CA 03177860 2022-09-28
DESCRIPTION
Title of the Invention: WATER-REPELLING FABRIC, AND TEXTILE
PRODUCT
Technical Field
[0001]
The present invention relates to a water-repellent cloth
that is excellent in water repellency as well as stretchability,
and also to a textile product using the water-repellent cloth.
Background Art
[0002]
Conventionally, cloths having water repellency have been
demanded in the fields of sportswear, casual clothing, umbrella
fabrics, and the like, and water repellents such as fluorine-
based water repellents have been attached to cloths (see, e.g.,
PTL 1 and PTL 2).
[0003]
In addition, in recent years, in order to be
environmentally friendly, cloths using a fluorine-free water
repellent without using a compound that may affect living
organisms (e.g., perfluorooctanoic acid, perfluorooctane
sulfonate, etc.) have been proposed (see, e.g., PTL3).
1
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
[0004]
However, these cloths have been problematic in that they
are not sufficient in terms of stretchability.
Citation List
Patent Literature
[0005]
[PTL 1] JP-A-60-94645
[PTL 2] JP-A-61-70043
[PTL 3] JP-A-2017-145521
Summary of Invention
[0006]
The invention has been accomplished against the above
background. An object thereof is to provide a water-repellent
cloth that is excellent in water repellency as well as
stretchability, and also a textile product using the water-
repellent cloth.
Solution to Problem
[0007]
The present inventors have conducted extensive research
to solve the above problems and, as a result, found that in a
water-repellent cloth given water repellent processing, by
skillfully devising fibers that constitute the cloth, etc., a
water-repellent cloth that is excellent in water repellency as
2
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
well as stretchability can be obtained. As a result of further
extensive research, they have accomplished the invention.
[0008]
Thus, the invention provides "a water-repellent cloth
given water repellent processing, the water-repellent cloth
being characterized in that the cloth includes a composite yarn
containing a stretch fiber and an ultrafine fiber having a
single fiber fineness of 1 dtex or less."
[0009]
At this time, it is preferable that the stretch fiber is
a conjugate fiber made of two components joined in a side-by-
side manner or an eccentric sheath-core manner or is a
polytrimethylene terephthalate fiber. In
addition, it is
preferable that the cloth is a woven fabric having a cover
factor CF of 1,000 or more. Note that the cover factor CF is
defined by the following formula.
CF = (DWp/1.1)1/2 x MWp + (DWf/1.1)1/2 x MWf
[DWp is the warp total fineness (dtex), MWp is the warp
weaving density (yarns/2.54 cm), DWf is the weft total fineness
(dtex), and MWf is the weft weaving density (yarns/2.54 cm).]
In the water-repellent cloth of the invention, it is
preferable that a surface of the cloth has formed thereon fine
3
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
fiber loops composed of the ultrafine fiber. In addition, it
is preferable that a surface of the cloth has a water-repellent
roll-off angle of 15 or less. In addition, it is preferable
that the degree of water repellency measured in accordance with
JIS L1092-2009 7.2, Test for Resistance to Surface Wetting
(Spray Method), is Level 4 or higher. In
addition, it is
preferable that after 10 washes as specified in JIS L0217-1995
(using the JAFET standard combination detergent), the degree of
water repellency measured in accordance with JIS L1092-2009 7.2,
Test for Resistance to Surface Wetting (Spray Method), is Level
3 or higher. In
addition, it is preferable that the
stretchability in the warp direction or the weft direction
measured in accordance with JIS L1096-2010 8.16, B Method, is
10% or more. In addition, it is preferable that the recovery
of stretchability in the warp direction or the weft direction
measured in accordance with JIS L1096-2010 8.16, B-1 Method, is
85% or more. In
addition, it is preferable that the tear
strength in the warp direction or the weft direction measured
in accordance with JIS L1096-2010 8.17, D Method, is 7 N or
more.
[0010]
In addition, the invention provides a textile product
using the water-repellent cloth described above.
4
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
Advantageous Effects of Invention
[0011]
According to the invention, a water-repellent cloth that
is excellent in water repellency as well as stretchability and
also a textile product using the water-repellent cloth are
obtained.
Description of Embodiments
[0012]
Hereinafter, embodiments of the invention will be
described in detail. The water-repellent cloth of the invention
is a water-repellent cloth given water repellent processing.
The cloth includes a composite yarn, and the composite yarn
contains an ultrafine fiber having a single fiber fineness of 1
dtex or less (more preferably 0.00002 to 0.8 dtex, and
particularly preferably 0.001 to 0.5 dtex) and a stretch fiber.
