CA2734872A1 - Extra fine filament yarn containing deodorant functional agent and producing the same - Google Patents
Extra fine filament yarn containing deodorant functional agent and producing the same Download PDFInfo
- Publication number
- CA2734872A1 CA2734872A1 CA2734872A CA2734872A CA2734872A1 CA 2734872 A1 CA2734872 A1 CA 2734872A1 CA 2734872 A CA2734872 A CA 2734872A CA 2734872 A CA2734872 A CA 2734872A CA 2734872 A1 CA2734872 A1 CA 2734872A1
- Authority
- CA
- Canada
- Prior art keywords
- functional agent
- extra fine
- deodorant functional
- deodorant
- multifilament
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002781 deodorant agent Substances 0.000 title claims abstract description 76
- 239000003795 chemical substances by application Substances 0.000 title claims abstract description 69
- 239000000835 fiber Substances 0.000 claims abstract description 58
- 229920000642 polymer Polymers 0.000 claims abstract description 33
- 239000002245 particle Substances 0.000 claims abstract description 31
- 229920000728 polyester Polymers 0.000 claims abstract description 9
- 239000011941 photocatalyst Substances 0.000 claims description 46
- 239000011163 secondary particle Substances 0.000 claims description 19
- 239000002131 composite material Substances 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 16
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 13
- -1 silver ions Chemical class 0.000 claims description 13
- 239000003463 adsorbent Substances 0.000 claims description 9
- 239000003242 anti bacterial agent Substances 0.000 claims description 5
- 238000002074 melt spinning Methods 0.000 claims description 5
- 239000000022 bacteriostatic agent Substances 0.000 claims description 4
- 230000002123 temporal effect Effects 0.000 claims description 4
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 4
- 238000004804 winding Methods 0.000 claims description 4
- 235000014692 zinc oxide Nutrition 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical class [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 claims description 2
- PTFCDOFLOPIGGS-UHFFFAOYSA-N Zinc dication Chemical compound [Zn+2] PTFCDOFLOPIGGS-UHFFFAOYSA-N 0.000 claims description 2
- 229910001431 copper ion Inorganic materials 0.000 claims description 2
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 2
- 150000004692 metal hydroxides Chemical class 0.000 claims description 2
- 229910001463 metal phosphate Inorganic materials 0.000 claims description 2
- OTCVAHKKMMUFAY-UHFFFAOYSA-N oxosilver Chemical class [Ag]=O OTCVAHKKMMUFAY-UHFFFAOYSA-N 0.000 claims description 2
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical class [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 2
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical class [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 claims description 2
- 229910052814 silicon oxide Inorganic materials 0.000 claims description 2
- 229910052709 silver Inorganic materials 0.000 claims description 2
- 239000004332 silver Substances 0.000 claims description 2
- 229910001923 silver oxide Inorganic materials 0.000 claims description 2
- RNWHGQJWIACOKP-UHFFFAOYSA-N zinc;oxygen(2-) Chemical class [O-2].[Zn+2] RNWHGQJWIACOKP-UHFFFAOYSA-N 0.000 claims description 2
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 2
- 229910021645 metal ion Inorganic materials 0.000 claims 1
- 229910044991 metal oxide Inorganic materials 0.000 claims 1
- 150000004706 metal oxides Chemical class 0.000 claims 1
- 230000001877 deodorizing effect Effects 0.000 abstract description 18
- 239000004744 fabric Substances 0.000 abstract description 7
- 238000011156 evaluation Methods 0.000 description 13
- 239000004065 semiconductor Substances 0.000 description 12
- 238000000034 method Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 9
- 238000012545 processing Methods 0.000 description 8
- 235000019645 odor Nutrition 0.000 description 7
- 238000009987 spinning Methods 0.000 description 7
- 239000000126 substance Substances 0.000 description 7
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 230000001699 photocatalysis Effects 0.000 description 6
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 5
- 239000004594 Masterbatch (MB) Substances 0.000 description 5
- 238000004332 deodorization Methods 0.000 description 5
- 238000004090 dissolution Methods 0.000 description 5
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- IKHGUXGNUITLKF-UHFFFAOYSA-N Acetaldehyde Chemical compound CC=O IKHGUXGNUITLKF-UHFFFAOYSA-N 0.000 description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 241000282320 Panthera leo Species 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 3
- 239000002202 Polyethylene glycol Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 238000000354 decomposition reaction Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000003317 industrial substance Substances 0.000 description 3
- 230000003287 optical effect Effects 0.000 description 3
- 229920002647 polyamide Polymers 0.000 description 3
- 229920001223 polyethylene glycol Polymers 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 230000000844 anti-bacterial effect Effects 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 229920005601 base polymer Polymers 0.000 description 2
- UHYPYGJEEGLRJD-UHFFFAOYSA-N cadmium(2+);selenium(2-) Chemical compound [Se-2].[Cd+2] UHYPYGJEEGLRJD-UHFFFAOYSA-N 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920002620 polyvinyl fluoride Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- YBNMDCCMCLUHBL-UHFFFAOYSA-N (2,5-dioxopyrrolidin-1-yl) 4-pyren-1-ylbutanoate Chemical compound C=1C=C(C2=C34)C=CC3=CC=CC4=CC=C2C=1CCCC(=O)ON1C(=O)CCC1=O YBNMDCCMCLUHBL-UHFFFAOYSA-N 0.000 description 1
- ISPYQTSUDJAMAB-UHFFFAOYSA-N 2-chlorophenol Chemical compound OC1=CC=CC=C1Cl ISPYQTSUDJAMAB-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 229910001218 Gallium arsenide Inorganic materials 0.000 description 1
- 229910016003 MoS3 Inorganic materials 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 230000010718 Oxidation Activity Effects 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 229940121375 antifungal agent Drugs 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000003421 catalytic decomposition reaction Methods 0.000 description 1
