To such a fabric, dyeing, water absorption, embossing, coloring and printing, and water repellent finishing, and various processings imparting functions of a UV shielding agent, an antibacterial agent, a deodorant, an insect repellent, a luminous agent, a retroreflector, and a minus ion generating agent, may be additionally applied.
The thus obtained fabric has excellent cotton-like appearance, excellent texture, excellent texture, snagging resistance, see-through-preventing properties, and water absorbing and quick drying properties. On that occasion, it is preferred that the snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.
Next, the fiber product of the present invention is a fiber product made of the aforementioned fabric, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding.
Since such a fiber product uses the aforementioned fabric, it is excellent in cotton-like appearance, snagging resistance, see-through-preventing properties, and water absorbing and quick drying properties.

EXAMPLES

Next, the present invention is described in detail by reference to Examples, but it should be construed that the present invention is by no means limited by these Examples.

(1) Basis Weight

The basis weight (g/m²) of a woven fabric was measured by JIS L1096-2010.

(2) Snagging Resistance

The test was performed for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method.

(3) Crimp Degree

The crimp degree was measured by the following method.
That is, a test filament thread is wound around a sizing reel having a peripheral length of 1.125 m to prepare a skein having a dry fineness of 3333 dtex.
The skein is hung on a hanger nail of a scale plate. An initial load of 6 g is applied to the lower part thereof, and a further load of 600 g is applied; and the skein length at that time is measured as L0. The load is then immediately removed from the skein, and the skein is removed from the hanger nail of the scale plate and immersed in boiling water for 30 minutes, thereby allowing crimps to be developed. The skein treated with boiling water is taken out from boiling water, and moisture contained in the skein is removed by absorption on a filter paper. The skein is then air-dried for 24 hours at room temperature. The air-dried skein is hung on a hanger nail of a scale plate. A load of 600 g is applied to the lower part thereof, and the skein length is measured after 1 minute as L1a. The load is then removed from the skein, and the skein length is measured after 1 minute as L2a. The crimp degree (CP) of the test filament thread is calculated according to the following equation.
CP(%)=(L1a−L2a)/L0)×100

(4) Degree of Interlace

An interlaced yarn is taken by a length of 1 m under a load of 8.82 mN×(nominal tex) (0.1 g/de), and after removing the load, the yarn is allowed to contract at room temperature for 24 hours, followed by reading the number of nodes, a value of which is indicated in terms of nodes/m.

(5) Ratios of Non-Aligned Part and Aligned Part in Composite Yarn

Ten composite yarns (20 cm) were extracted from the fabric, each of the ratios relative to the composite yarn (20 cm) was calculated, and an average of the 10 yarns was determined.

(6) Spun-Like Appearance

The spun-like appearance was evaluated according to criteria of three stages of “∘” (excellent), “Δ” (moderate), and “x” (inferior) by visual judgment by the tester.

Examples 1 to 5 and Comparative Examples 1 to 2

Non-crimped thick and thin yarns as shown in Table 1 each having thickness unevenness similar to a spun yarn and also having random thickness unevenness between single fibers were obtained according to the method described in Example 1 of JP 2000-234232 A. In addition, in Examples 1 to 5, the false-twist crimped textured yarn shown in Table 1 was obtained by a conventional method. In Table 1, “FD” indicates a chemical recycled full dull polyester; “SD” indicates a chemical recycled semi dull polyester; and “CD” indicates a chemical recycled cationic dyeable polyester. In addition, for example, the term “44T36” means one having a total fineness of 44 dtex and a filament number of 36.
Subsequently, in Examples 1 to 5, the thick and thin yarn and the false-twist crimped textured yarn were aligned and interlaced, thereby obtaining a composite yarn in which the thick and thin yarn and the crimped yarn were interlaced with each other, or in which a non-aligned part where the thick and thin yarn was located in a core and the crimped yarn was located in a sheath was intermingled with an aligned part where the thick and thin yarn and the crimped yarn were in an aligned state. Subsequently, knitted fabrics were obtained using a circular knitting machine as shown in Table 1.
In Example 1, the non-aligned part was 74%, and the aligned part was 26%. The evaluation results of Examples 1 to 5 and Comparative Examples 1 to 2 are shown in Table 1.