Because of such a configuration, fine fiber loops composed of
the ultrafine fiber are formed on the cloth surface, whereby
lotus leaf-like fine irregularities are formed on the cloth
surface, resulting in excellent water repellency. In addition,
at the same time, due to the effect of the stretch fiber, the
cloth is also excellent in stretchability.
Here, when the
single fiber fineness of the ultrafine fiber is more than 1
dtex, fine fiber loops are not formed; therefore, this is
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
undesirable. In addition, for the formation of fine fiber loops,
it is preferable that the ultrafine fiber is a non-crimped fiber.
For example, when the ultrafine fiber is a false-twist crimped
yarn, fine fiber loops may not be formed.
[0013]
As the ultrafine fiber, polyester fibers, acrylic fibers,
nylon fibers, rayon fibers, and acetate fibers, as well as
natural fibers such as cotton, wool, silk, and the like and
combinations thereof, are usable.
Polyester fibers include
conjugate fibers containing at least one polyester component.
At this time, examples of conjugate fibers include side-by-side
conjugate fibers, eccentric sheath-core conjugate fibers,
sheath-core conjugate fibers, and islands-in-sea conjugate
fibers. In addition, nylon fibers include Nylon 6 fibers and
Nylon 66 fibers.
[0014]
As polyester fiber-forming polyesters, polyesters in
which the main acid component is terephthalic acid, and the main
glycol component is at least one member selected from the group
consisting of 02-6 alkylene glycols, that is, ethylene glycol,
trimethylene glycol, tetramethylene glycol, pentamethylene
glycol, and hexamethylene glycol, are preferable. Among them,
a polyester whose main glycol component is ethylene glycol
6
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
(polyethylene terephthalate) and a polyester whose main glycol
component is trimethylene glycol (polytrimethylene
terephthalate) are particularly preferable.
[0015]
Such a polyester may have a copolymerized component in a
small amount (usually 30 mol % or less) as necessary. At this
time, as bifunctional carboxylic acids used other than
terephthalic acid, for example, aromatic, aliphatic, and
alicyclic bifunctional carboxylic acids such as isophthalic acid,
naphthalenedicarboxylic acid, diphenyldicarboxylic acid,
diphenoxyethanedicarboxylic acid, D-hydroxyethoxybenzoic acid,
p-oxybenzoic acid, 5-sodium sulfoisophthalic acid, adipic acid,
sebacic acid, and 1,4-cyclohexanedicarboxylic acid can be
mentioned. In addition, as diol compounds other than the above
glycols, for example, aliphatic, alicyclic, and aromatic diol
compounds such as cyclohexane-1,4-dimethanol, neopentyl glycol,
bisphenol A, and bisphenol S, polyoxyalkylene glycols, and the
like can be mentioned.
[0016]
The polyester may be synthesized by an arbitrary method.
For example, in the case of polyethylene terephthalate, its
production is possible through a first-stage reaction in which
terephthalic acid and ethylene glycol are directly subjected to
7
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
an esterification reaction, a lower alkyl ester of terephthalic
acid, such as dimethyl terephthalate, and ethylene glycol are
subjected to a transesterification reaction, or terephthalic
acid and ethylene oxide are allowed to react, thereby producing
a glycol ester of terephthalic acid and/or an oligomer thereof,
and a second-stage reaction in which the product of the first-
stage reaction is heated under reduced pressure to cause a
polycondensation reaction until the desired degree of
polymerization is reached. In addition, the polyester may also
be a material-recycled or chemically recycled polyester, or
alternatively a polyester obtained using a catalyst containing
a specific phosphorus compound or titanium compound as described
in JP-A-2004-270097 or JP-A-2004-211268.
Further, a
biodegradable polyester such as polylactic acid or stereocomplex
polylactic acid is also possible.
[0017]
In addition, when the ultrafine fiber contains a UV
absorber in an amount of 0.1 wt% or more (preferably 0.1 to 5.0
wt%) based on the fiber weight, the cloth is provided with UV-
shielding properties; therefore, this is preferable. Examples
of such UV absorbers include benzoxazine-based organic UV
absorbers, benzophenone-based organic UV
absorbers,
benzotriazole-based organic UV absorbers, and salicylic-acid-
8
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
based organic UV absorbers.
Among them, benzoxazine-based
organic UV absorbers are particularly preferable in that they
do not decompose at the spinning stage.
[0018]
Preferred examples of such benzoxazine-based organic UV
absorbers include those disclosed in JP-A-62-11744, such as 2-
methy1-3,1-benzoxazin-4-one, 2-butyl-3,1-benzoxazin-4-one, 2-
pheny1-3,1-benzoxazin-4-one, 2,2'-ethylenebis(3,1-benzoxazin-
4-one), 2,2'-tetramethylenebis(3,1-benzoxazin-4-one), 2,2'-p-
phenylenebis(3,1-benzoxazin-4-one),
1,3,5-tri(3,1-benzoxazin-
4-on-2-yl)benzene, and
1,3,5-tri(3,1-benzoxazin-4-on-2-
yl)naphthalene.