- 150000004770 chalcogenides Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 235000019504 cigarettes Nutrition 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- BERDEBHAJNAUOM-UHFFFAOYSA-N copper(I) oxide Inorganic materials [Cu]O[Cu] BERDEBHAJNAUOM-UHFFFAOYSA-N 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- KRFJLUBVMFXRPN-UHFFFAOYSA-N cuprous oxide Chemical compound [O-2].[Cu+].[Cu+] KRFJLUBVMFXRPN-UHFFFAOYSA-N 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- GDVKFRBCXAPAQJ-UHFFFAOYSA-A dialuminum;hexamagnesium;carbonate;hexadecahydroxide Chemical class [OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Al+3].[Al+3].[O-]C([O-])=O GDVKFRBCXAPAQJ-UHFFFAOYSA-A 0.000 description 1
- 238000002296 dynamic light scattering Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000009998 heat setting Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012510 hollow fiber Substances 0.000 description 1
- 239000000077 insect repellent Substances 0.000 description 1
- QQVIHTHCMHWDBS-UHFFFAOYSA-L isophthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC(C([O-])=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-L 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 230000031700 light absorption Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- TVWWSIKTCILRBF-UHFFFAOYSA-N molybdenum trisulfide Chemical compound S=[Mo](=S)=S TVWWSIKTCILRBF-UHFFFAOYSA-N 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 230000009965 odorless effect Effects 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- SOQBVABWOPYFQZ-UHFFFAOYSA-N oxygen(2-);titanium(4+) Chemical class [O-2].[O-2].[Ti+4] SOQBVABWOPYFQZ-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 238000013032 photocatalytic reaction Methods 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
- 229910000108 silver(I,III) oxide Inorganic materials 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000010902 straw Substances 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
- D01F1/103—Agents inhibiting growth of microorganisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/36—Matrix structure; Spinnerette packs therefor
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
- D01F6/92—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L9/00—Disinfection, sterilisation or deodorisation of air
- A61L9/01—Deodorant compositions
- A61L9/012—Deodorant compositions characterised by being in a special form, e.g. gels, emulsions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
- B01J21/063—Titanium; Oxides or hydroxides thereof
-
- B01J35/39—
-
- B01J35/58—
Abstract
An extra fine multifilament obtained in the present invention contains a deodorant functional agent having a particle diameter equal to or more than the average diameter of extra fine single yam fibers, and the deodorant functional agent is not completely covered with polymer and is partially exposed on the surface of the multifilament, whereby a dramatically improved deodorizing function can be achieved. Accordingly, a polyester cloth made of the multifilament has a durable deodorizing function, a high strength, and an excellent texture, and thereby is useful for apparel products (such as sports wears, casual wears, and mens and womens suits), medical applications, interior applications, etc.
Description
EXTRA FINE FILAMENT YARN CONTAINING DEODORANT FUNCTIONAL
AGENT AND PRODUCING THE SAME
Technical Field The present invention relates to a deodorant functional agent-containing extra fine filament yarn having an excellent deodorizing function and a method for producing the same. The invention relates more specifically to an extra fine multifilament, which can hold a deodorant functional agent without dropping and can show a deodorizing function more effectively than in the past, and a method for producing the same.
Background Art Recently, with the diversification of living environments intended for comfortable lifestyles, there has been increasing attention to various odors not only in homes but also in offices, hospitals, etc. Furthermore, with the increase in house airtightness, there has been a significant problem of treating bad odors and harmful components (such as formaldehyde) in house.
Under such circumstances, various attempts have been made to use a filament structure having a deodorizing function for removing a bad odor. A proposed filament structure has not only an adsorbent function but also a decomposition function such as a photocatalytic activity, and thereby can exhibit a permanent deodorizing function.
For example, in a conventional method, a filament structure is subjected to an aftertreatment for attaching a deodorant component, to obtain a photocatalytic deodorizing function (JP-A-2001-254281, etc.) However, in this method, deodorant functional agent particles are placed on the filament surfaces, so that the particles are easily dropped disadvantageously. Furthermore, a binder is used in the attaching treatment, so that the filament cloth per se has a hard texture disadvantageously.
In view of solving the durability and texture disadvantages, various filament structures obtained by kneading a photocatalyst into fibers have been proposed (JP-A-2005-220471, etc.) However, in this method, since the photocatalyst is embedded in the fibers, a reaction between the photocatalyst and an odorous component is inhibited by the fiber polymer, and the photocatalyst cannot sufficiently exhibit its ability.
Furthermore, the matrix is disadvantageously deteriorated by the photocatalyst per se to lower the fiber strength with time. A core-sheath composite filament structure is proposed in JP-A-2004-169217, etc. in view of this disadvantage. In this structure, a photocatalyst is disposed only on the sheath portion, and the core portion ensures the strength.
However, in this method, though the strength disadvantage is solved, the photocatalyst is embedded in the sheath portion and thereby cannot sufficiently exhibit its ability. In a method proposed to solve the problems, a photocatalyst is kneaded into a peel-off dividable composite filament structure, and the structure is divided to increase the photocatalytic area exposed on the filament surfaces, so that the photocatalyst can easily exhibit its ability (JP-A-10-204727). In this method, the exposed area can be increased and the fineness can be improved, whereby the photocatalytic effect and the texture can be improved to some extent. However, this method is disadvantageous in that the structure cannot be produced with stable quality because of division ratio variation.
Disclosure of the Invention An object of the present invention is to solve the problems of conventional technologies, thereby providing a deodorant functional agent-containing extra fine multifilament, which exhibits an excellent deodorizing function with only a small deterioration of the initial function in long-term use, repeated washings, etc., and a method for producing the same.