TABLE 1

			Comparative	Comparative
Example 1	Example 2	Example 3	Example 1	Example 2	Example 4	Example 5

Yarn

Thick and thin yarn

FD44T36

FD110T36

FD66T72

FD33T36

	False-twist crimped	Yarn type	FD33T36	SD33T72	CD33T36	—	—	FD44T36	FD33T36
	textured yarn	Crimp degree (%)	26	6	15	—	—	25	40

	IL number (per meter)	100	98	98	—	—	110	123
	Total fineness	77T72	77T108	77T72	110T36	66T72	FD77T72	FD77T72
Knitted	Type of knitting machine (gauge)	46 G single	46 G single	28 G single	28 G	28 G	46 G	46 G
fabric	Structure	Jersey stitch	Jersey stitch	Jersey stitch	Jersey stitch	Jersey stitch	Jersey stitch	Jersey stitch
	Basis weight (g/m²)	115	113	89	115	105	110	110
	Course (per 2.54 cm)	82	75	64	55	90	79	79
	Wale (per 2.54 cm)	66	72	54	45	73	70	70
	Snagging (D-3 Method, grade)	4.5	4.5	4.5	1	1	4.5	4.5
	Spun-like appearance	∘	∘	∘	x	x	Δ	Δ

INDUSTRIAL APPLICABILITY

In accordance with the present invention, a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties are provided, and an industrial value thereof is extremely large.

Claims

1. A composite yarn comprising a thick and thin yarn and a crimped yarn.

2. The composite yarn according to claim 1, wherein the thick and thin yarn is a non-crimped yarn.

3. The composite yarn according to claim 1, wherein the composite yarn contains the thick and thin yarn in a ratio within a range of 30 to 85% by weight relative to the weight of the composite yarn.

4. The composite yarn according to claim 1, wherein the composite yarn is interlaced such that an interlace number is 120 or less per meter.

5. The composite yarn according to claim 1, wherein in the composite yarn, the thick and thin yarn and the crimped yarn are interlaced with each other; or a non-aligned part in which the thick and thin yarn is located in a core, and the crimped yarn is located in a sheath is intermingled with an aligned part in which the thick and thin yarn and the crimped yarn are in an aligned state.

6. The composite yarn according to claim 5, wherein in the composite yarn, the non-aligned part is 40 to 95% relative to the length of the composite yarn.

7. The composite yarn according to claim 5, wherein in the composite yarn, the aligned part is 5 to 40% relative to the length of the composite yarn.

8. The composite yarn according to claim 1, wherein a single fiber fineness of the thick and thin yarn is 1.0 dtex or more.

9. The composite yarn according to claim 1, wherein a single fiber fineness of the crimped yarn is 1.5 dtex or less.

10. The composite yarn according to claim 1, wherein the thick and thin yarn and/or the crimped yarn is made of a polyester fiber or a nylon fiber.

11. The composite yarn according to claim 1, wherein the thick and thin yarn and/or the crimped yarn is made of a chemical or material recycled polymer.

12. The composite yarn according to claim 1, wherein the thick and thin yarn and/or the crimped yarn is made of a cationic dyeable polyester.

13. The composite yarn according to claim 1, wherein in the thick and thin yarn and/or the crimped yarn, the content of a matting agent is 0.1% by mass or more.

14. A fabric comprising the composite yarn according to claim 1.

15. The fabric according to claim 14, wherein the fabric is a knitted fabric having a density of 35 to 100 courses/2.54 cm and 30 to 100 wales/2.54 cm.

16. The fabric according to claim 1, wherein a snagging resistance as tested for 15 hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.

17. A fiber product made of the composite yarn according to claim 1, which is any one selected from the group consisting of sportswear, outerwear, innerwear, men's clothing, women's clothing, nursing clothing, work clothing, car seat skin material, and bedding.

18. The composite yarn according to claim 2, wherein the composite yarn contains the thick and thin yarn in a ratio within a range of 30 to 85% by weight relative to the weight of the composite yarn.