[0019]
In addition, when the ultrafine fiber contains a
delusterant (titanium dioxide) in an amount of 1 wt% or more
(preferably 0.2 to 4.0 wt%) based on the fiber weight, the cloth
has improved anti-see-through properties; therefore, this is
preferable.
[0020]
Further, as necessary, the ultrafine fiber may also
contain one or more kinds of micropore-forming agents (organic
metal sulfonates), coloring inhibitors, heat stabilizers, flame
retardants (diantimony trioxide), fluorescent brighteners,
9
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
coloring pigments, antistatic agents (metal sulfonates),
moisture absorbents (polyoxyalkylene glycols), antibacterial
agents, and other inorganic particles.
[0021]
Meanwhile, as the stretch fiber, a fiber composed of one
polytrimethylene terephthalate component, a conjugate fiber
made of two components joined in a side-by-side manner or an
eccentric sheath-core manner, an elastic fiber (polyurethane-
based fiber, polyether ester-based fiber, moisture-absorbing
elastomer fiber, etc.), an undrawn polyester fiber, a false-
twist crimped yarn, or the like is preferable.
[0022]
Here, the conjugate fiber is preferably a conjugate fiber
in which at least one component is composed of polytrimethylene
terephthalate, polybutylene terephthalate, or polyethylene
terephthalate. Specifically, examples of such two components
include polytrimethylene terephthalate and polytrimethylene
terephthalate, polytrimethylene terephthalate and polyethylene
terephthalate, polyethylene terephthalate and polyethylene
terephthalate, and polyethylene terephthalate and polybutylene
terephthalate.
[0023]
Here, polytrimethylene terephthalate refers to a fiber
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
made of a polyester whose main repeating unit is a trimethylene
terephthalate unit, in which the trimethylene terephthalate unit
is 50 mol% or more, preferably 70 mol% or more, still more
preferably 80 mol% or more, and particularly preferably 90 mol%
or more. Therefore, polytrimethylene terephthalate containing
another acid component and/or another glycol component as a
third component in a total amount within a range of 50 mol% or
less, preferably 30 mol% or less, still more preferably 20 mol%
or less, and particularly preferably 10 mol% or less, is
contained.
[0024]
Polytrimethylene terephthalate is produced by condensing
terephthalic acid or a functional derivative thereof and
trimethylene glycol or a functional derivative thereof in the
presence of a catalyst under appropriate reaction conditions.
[0025]
As third components to be added, aliphatic dicarboxylic
acids (oxalic acid, adipic acid, etc.), alicyclic dicarboxylic
acids (cyclohexanedicarboxylic acid, etc.),
aromatic
dicarboxylic acids (isophthalic acid, sodium sulfoisophthalic
acid, etc.), aliphatic glycols (ethylene glycol, 1,2-
trimethylene glycol, tetramethylene glycol, etc.), alicyclic
11
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
glycols (cyclohexane glycol, etc.), aromatic dioxy compounds
(hydroquinone bisphenol A, etc.), aromatic-containing aliphatic
glycols (1,4-bis(D-hydroxyethoxy)benzene, etc.), aliphatic
oxycarboxylic acids (p-oxybenzoic acid, etc.), and the like can
be mentioned.
[0026]
The polyethylene terephthalate may be obtained by the
copolymerization of three components or may also be obtained by
material recycling or chemical recycling. Further, it may also
be obtained using a catalyst containing a specific phosphorus
compound or titanium compound as described in JP-A-2004-270097
or JP-A-2004-211268.
[0027]
The polytrimethylene terephthalate, polyethylene
terephthalate, polybutylene terephthalate, and the like
described above may contain one or more kinds of micropore-
forming agents, cationic dye dyeable agents, coloring inhibitors,
heat stabilizers, fluorescent brighteners, delusterants,
colorants, moisture absorbents, and inorganic fine particles.
[0028]
The conjugate fiber can be produced, for example, by the
method described in JP-A-2009-46800.
12
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
[0029]
In the stretch fiber, the single fiber fineness is not
particularly limited, but is preferably within a range of
0.00002 to 5.0 dtex (more preferably 0.1 to 3.0 dtex, and
particularly preferably 1.1 to 2.5 dtex).
[0030]
In addition, in the ultrafine fiber and/or the stretch
fiber, as the single-fiber cross-sectional shape, in addition
to a round cross-section, the cross-section may also be
elliptical, triangular, quadrangular, cross-shaped, flat, flat
with constrictions, H-shaped, W-shaped, or the like, for example.