As a result of intense research in view of solving the above problems, the inventors have found that the above extra fine multifilament can be obtained by controlling the diameter of fibers and the particle diameter of a deodorant functional agent contained in
AGENT AND PRODUCING THE SAME
Technical Field The present invention relates to a deodorant functional agent-containing extra fine filament yarn having an excellent deodorizing function and a method for producing the same. The invention relates more specifically to an extra fine multifilament, which can hold a deodorant functional agent without dropping and can show a deodorizing function more effectively than in the past, and a method for producing the same.
Background Art Recently, with the diversification of living environments intended for comfortable lifestyles, there has been increasing attention to various odors not only in homes but also in offices, hospitals, etc. Furthermore, with the increase in house airtightness, there has been a significant problem of treating bad odors and harmful components (such as formaldehyde) in house.
Under such circumstances, various attempts have been made to use a filament structure having a deodorizing function for removing a bad odor. A proposed filament structure has not only an adsorbent function but also a decomposition function such as a photocatalytic activity, and thereby can exhibit a permanent deodorizing function.
For example, in a conventional method, a filament structure is subjected to an aftertreatment for attaching a deodorant component, to obtain a photocatalytic deodorizing function (JP-A-2001-254281, etc.) However, in this method, deodorant functional agent particles are placed on the filament surfaces, so that the particles are easily dropped disadvantageously. Furthermore, a binder is used in the attaching treatment, so that the filament cloth per se has a hard texture disadvantageously.
In view of solving the durability and texture disadvantages, various filament structures obtained by kneading a photocatalyst into fibers have been proposed (JP-A-2005-220471, etc.) However, in this method, since the photocatalyst is embedded in the fibers, a reaction between the photocatalyst and an odorous component is inhibited by the fiber polymer, and the photocatalyst cannot sufficiently exhibit its ability.
Furthermore, the matrix is disadvantageously deteriorated by the photocatalyst per se to lower the fiber strength with time. A core-sheath composite filament structure is proposed in JP-A-2004-169217, etc. in view of this disadvantage. In this structure, a photocatalyst is disposed only on the sheath portion, and the core portion ensures the strength.
However, in this method, though the strength disadvantage is solved, the photocatalyst is embedded in the sheath portion and thereby cannot sufficiently exhibit its ability. In a method proposed to solve the problems, a photocatalyst is kneaded into a peel-off dividable composite filament structure, and the structure is divided to increase the photocatalytic area exposed on the filament surfaces, so that the photocatalyst can easily exhibit its ability (JP-A-10-204727). In this method, the exposed area can be increased and the fineness can be improved, whereby the photocatalytic effect and the texture can be improved to some extent. However, this method is disadvantageous in that the structure cannot be produced with stable quality because of division ratio variation.
Disclosure of the Invention An object of the present invention is to solve the problems of conventional technologies, thereby providing a deodorant functional agent-containing extra fine multifilament, which exhibits an excellent deodorizing function with only a small deterioration of the initial function in long-term use, repeated washings, etc., and a method for producing the same.
As a result of intense research in view of solving the above problems, the inventors have found that the above extra fine multifilament can be obtained by controlling the diameter of fibers and the particle diameter of a deodorant functional agent contained in
2 the fibers within particular ranges.
Thus, according to the invention, there is provided a deodorant functional agent-containing extra fine multifilament, characterized in that a) the multifilament comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, and b) the multifilament comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yarn fibers, wherein 5 or more particles of the deodorant functional agent per 25 m2 are not completely covered with a fiber polymer and are partially exposed on the surface of the multifilament.
Further, according to the invention, there is provided a method for producing a deodorant functional agent-containing extra fine multifilament, comprising removing a sea component from a sea-island composite filament yarn including the sea component and island component to obtain an extra fine multifilament containing an island component, characterized in that a) the island component comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, b) the island component comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yam fibers, and c) the sea-island composite filament yam is prepared by melt spinning and direct drawing without temporal winding.
Brief Description of the Drawings Figs. I and 2 are schematic, cross-sectional conceptual view each showing an example of a spinneret for preparing a sea-island composite filament yarn used in the present invention. In Figs, I and 2, 1 represents an undistributed island component
Thus, according to the invention, there is provided a deodorant functional agent-containing extra fine multifilament, characterized in that a) the multifilament comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, and b) the multifilament comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yarn fibers, wherein 5 or more particles of the deodorant functional agent per 25 m2 are not completely covered with a fiber polymer and are partially exposed on the surface of the multifilament.
Further, according to the invention, there is provided a method for producing a deodorant functional agent-containing extra fine multifilament, comprising removing a sea component from a sea-island composite filament yarn including the sea component and island component to obtain an extra fine multifilament containing an island component, characterized in that a) the island component comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, b) the island component comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yam fibers, and c) the sea-island composite filament yam is prepared by melt spinning and direct drawing without temporal winding.
Brief Description of the Drawings Figs. I and 2 are schematic, cross-sectional conceptual view each showing an example of a spinneret for preparing a sea-island composite filament yarn used in the present invention. In Figs, I and 2, 1 represents an undistributed island component
3 polymer reservoir, 2 represents an island component distributing pipe, 3 represents a sea component inlet, 4 represents an undistributed sea component polymer reservoir, 5 represents an individual sea/island structure forming portion, and 6 represents an entire combined sea/island structure reducing portion.
Best Mode for Carrying Out the Invention An embodiment of the present invention will be described in detail below.
A polymer for forming an extra fine filament yam containing a deodorant functional agent according to the invention is not particularly limited, and may be any 'crystalline thermoplastic polymer having a fiber forming ability. Examples of the polymers include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polytrimethylene terephthalate, and polyamides such as nylon 6 and nylon 66. The polymer is preferably a polyethylene terephthalate, which is versatile and excellent in balance between costs and properties.