[0031]
The water-repellent cloth of the invention includes a
composite yarn containing the ultrafine fiber and the stretch
fiber. At this time, the method for producing the composite
yarn is not particularly limited. For example, it is possible
that the ultrafine fiber, the stretch fiber, and other fibers
as necessary are aligned, and then air-mingled by air-texturing
(interlacing processing or Taslan processing) or composite
false-twisted.
The air-mingling method is particularly
preferable.
[0032]
At this time, the composite yarn is preferably an
13
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
entangled yarn that has been subjected to interlacing processing
to have 1 to 150 entanglements/m.
[0033]
In addition, when the three kinds of fibers are combined,
the overfeed rate may be suitably changed. In addition, it is
also possible that two kinds of fibers are first combined, and
then the other yarn is combined in the subsequent step.
[0034]
In the composite yarn, the total fineness is preferably
within a range of 40 to 180 dtex.
[0035]
The cloth of the invention includes the composite yarn.
At this time, the composite yarn is preferably contained in an
amount of 30 wt% or more (most preferably 100 wt%) based on the
cloth weight.
[0036]
In the cloth of the invention, the structure of the cloth
is not particularly limited, but a woven fabric is preferable
in order to obtain excellent water repellency. At this time,
the structure of the woven fabric is not particularly limited.
For example, examples thereof include three foundation weaves
such as a plain weave, a twill weave, and a satin weave, modified
weaves, one-side backed weaves such as a warp-backed weave and
14
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
a weft-backed weave, and warp velvet. Also with respect to the
number of layers, the structure may be monolayer or multilayer
including two or more layers.
[0037]
In addition, when the cover factor CF of the woven fabric
defined by the following formula is 1,000 or more (preferably
1,500 to 4,000, and particularly preferably 2,300 to 3,500),
even better water repellency can be obtained; therefore, this
is preferable.
CF = (DWp/1 . 1) 1/2 x MWp + (DWf/1.1)1/2 x MWf
Note that DWp is the warp total fineness (dtex), MWp is
the warp weaving density (yarns/2.54 cm), DWf is the weft total
fineness (dtex), and MWf is the weft weaving density (yarns/2.54
cm).
[0038]
In addition, the weaving density is, in order to obtain
excellent water repellency, preferably such that the warp
density is not less than 110 yarns/2.54 cm (more preferably 120
to 170 yarns/2.54 cm) and the weft density is not less than 90
yarns/2.54 cm (more preferably 100 to 150 yarns/2.54 cm).
[0039]
The cloth of the invention can be produced, for example,
by the following method. That is, first, a cloth is knitted or
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
woven using the composite yarn. At this time, the knitting or
weaving method may be an ordinary method using an ordinary
weaving machine (e.g., ordinary water jet loom, air jet loom,
rapier loom, etc.) or knitting machine. In
addition, the
composite yarn may also be twisted with the twist coefficient
represented by the following formula being about 30,000 or less
(preferably 500 to 30,000). The number of twists is preferably
within a range of 100 to 2,000 t/m.
(Twist coefficient) = the number of twists [t/m] x
(fineness [de])1/2
Note that the fineness [de] is a product of the fineness
[dtex] multiplied by 0.9.
[0040]
Next, the cloth is subjected to a scouring treatment or
dyeing processing (preferably a scouring treatment and dyeing
processing). At this time, as a result of the heat treatment
during the scouring treatment or dyeing processing, in the case
where the stretch fiber is a conjugate fiber, the latent crimp
of the conjugate fiber becomes apparent, whereby the cloth
shrinks to increase the cloth density. At the same time, the
ultrafine fiber becomes relatively long, and fine fiber loops
composed of the ultrafine fiber are formed on the cloth surface.
16
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
[0041]
Next, the cloth is subjected to water repellent processing.
In such water repellent processing, the kind of water repellent
is not particularly limited.
For example, fluorine-based
compounds are applicable, and examples also include
environmentally friendly water repellents such as hydrocarbon-
based compounds and silicone-based compounds. It is preferable
that, as necessary, an antistatic agent, a melamine resin, and
a catalyst are mixed to give a processing agent having a water
repellent concentration of about 3 to 15 wt%, and the surface
of the cloth is treated using the processing agent at a pick-up
rate of about 50 to 90%. Examples of methods for treating the
surface of the cloth with the processing agent include a padding
method and a spray method.
Among them, in order for the
processing agent to penetrate the inside of the cloth, a padding
method is preferable. The pick-up rate is the weight percentage
(%) of the processing agent relative to the cloth (before
processing agent application) weight.
[0042]
Incidentally, as the antistatic agent, a polyester-based
resin containing a polyethylene glycol group, a urethane-based
resin containing a polyethylene glycol group, a reaction product
17
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
of a polycationic compound containing a polyethylene glycol
group and diglycidyl ether, or the like is preferable. Anionic
surfactants such as higher alcohol sulfate ester salts, sulfated
oils, sulfonate salts, and phosphate ester salts, cationic
surfactants such as amine salt type, quaternary ammonium salts,
and imidazole type quaternary salts, nonionic surfactants such
as polyethylene glycol type and polyhydric alcohol ester type,
antistatic compounds, e.g., amphoteric surfactants such as
imidazole type quaternary salts, alanine type, and betaine type,
are also applicable.
[0043]
In addition, in at least either the pre-process or post-
process of the water repellent processing step, conventional
dyeing processing, alkaline weight reduction processing, and
napping processing may be performed. Further, a UV shielding
agent, an antibacterial agent, a deodorant, an insect repellent,
a phosphorescent agent, a retroreflective agent, a negative ion
generator, and the like may be additionally applied.
Incidentally, in the case where the cloth contains a conjugate
fiber, the latent crimp of the conjugate fiber becomes apparent
(coiled) due to the thermal history of the dyeing processing or
the like.
18
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
[0044]
In the water-repellent cloth thus obtained, because the
cloth includes the composite yarn, fine fiber loops composed of
the ultrafine fiber are formed on the cloth surface, and lotus
leaf-like fine irregularities are formed on the cloth surface.
Then, such fine fiber loops form a microscopic layer of air,
and thus excellent water repellency is exhibited when water
droplets fall on the cloth surface.
Incidentally, such an
effect is sometimes referred to as "lotus effect".
[0045]
At this time, as the water repellency, it is preferable
that the water-repellent roll-off angle of the cloth surface is
20 or less (more preferably 15 or less, still more preferably
12 or less, and particularly preferably 5 to 11').
[0046]
Note that the water-repellent roll-off angle is, when 0.2
cc of water is gently dropped onto a planar test sample mounted
on a horizontal plate, and the flat plate is gently tilted at a
constant speed, the angle at which the water droplet begins to
roll.
[0047]
In addition, it is preferable that the degree of water
repellency measured in accordance with JIS L1092-2009 7.2, Test
19
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
for Resistance to Surface Wetting (Spray Method), is Level 4 or
higher. In addition, it is preferable that after 10 washes as
specified in JIS L0217-1995 (using the JAFET standard
combination detergent), the degree of water repellency measured
in accordance with JIS L1092-2009 7.2, Test for Resistance to
Surface Wetting (Spray Method), is Level 3 or higher.
[0048]
The water-repellent cloth of the invention includes the
composite yarn, the composite yarn contains the stretch fiber,
and thus the cloth also has stretchiness (stretchability). At
this time, it is preferable that the stretchability in the warp
direction or the weft direction (preferably the warp direction
and the weft direction) measured in accordance with JIS L1096-
2010 8.16, B Method, is 10% or more (more preferably 10 to 30%).
In addition, it is preferable that the recovery of
stretchability in the warp direction or the weft direction
(preferably the warp direction and the weft direction) measured
in accordance with JIS L1096-2010 8.16, B-1 Method, is 85% or
more.
[0049]
In addition, in the water-repellent cloth of the invention,
it is preferable that the tear strength in the warp direction
or the weft direction (preferably the warp direction and the
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
weft direction) measured in accordance with JIS L1096-2010 8.17,
D Method, is 7 N or more (more preferably 20 to 100 N). In
addition, in terms of lightweightness, it is preferable that
the weight per unit of the cloth is 200 g/m2 or less (more
preferably 100 to 180 g/m2).
[0050]
Next, the textile product of the invention includes the
water-repellent cloth described above.
Because the textile
product includes the cloth described above, its water repellency
and stretchability are excellent. Incidentally, such textile
products include umbrella fabrics and garments.
Then, such
garments include down garments, badminton shirts, running shirts,
soccer pants, tennis pants, basketball pants, table tennis pants,
badminton pants, running pants, golf pants, undershirts for
various sports, innerwear for various sports, sweaters, T-shirts,
jerseys, sweatshirts, windbreakers, jackets, dust-proof
garments, medical gowns, and the like.
EXAMPLES
[0051]
Next, examples and comparative examples of the invention
will be described in detail, but the invention is not limited
thereto. Incidentally, measurement items in the Examples were
measured by the following methods.
21
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
(1) Stretchability
Stretchability (%) was measured in accordance with JIS
L1096-2010 8.16, B Method.
(2) Recovery of Stretchability
Recovery of stretchability (%) was measured in accordance
with JIS L1096-2010 8.16, B-1 Method.
(3) Tear Strength of Woven Fabric
Tear strength (N) was measured in accordance with JIS
L1096-2010 8.17, D Method.