Extra fine single yarn fibers contained in the deodorant functional agent-containing extra fine multifilament of the invention have an average diameter of 200 to 2000 nm in a cross-section perpendicular to the axial direction. When the average diameter is less than 200 nm, the deodorant functional agent particles are aggregated, whereby it is difficult to form the filament yarn. On the other hand, when the average diameter is more than 2000 rim, the resultant multifilament does not have a soft texture, the exposed photocatalytic area is reduced in the case of using small deodorant functional agent particles, and the multifilament has a small specific surface area, whereby the photocatalytic reaction efficiency is deteriorated. The average diameter is preferably 300 to 1000 nm.
In the case of using a photocatalyst as the deodorant functional agent, the photocatalyst absorbs a light to exhibit the function. However, when the photocatalyst is kneaded into the filament, generally the fiber polymer per se inhibits the light absorption and the contact between the photocatalyst and a decomposition subject, thereby lowering
Best Mode for Carrying Out the Invention An embodiment of the present invention will be described in detail below.
A polymer for forming an extra fine filament yam containing a deodorant functional agent according to the invention is not particularly limited, and may be any 'crystalline thermoplastic polymer having a fiber forming ability. Examples of the polymers include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polytrimethylene terephthalate, and polyamides such as nylon 6 and nylon 66. The polymer is preferably a polyethylene terephthalate, which is versatile and excellent in balance between costs and properties.
Extra fine single yarn fibers contained in the deodorant functional agent-containing extra fine multifilament of the invention have an average diameter of 200 to 2000 nm in a cross-section perpendicular to the axial direction. When the average diameter is less than 200 nm, the deodorant functional agent particles are aggregated, whereby it is difficult to form the filament yarn. On the other hand, when the average diameter is more than 2000 rim, the resultant multifilament does not have a soft texture, the exposed photocatalytic area is reduced in the case of using small deodorant functional agent particles, and the multifilament has a small specific surface area, whereby the photocatalytic reaction efficiency is deteriorated. The average diameter is preferably 300 to 1000 nm.
In the case of using a photocatalyst as the deodorant functional agent, the photocatalyst absorbs a light to exhibit the function. However, when the photocatalyst is kneaded into the filament, generally the fiber polymer per se inhibits the light absorption and the contact between the photocatalyst and a decomposition subject, thereby lowering
4 the efficiency.
In addition, also when an adsorbent is kneaded into the filament as the deodorant functional agent, the fiber polymer per se inhibits the absorption function of the adsorbent, thereby lowering the efficiency.
Thus, the deodorant functional agent-containing extra fine multifilament of the invention contains at least the deodorant functional agent having a secondary particle diameter more than the average diameter of the extra fine single yam fibers, and the deodorant functional agent is not completely covered with the fiber polymer.
As a result, the deodorant efficiency is dramatically improved.
In general, it is difficult to produce a filament yarn, particularly an extra fine filament yarn, containing particles larger than the fiber diameter, because the spinnability is deteriorated by the particles in the production.
However, in the invention, it has found that the above extra fine multifilament can be produced by the steps of adding the deodorant functional agent to an island component of a sea-island composite filament yarn, and removing a sea component from the yam to obtain the extra fine filament yarn containing the island component. Even when the island component has a brittle fiber structure (a structure containing the particles having a secondary particle diameter more than the extra fine single yam fiber diameter, thus a low-strength structure), the sea-island composite filament yarn can have a strength sufficient for spin-drawing due to the sea component. Further, even after removing the sea component, the resultant extra fine filament yam can have a sufficient strength due to the multifilament structure.
In the preparation of the sea-island composite filament yarn, it is preferred that a spun composite yarn is not winded up temporarily and is successively subjected to a drawing treatment in a spinning-direct drawing method. In the spinning-direct drawing method, the deodorant functional agent particles having the secondary particle diameter equal to or more than the extra fine single yarn fiber diameter cannot follow the stretch of the fiber polymer. Therefore, the area of the particles, not covered with the fiber polymer and exposed on the yarn surface, is increased. In view of improving the balance between the deodorant effect and fiber properties, 5 or more particles of the deodorant functional agent per 25 m2 are not completely covered with the fiber polymer and are partially exposed on the surface of the multifilament.
It should be noted that, when excessively many particles are exposed on the multifilament surface, the qualities (the strength, elongation, and fluff) of the multifilament are remarkably deteriorated disadvantageously. Thus, the number of the particles exposed on the multifilament surface is preferably 25 or less per 25 m2.
In this embodiment, the deodorant functional agent acts as a foreign substance in the fiber polymer. Each portion containing the deodorant functional agent has a low fiber polymer content, and thereby cannot follow the stretch of the fiber polymer.
Thus, the portion is cracked, and the deodorant functional agent is partially separated from the fiber polymer therein to form an exposed area. In the exposed area, light incident and photocatalytic decomposition of a subject component are efficiently carried out, so that the deodorant function is dramatically improved.
The cross-sectional shape of the deodorant functional agent-containing extra fine filament yarn of the invention is not particularly limited, and may be a modified cross-sectional shape. Specific examples of the modified cross-sectional shapes include, but not limited thereto, T shapes, U shapes, V shapes, H shapes, Y shapes, W
shapes, 3- to 14-leaf shapes, and polygonal shapes. The filament yarn may have a solid or hollow fiber structure.
In the invention, the photocatalyst used as the deodorant functional agent may be an oxidation photocatalyst, which generates active radicals under irradiation of a light such as an ultraviolet ray to oxidation-decompose various harmful substances and bad odor substances.
Thus, the photocatalyst preferably has an oxidation activity. Such a photocatalyst exhibits a deodorant function utilizing not only adsorbent but also catalytic decomposition, and thereby can maintain a deodorant or deodorization effect over a long period.