(4) Cover Factor
The cover factor CF of a woven fabric was calculated by
the following formula.
CF = (DWp/1.1)1/2 x MWp + (DWf/1.1)1/2 x MWf
Note that DWp is the warp total fineness (dtex), MWp is
the warp weaving density (yarns/2.54 cm), DWf is the weft total
fineness (dtex), and MWf is the weft weaving density (yarns/2.54
cm).
(5) Water Repellency (Water-Repellent Roll-Off Angle)
0.2 cc of water was gently dropped onto a planar test
sample mounted on a horizontal plate, and the flat plate was
gently tilted at a constant speed. The angle at which the water
droplet began to roll was defined as the water-repellent roll-
off angle. Incidentally, the smaller the water-repellent roll-
22
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
off angle, the better the water repellency, and an angle of 25
or less is rated as pass.
(6) Degree of Water Repellency
The degree of water repellency (level) was measured in
accordance with JIS L1092-2009 7.2, Test for Resistance to
Surface Wetting (Spray Method).
(7) Weight per Unit of Woven Fabric
The weight per unit (g/m2) of a woven fabric was measured
in accordance with JIS L1096-2010 8.3.
[0052]
[Example 1]
Polyethylene terephthalate was spun at a spinning
temperature of 300 C, taken up at 4,000 m/min, and, without
being wound up once, successively drawn to 1.3 times its
original length, thereby giving a polyester multifilament of 70
dtex/144 fil (ultrafine fiber formed of a non-crimped fiber) in
which the filament transverse cross-sectional shape was a round
cross-section.
[0053]
In addition, in the method described in JP-A-2009-46800,
Example 24, only the total fineness and the number of filaments
were changed, and a conjugate fiber (stretch fiber) having a
total fineness of 56 dtex/36 fil made of a polytrimethylene
23
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
terephthalate (PTT) component and a polyethylene terephthalate
(PET) component joined in a side-by-side manner was obtained.
[0054]
Next, the non-crimped yarn and the conjugate fiber
(stretch fiber) were combined and subjected to an air-entangling
treatment, thereby giving a composite yarn (total fineness: 126
dtex/180 fil).
[0055]
Next, using the composite yarn as warp and weft, a woven
fabric having a plain structure (woven fabric composed only of
the composite yarn) was woven using an ordinary water jet loom
weaving machine.
[0056]
Next, the woven fabric was subjected to an open-width
scouring treatment at 95 C using a scouring apparatus. Next,
dyeing processing with a disperse dye was performed at a
temperature of 130 C using a jet dyeing machine, and then the
following water repellent processing was performed. In
the
water repellent processing, the following processing agent was
used, and the liquid was squeezed out at a pick-up rate of 80%,
followed by drying at 130 C for 3 minutes and then a heat
treatment at 170 C for 45 seconds.
<Processing Agent Composition>
24
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
- Fluorine-free water repellent: 5.0 wt%
(Neoseed NR-7080 manufactured by Nichika Chemical Co.,
Ltd., hydrocarbon-based compound)
- Melamine resin: 0.3 wt%
(SUMITEX Resin M-3 manufactured by Sumitomo Chemical Co.,
Ltd.)
- Catalyst: 0.3 wt%
(SUMITEX Accelerator ACX manufactured by Sumitomo
Chemical Co., Ltd.)
- Water: 94.4 wt%
In the water-repellent woven fabric thus obtained, the
weight per unit was 153 g/m2, the warp density was 123 yarns/2.54
cm, the weft density was 104/2.54 cm, the cover factor was 2,417,
the tear strength was 46 N (warp) and 25 N (weft), the warp
stretchability was 11%, the recovery of warp stretchability was
90%, the weft stretchability was 35%, the recovery of weft
stretchability was 87%, and the roll-off angle was 9 .
The
surface of the water-repellent woven fabric had formed thereon
fine fiber loops composed of the ultrafine fiber (lotus leaf-
like fine irregularities), and the degree of water repellency
of the water-repellent woven fabric was Level 4, while after 10
washes as specified in JIS L0217-1995 (using the JAFET standard
combination detergent), the degree of water repellency was Level
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
3. In addition, because the water-repellent woven fabric had
attached thereto the water repellent described above, the water-
repellent woven fabric was an environmentally friendly woven
fabric. A windbreaker (sportswear) was sewn using the water-
repellent woven fabric, and a tester wore the windbreaker. As
a result, the windbreaker was excellent in water repellency and
stretchability.
[0057]
[Example 2]
Polyethylene terephthalate was spun at a spinning
temperature of 300 C, taken up at 4,000 m/min, and, without
being wound up once, successively drawn to 1.3 times its
original length, thereby giving a polyester multifilament of 70
dtex/144 fil (ultrafine fiber formed of a non-crimped fiber) in
which the filament transverse cross-sectional shape was a round
cross-section.
[0058]
In addition, in the method described in JP-A-2009-46800,
Example 24, only the total fineness and the number of filaments
were changed, and a conjugate fiber (stretch fiber) having a
total fineness of 56 dtex/36 fil made of a polytrimethylene
terephthalate (PTT) component and a polyethylene terephthalate
(PET) component joined in a side-by-side manner was obtained.
26
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
[0059]
Next, the non-crimped yarn and the conjugate fiber
(stretch fiber) were combined and subjected to an air-entangling
treatment to give a composite yarn (total fineness: 126 dtex/180
fil).
[0060]
Next, the yarn was twisted at Z 400 t/m, and then, using
the composite yarn as warp and weft, a woven fabric having a
plain structure (woven fabric composed only of the composite
yarn) was woven using an ordinary water jet loom weaving machine.
[0061]
Next, the woven fabric was subjected to an open-width
scouring treatment at 95 C using a scouring apparatus. Next,
dyeing processing with a disperse dye was performed at a
temperature of 130 C using a jet dyeing machine, and then the
following water repellent processing was performed. In
the
water repellent processing, the following processing agent was
used, and the liquid was squeezed out at a pick-up rate of 80%,
followed by drying at 130 C for 3 minutes and then a heat
treatment at 170 C for 45 seconds.
<Processing Agent Composition>
- Fluorine-free water repellent: 5.0 wt%
(Neoseed NR-7080 manufactured by Nichika Chemical Co.,
27
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
Ltd., hydrocarbon-based compound)
- Melamine resin: 0.3 wt%
(SUMITEX Resin M-3 manufactured by Sumitomo Chemical Co.,
Ltd.)
- Catalyst: 0.3 wt%
(SUMITEX Accelerator ACX manufactured by Sumitomo
Chemical Co., Ltd.)
- Water: 94.4 wt%
In the water-repellent woven fabric thus obtained, the
weight per unit was 155 g/m2, the warp density was 125 yarns/2.54
cm, the weft density was 106/2.54 cm, the cover factor was 2,459,
the tear strength was 44 N (warp) and 24 N (weft), the warp
stretchability was 11%, the recovery of warp stretchability was
91%, the weft stretchability was 36%, the recovery of weft
stretchability was 88%, and the roll-off angle was 8 .
The
surface of the water-repellent woven fabric had formed thereon
fine fiber loops composed of the ultrafine fiber (lotus leaf-
like fine irregularities), and the degree of water repellency
of the water-repellent woven fabric was Level 4, while after 10
washes as specified in JIS L0217-1995 (using the JAFET standard
combination detergent), the degree of water repellency was Level
3. In addition, because the water-repellent woven fabric had
attached thereto the water repellent described above, the water-
28
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
repellent woven fabric was an environmentally friendly woven
fabric. A windbreaker (sportswear) was sewn using the water-
repellent woven fabric, and a tester wore the windbreaker. As
a result, the windbreaker was excellent in water repellency and
stretchability.
[0062]
[Example 3]
Polyethylene terephthalate was spun at a spinning
temperature of 300 C, taken up at 4,000 m/min, and, without
being wound up once, successively drawn to 1.3 times its
original length, thereby giving a polyester multifilament of 70
dtex/72fi1 (ultrafine fiber formed of a non-crimped fiber) in
which the filament transverse cross-sectional shape was a round
cross-section.
[0063]
In addition, in the method described in JP-A-2009-46800,
Example 24, only the total fineness and the number of filaments
were changed, and a conjugate fiber (stretch fiber) having a
total fineness of 33 dtex/24 fil made of a polytrimethylene
terephthalate (PTT) component and a polyethylene terephthalate
(PET) component joined in a side-by-side manner was obtained.
[0064]
Next, the non-crimped yarn and the conjugate fiber
29
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
(stretch fiber) were combined and subjected to an air-entangling
treatment to give a composite yarn (total fineness: 100 dtex/96
fil).
[0065]
Next, the yarn was twisted at Z 800 t/m, and then, using
the composite yarn as warp and weft, a woven fabric having a
twill structure (woven fabric composed only of the composite
yarn) was woven using an ordinary water jet loom weaving machine.
[0066]
Next, the woven fabric was subjected to an open-width
scouring treatment at 95 C using a scouring apparatus. Next,
dyeing processing with a disperse dye was performed at a
temperature of 130 C using a jet dyeing machine, and then the
following water repellent processing was performed. In
the
water repellent processing, the following processing agent was
used, and the liquid was squeezed out at a pick-up rate of 80%,
followed by drying at 130 C for 3 minutes and then a heat
treatment at 170 C for 45 seconds.