Furthermore, the photocatalyst has a bactericidal effect, an antibacterial effect, etc. in addition to the effect of decomposing the harmful substances and bad odor substances.
The photocatalyst may be an inorganic or organic substance, and may be selected from various optical semiconductors. The photocatalyst is generally an inorganic optical semiconductor, and examples thereof include sulfide semiconductors (such as CdS, ZnS, In2S3, PbS, Cu2S, MoS3, WS2, Sb3S3, Bi3S3, and ZnCdS2), metal chalcogenides (such as CdSe, In2Se3i WSe3, HgSe, PbSe, and CdSe), and oxide semiconductors (such as TiO2, ZnO, W03, CdO, In203, Ag2O, Mn02, Cu2O, Fe203, V205, and Sn02). The examples further include semiconductors other than sulfide and oxide semiconductors, such as GaAs, Si, Se, CdP3, and Zn2P3. The photocatalysts may be used singly or as a combination of two or more.
Among the above photocatalyst, preferred are sulfide semiconductors (such as CdS
and ZnS) and oxide semiconductors (such as Ti02, ZnO, Sn02, and W03), and particularly preferred are Ti02 oxide semiconductors. The crystal structure of the optical semiconductor for the photocatalyst is not particularly limited. For example, the Ti02 semiconductor may be of anatase type, brookite type, rutile type, amorphous type, etc.
Particularly preferred TiO2 semiconductors include anatase-type titanium oxides.
The photocatalyst may be used in the state of a sol, a gel, or a powder (particles).
In the case of using the sol or gel of the photocatalyst, it is dried, solidified, and crushed into a desired particle diameter. The crushing may be carried out using a ball mill, a jet mill, etc., but the apparatus is not limited thereto. In the case of using the powder of the photocatalyst, the average secondary particle diameter of the photocatalyst is preferably 0.1 to 2 m, more preferably 0.2 to 1.5 m. When the particle diameter of the photocatalyst is more than 2 m, for example, filter clogging or fluff yarn breakage is often caused in the melt spinning step, and yarn breakage is increased in the drawing step.
The amount of the photocatalyst used may be selected from a wide range depending on the fiber structure, as long as the catalytic activity is not deteriorated. The ratio of the photocatalyst to the entire filament yarn is, for example, 0.1 %
to 25% by mass, preferably 0.3% to 20% by mass, more preferably 0.5% to 10% by mass.
In the invention, the deodorant functional agent may comprise an adsorbent, a deodorant, an antibacterial agent, a bacteriostatic agent, or a combination thereof.
The adsorbent, deodorant, antibacterial agent, bacteriostatic agent cannot be clearly distinguished, and are not particularly limited. Examples of the agents include those containing, as main component, at least one selected from the group consisting of tetravalent metal phosphates, divalent metal hydroxides, silver oxides, zinc oxides, aluminum oxides, silicon oxides, zirconium oxides, silver ions, copper ions, and zinc ions.
Specifically, the agent may be selected from MIZUKANITE available from Mizusawa Industrial Chemicals, Ltd., LIONITE available from Lion Corporation, hydrotalcite compounds available from Kyowa Chemical Industry Co., Ltd., KESMON series and NOVARON series available from Toagosei Co., Ltd., KD-211GF available from Rasa Industries, Ltd., TZ-100 and SZ-100S available from Titan Kogyo, Ltd., and mixtures thereof, etc.
The average secondary particle diameter of the deodorant functional agent is preferably 0.1 to 2 m, more preferably 0.2 to 1.5 m. When the particle diameter is more than 2 m, for example, filter clogging or fluff yarn breakage is often caused in the melt spinning step, and yarn breakage is increased in the drawing step.
The amount of the deodorant functional agent used may be selected from a wide range as long as the qualities (the strength, elongation, and fluff) of the filament yam are not deteriorated. The ratio of the agent to the entire filament yarn is, for example, 0.1%
to 25% by mass, preferably 0.3% to 20% by mass, more preferably 0.5% to 10% by mass.
The deodorant functional agent may be attached to the island component polymer as described above as follows: 1. the deodorant functional agent is added in or immediately after the polymerization of the island component polymer; 2. a masterbatch containing a base of the island component polymer and the deodorant functional agent is prepared and used; or 3. the deodorant functional agent is added in an optional step (such as a polymer pellet preparation step or a melt spinning step) before completion of the spinning; etc. The method using the masterbatch is preferred from the viewpoint of preventing side reactions due to the catalytic activity in the polymerization, etc.
In the deodorant functional agent-containing extra fine multifilament of the invention, a plurality of the deodorant functional agents may be used in combination to improve the catalytic function.
The sea-island composite filament yarn used in the invention may be prepared by using a known sea-island composite spinneret as shown in Figs. 1 and 2. The island component and the sea component are extruded in the melt states, and the resultant fibers are melt-spun at a rate of 500 to 3500 mlminute and then subjected to a drawing treatment and a heat treatment without temporal winding.
As the number of the islands is larger, the fibers of the island component are thinner after dissolution in the sea. The number of the islands is preferably 100 to 1,000 per single yarn. When the number is less than 100, the resultant yam has a low island ratio and cannot show properties specific to the extra fine filament yarn. On the other hand, when the number is more than 1,000, costs for producing the spinneret are increased, and its processing accuracy is often deteriorated. The number is further preferably 500 to 1,000.
The dissolution rate of the sea component is preferably 30 to 5,000 times, more preferably 100 to 4,000 times as high as that of the island component. When the dissolution rate ratio is less than 30 times, in a cross-section of the filament yarn, the separate island component is partially dissolved in a surface portion, and the sea component is often not dissolved in a center portion. As a result, the thickness of the island component is made uneven to deteriorate the quality. On the other hand, when the dissolution rate ratio is more than 5,000 times, it is difficult to form the filament yarn.
The sea component polymer for forming the sea-island composite filament yarn may be any fiber forming polymer such as polyamide, polystyrene, polyethylene, or polyester, as long as a difference between it and the island component in the solvent dissolution rate is 30 times or more. Particularly polyesters are preferred in view of controlling the solvent solubility. For example, the sea component polymer may be a polymer soluble in an alkaline aqueous solution of potassium hydroxide, sodium hydroxide, etc., which is optimally a polylactic acid, a polyethylene glycol-based polyester copolymer, or a polyester copolymer of 5-sodium sulfonate isophthalate. It is particularly preferred that the sea-island composite filament yarn is knitted or woven, and the sea component is dissolved and removed by a known alkali weight loss apparatus to obtain the extra fine yarn. It should be noted that nylon 6 is soluble in formic acid, and polystyrene is soluble in an organic solvent such as toluene.
The island component polymer may be any fiber forming polymer such as polyamide, polystyrene, polyethylene, or polyester, and is preferably a polyethylene terephthalate.
The shape of the deodorant functional agent-containing extra fine filament yam of the invention in the length direction is not particularly limited. Thus, the filament yarn may be a yarn having a substantially constant diameter in the length direction, a thick and thin yam having a diameter variation in the length direction, or another yarn.
The photocatalyst-containing extra fine filament yarn may comprise a short or long fiber, and may be a spun yarn, a multifilament yarn, or a composite yarn of short and long fibers.
The filament yam of the invention may be subjected to an optional processing or treatment such as a false-twist processing, an air entanglement treatment (e.g. an interlacing processing), a crimping processing, an antishrink treatment, an anticrease treatment, a hydrophilization processing, a waterproofing processing, or an antidyeing processing, depending on the application or fiber type.
The deodorant functional agent-containing extra fine filament yam of the invention may contain a common additive in addition to the deodorant functional agent depending on the fiber type. Examples of such additives include antioxidants, flame retardants, antistatics, colorants, lubricants, insect repellents, tick repellents, antifungals, ultraviolet absorbents, and flatting agents.
The deodorant functional agent-containing extra fine filament yam of the invention can be used in various fibrous products. Examples of such products include yarns, clothes (such as woven fabrics, knitted fabrics, and nonwoven fabrics), pile clothes (such as woven pile fabrics and knitted pile fabrics), apparel clothes and other wears produced therefrom, interior products, bedclothes, and food packing materials. Specific examples thereof include apparel clothes and other wears such as underwears, sweaters, jackets, pajamas, summer kimonos (yukatas), white garments, slacks, socks, gloves, stockings, aprons, masks, towels, handkerchiefs, supporters, headhands, caps, shoe insoles, and padding clothes, and further include carpets, curtains, shop curtains (norens), wallpapers, sliding screen papers (shoji papers), sliding paper doors (fusumas), fiber blinds, artificial houseplants, fabrics for chairs, tableclothes, electric apparatus covers, straw mats (tatamis), fillings (e.g. cotton fillings) and side fabrics for Japanese beddings (futons), sheets, blankets, futon covers, pillows, pillow cases, bedcovers, fillings for beds, mats, hygiene materials, toilet seat covers, wiping clothes, and filters for air cleaners and air conditioners.
For example, under irradiation of a solar light, a fluorescent lamp, an ultraviolet ray lamp, etc., the deodorant functional agent-containing extra fine filament yarn of the invention and the fibrous product containing the filament yam can decompose various odorous components and make the components odorless rapidly over a long period. The odorous components include basic odorous components (such as ammonia and amines), acidic odorous components (such as acetic acid), and neutral odorous components (such as fonmalin and acetaldehyde). Thus, the filament yarn can efficiently remove even an odor containing many odorous components, such as a cigarette odor, and thereby is useful for deodorizing rooms and cars. In addition, the filament yarn is useful also for deodorizing aldehydes such as formalin or acetaldehyde generated from furnitures and new building materials.
In the light irradiation, the light wavelength may be selected depending on the photocatalyst. The light wavelength is not limited as long as the photocatalyst can be activated, and the light generally contains an ultraviolet ray. The titanium oxide used as the photocatalyst can show a sufficiently effective catalytic activity even under a solar light or a fluorescent lamp light. The light irradiation.is generally carried out in the presence of oxygen or an oxygen-containing matrix such as air.
Examples The present invention will be described more specifically with reference to Examples and Comparative Examples below. It is to be understood that the invention is not limited to Examples, and various modifications may be made therein without departing from the scope of the invention. Characteristic values described in Examples were measured as follows.
(1) Deodorizing function Deodorizing function was evaluated using a deodorization rate by the following method.
Using ammonia as an odorous component, 3 L of a gas having an initial odorous component concentration of 100 ppm was enclosed together with 1 g of a cylindrically knitted sample in a Tedlar bag. In the case of using a photocatalyst as a deodorant functional agent, the sample was irradiated with an ultraviolet ray lamp at 1.2 mW/cm2=hr.
After 24 hours, the residual odorous component concentration in the container was measured by a detecting tube. A blank examination was carried out in the same manner except for not using the sample. The deodorization rate was calculated using the following equation.
Deodorization rate (%) = l00x(Co-C1)/Co Co: Concentration measured after 24 hours in blank examination C1 : Concentration measured after 24 hours in Tedlar bag containing sample (2) Number of exposed particles A photograph of a side of drawn yarns arranged in parallel was taken at 5000 magnification using a scanning electron microscope. The number of particles exposed between cracked fiber surfaces per 25 m2 was counted, and the average value was calculated at n=10.
(3) Number of portions thicker than single yarn diameter.