<Processing Agent Composition>
- Fluorine-free water repellent: 5.0 wt%
(Neoseed NR-7080 manufactured by Nichika Chemical Co.,
Ltd., hydrocarbon-based compound)
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
- Melamine resin: 0.3 wt%
(SUMITEX Resin M-3 manufactured by Sumitomo Chemical Co.,
Ltd.)
- Catalyst: 0.3 wt%
(SUMITEX Accelerator ACX manufactured by Sumitomo
Chemical Co., Ltd.)
- Water: 94.4 wt%
In the water-repellent woven fabric thus obtained, the
weight per unit was 156 g/m2, the warp density was 163 yarns/2.54
cm, the weft density was 130/2.54 cm, the cover factor was 2,459,
the tear strength was 42 N (warp) and 37 N (weft), the warp
stretchability was 12%, the recovery of warp stretchability was
96%, the weft stretchability was 21%, the recovery of weft
stretchability was 90%, and the roll-off angle was 9 .
The
surface of the water-repellent woven fabric had formed thereon
fine fiber loops composed of the ultrafine fiber (lotus leaf-
like fine irregularities), and the degree of water repellency
of the water-repellent woven fabric was Level 4, while after 10
washes as specified in JIS L0217-1995 (using the JAFET standard
combination detergent), the degree of water repellency was Level
3. In addition, because the water-repellent woven fabric had
attached thereto the water repellent described above, the water-
repellent woven fabric was an environmentally friendly woven
31
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
fabric. A windbreaker (sportswear) was sewn using the water-
repellent woven fabric, and a tester wore the windbreaker. As
a result, the windbreaker was excellent in water repellency and
stretchability.
[0067]
[Comparative Example 1]
The same procedure as in Example 1 was performed, except
that the ultrafine fiber in Example 1 was changed in the number
of filaments to a polyester multifilament of 70 dtex/36 fil
(non-crimped fiber, single fiber fineness: 1.9 dtex), and the
resulting composite yarn (total fineness: 126 dtex/72 fil) was
used as warp and weft.
[0068]
In the obtained water-repellent woven fabric, the weight
per unit was 155 g/m2, the warp density was 125 yarns/2.54 cm,
the weft density was 105/2.54 cm, the cover factor was 2,449,
the tear strength was 42 N (warp) and 27 N (weft), the warp
stretchability was 12%, the recovery of warp stretchability was
92%, the weft stretchability was 33%, and the recovery of weft
stretchability was 88%, which were excellent, but the roll-off
angle was 18 . In addition, fine irregularities were not formed,
and the degree of water repellency after 10 washes as specified
in JIS L0217-1995 (using the JAFET standard combination
32
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
detergent) was Level 2.
[0069]
[Comparative Example 2]
The same procedure as in Example 1 was performed, except
that the conjugate fiber (stretch fiber) in Example 1 was
replaced with a polyester multifilament of 56 dtex/36 fil (non-
crimped fiber) to give a composite yarn (total fineness: 126
dtex/180 fil), and then the composite yarn was used as warp and
weft.
[0070]
In the obtained water-repellent woven fabric, the weight
per unit was 144 g/m2, the warp density was 116 yarns/2.54 cm,
the weft density was 98/2.54 cm, the cover factor was 2,279,
and the tear strength was 35 N (warp) and 22 N (weft), which
were excellent, but the stretchability was less than 10%. The
roll-off angle was 12 .
[0071]
[Comparative Example 3]
The same procedure as in Example 1 was performed, except
that the water repellent processing in Example 1 was not
performed. In the woven fabric thus obtained, the weight per
unit was 154 g/m2, the warp density was 124 yarns/2.54 cm, the
weft density was 102/2.54 cm, the cover factor was 2,406, the
33
Date Recue/Date Received 2022-09-28
CA 03177860 2022-09-28
tear strength was 30 N (warp) and 20 N (weft), the warp
stretchability was 12%, the recovery of warp stretchability was
90%, the weft stretchability was 36%, the recovery of weft
stretchability was 90%, and fine fiber loops composed of the
ultrafine fiber (lotus leaf-like fine irregularities) were
formed on the surface of the woven fabric. However, the degree
of water repellency of the water-repellent woven fabric was
Level 0, and, after 10 washes as specified in JIS L0217-1995
(using the JAFET standard combination detergent), the degree of
water repellency was Level 0; that is, its water repellency was
inferior.
Industrial Applicability
[0072]
The invention provides a water-repellent cloth that is
excellent in water repellency as well as stretchability and also
a textile product using the water-repellent cloth, and the
industrial value thereof is extremely high.
34
Date Recue/Date Received 2022-09-28