In the same manner as the measurement of the exposed particle number, using the above photograph, the number of portions clearly thicker than the average single yarn diameter per 25 m2 was counted, and the average value was calculated at n=10.
(4) Average secondary particle diameter of deodorant functional agent The average secondary particle diameter of the deodorant functional agent can be measured by various methods. For example, the particle diameter can be measured using a dynamic light scattering particle size distribution measuring apparatus. For example, MICROTRAC UPA (model 9340-UPA150) manufactured by Nikkiso Co., Ltd. may be used as the particle size distribution measuring apparatus.
[Example I]
A polyethylene terephthalate having an intrinsic viscosity of 0.64 (at 35 C, in orthochlorophenol) was used as a base polymer, 10% by weight of a masterbatch was chip-blended with the base polymer, and the resultant was melted at 285 C by an extruder.
The masterbatch was prepared using 10 parts by weight of a deodorant functional agent (a titanium oxide photocatalyst ST 01 available from Ishihara Sangyo Kaisha, Ltd.), which had an average secondary particle diameter of 1.2 gm measured by MICROTRACUPA
(model 9340-UPA150) manufactured by Nikkiso Co., Ltd.
A modified polyethylene terephthalate copolymerized with 4 wt% of a polyethylene glycol (PEG) having an average molecular weight of 4000 and a melt viscosity of 1600 poise at 285 C and 8 mol% of 5-sodium sulfoisophthalate (SIP) as a sea component was melted by another extruder.
The photocatalyst-containing polyester was used as an island component, and each of the melted polymers were extruded at a sea/island component weight ratio of from a spinneret having an island number of 836 at a spinning temperature of 285 C.
The extruded polymers were pulled at a spinning speed of 1000 m/minute, and drawn at a preheating temperature of 90 C, a heat setting temperature of 140 C, and a draw ratio of 4.0 without temporal winding. The resultant was winded at 3950 m/minute to obtain a 56-dtex/I0-fil drawn yarn.
A cylindrically knitted sample was prepared using the obtained drawn yam, and its weight was reduced by 30% at 55 C by a 2.5% aqueous NaOH solution. As a result of observing a cross-section of the filament yarn, a uniform aggregate of extra fine fibers was formed, and the extra fine single yarn fibers had an average diameter of 690 nm.
Furthermore, thick and thin portions containing the deodorant functional agent particles thicker than the fiber diameter were found on the side surface of the filament yarn. The deodorant functional agent particles thinner than the fiber diameter were directly observed in cracks on the yarn surface. As a result of evaluating the deodorizing function of the cylindrically knitted sample, the sample exhibited a deodorization rate of 100%. The results are shown in Table 1.
[Example 2]
Production and evaluation were carried out in the same manner as Example 1 except for changing the extrusion amount to prepare extra fine single yam fibers having an average diameter of 385 nm. The results are shown in Table 1.
[Comparative Example 1]
Production and evaluation were carried out in the same manner as Example I
except for not using the photocatalyst masterbatch. The results are shown in Table 1.
[Comparative Example 2]
Production and evaluation were carried out in the same manner as Example 1 except for using another spinneret in the spinning to prepare extra fine single yarn fibers having an average diameter of 2510 nm. The results are shown in Table 1.
[Comparative Example 3]
Production and evaluation were carried out in the same manner as Example I
except for significantly reducing the extrusion amount to prepare extra fine single yam fibers having an average diameter of 153 nm. However, the resultant single yarn fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 3]
Production and evaluation were carried out in the same manner as Example 1 except that LIONITE PC available from Lion Corporation (average secondary particle diameter 3 m) was used instead of the above photocatalyst and crushed into an average particle diameter of 1.9 gm using a jet mill manufactured by Seishin Enterprise Co., Ltd.
(model STJ-200). The results are shown in Table 1.
[Comparative Example 4]
Production and evaluation were carried out in the same manner as Example 3 except for not crushing the LIONITE PC available from Lion Corporation (average secondary particle diameter 3 m). However, the resultant single yam fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 4]
Production and evaluation were carried out in the same manner as Example I
except that an adsorbent MIZUKANITE HF available from Mizusawa Industrial Chemicals, Ltd. (average secondary particle diameter 2.7 m) was used instead of the above photocatalyst and crushed into an average particle diameter of 1.9 pm using a jet mill manufactured by Seishin Enterprise Co., Ltd. (model STJ-200). The results are shown in Table 1.
[Comparative Example 5]
Production and evaluation were carried out in the same manner as Example 4 except for not crushing the MIZUKANITE HF available from Mizusawa Industrial Chemicals, Ltd. (average secondary particle diameter 2.7 m). However, the resultant single yarn fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 5]
Production and evaluation were carried out in the same manner as Example I
except for using a deodorant KESMON NS- 10 available from Toagosei Co., Ltd.
(average secondary particle diameter 0.9 gm) instead of the above photocatalyst. The results are shown in Table 1.
[Example 6]
Production and evaluation were carried out in the same manner as Example 1 except for using an antibacterial agent NOVARON AG300 available from Toagosei Co., Ltd. (average secondary particle diameter 0.9 m) instead of the above photocatalyst.
The results are shown in Table 1.
The samples of Examples 2 to 6, as well as the sample of Example 1, included in the scope of the invention were excellent in the deodorizing function. In contrast, the photocatalyst was not used in Comparative Example 1, and the numbers of the exposed photocatalyst particles and the portions thicker than the fiber diameter were significantly small in Comparative Example 2, whereby the samples of Comparative Examples 1 and 2 were remarkably poor in the deodorizing function. The results are shown in Table 1.
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In addition, also when an adsorbent is kneaded into the filament as the deodorant functional agent, the fiber polymer per se inhibits the absorption function of the adsorbent, thereby lowering the efficiency.
Thus, the deodorant functional agent-containing extra fine multifilament of the invention contains at least the deodorant functional agent having a secondary particle diameter more than the average diameter of the extra fine single yam fibers, and the deodorant functional agent is not completely covered with the fiber polymer.
As a result, the deodorant efficiency is dramatically improved.
In general, it is difficult to produce a filament yarn, particularly an extra fine filament yarn, containing particles larger than the fiber diameter, because the spinnability is deteriorated by the particles in the production.
However, in the invention, it has found that the above extra fine multifilament can be produced by the steps of adding the deodorant functional agent to an island component of a sea-island composite filament yarn, and removing a sea component from the yam to obtain the extra fine filament yarn containing the island component. Even when the island component has a brittle fiber structure (a structure containing the particles having a secondary particle diameter more than the extra fine single yam fiber diameter, thus a low-strength structure), the sea-island composite filament yarn can have a strength sufficient for spin-drawing due to the sea component. Further, even after removing the sea component, the resultant extra fine filament yam can have a sufficient strength due to the multifilament structure.
In the preparation of the sea-island composite filament yarn, it is preferred that a spun composite yarn is not winded up temporarily and is successively subjected to a drawing treatment in a spinning-direct drawing method. In the spinning-direct drawing method, the deodorant functional agent particles having the secondary particle diameter equal to or more than the extra fine single yarn fiber diameter cannot follow the stretch of the fiber polymer. Therefore, the area of the particles, not covered with the fiber polymer and exposed on the yarn surface, is increased. In view of improving the balance between the deodorant effect and fiber properties, 5 or more particles of the deodorant functional agent per 25 m2 are not completely covered with the fiber polymer and are partially exposed on the surface of the multifilament.
It should be noted that, when excessively many particles are exposed on the multifilament surface, the qualities (the strength, elongation, and fluff) of the multifilament are remarkably deteriorated disadvantageously. Thus, the number of the particles exposed on the multifilament surface is preferably 25 or less per 25 m2.
In this embodiment, the deodorant functional agent acts as a foreign substance in the fiber polymer. Each portion containing the deodorant functional agent has a low fiber polymer content, and thereby cannot follow the stretch of the fiber polymer.
Thus, the portion is cracked, and the deodorant functional agent is partially separated from the fiber polymer therein to form an exposed area. In the exposed area, light incident and photocatalytic decomposition of a subject component are efficiently carried out, so that the deodorant function is dramatically improved.
The cross-sectional shape of the deodorant functional agent-containing extra fine filament yarn of the invention is not particularly limited, and may be a modified cross-sectional shape. Specific examples of the modified cross-sectional shapes include, but not limited thereto, T shapes, U shapes, V shapes, H shapes, Y shapes, W
shapes, 3- to 14-leaf shapes, and polygonal shapes. The filament yarn may have a solid or hollow fiber structure.
In the invention, the photocatalyst used as the deodorant functional agent may be an oxidation photocatalyst, which generates active radicals under irradiation of a light such as an ultraviolet ray to oxidation-decompose various harmful substances and bad odor substances.
Thus, the photocatalyst preferably has an oxidation activity. Such a photocatalyst exhibits a deodorant function utilizing not only adsorbent but also catalytic decomposition, and thereby can maintain a deodorant or deodorization effect over a long period.
Furthermore, the photocatalyst has a bactericidal effect, an antibacterial effect, etc. in addition to the effect of decomposing the harmful substances and bad odor substances.
The photocatalyst may be an inorganic or organic substance, and may be selected from various optical semiconductors. The photocatalyst is generally an inorganic optical semiconductor, and examples thereof include sulfide semiconductors (such as CdS, ZnS, In2S3, PbS, Cu2S, MoS3, WS2, Sb3S3, Bi3S3, and ZnCdS2), metal chalcogenides (such as CdSe, In2Se3i WSe3, HgSe, PbSe, and CdSe), and oxide semiconductors (such as TiO2, ZnO, W03, CdO, In203, Ag2O, Mn02, Cu2O, Fe203, V205, and Sn02). The examples further include semiconductors other than sulfide and oxide semiconductors, such as GaAs, Si, Se, CdP3, and Zn2P3. The photocatalysts may be used singly or as a combination of two or more.
Among the above photocatalyst, preferred are sulfide semiconductors (such as CdS
and ZnS) and oxide semiconductors (such as Ti02, ZnO, Sn02, and W03), and particularly preferred are Ti02 oxide semiconductors. The crystal structure of the optical semiconductor for the photocatalyst is not particularly limited. For example, the Ti02 semiconductor may be of anatase type, brookite type, rutile type, amorphous type, etc.
Particularly preferred TiO2 semiconductors include anatase-type titanium oxides.
The photocatalyst may be used in the state of a sol, a gel, or a powder (particles).
In the case of using the sol or gel of the photocatalyst, it is dried, solidified, and crushed into a desired particle diameter. The crushing may be carried out using a ball mill, a jet mill, etc., but the apparatus is not limited thereto. In the case of using the powder of the photocatalyst, the average secondary particle diameter of the photocatalyst is preferably 0.1 to 2 m, more preferably 0.2 to 1.5 m. When the particle diameter of the photocatalyst is more than 2 m, for example, filter clogging or fluff yarn breakage is often caused in the melt spinning step, and yarn breakage is increased in the drawing step.
The amount of the photocatalyst used may be selected from a wide range depending on the fiber structure, as long as the catalytic activity is not deteriorated. The ratio of the photocatalyst to the entire filament yarn is, for example, 0.1 %
to 25% by mass, preferably 0.3% to 20% by mass, more preferably 0.5% to 10% by mass.
In the invention, the deodorant functional agent may comprise an adsorbent, a deodorant, an antibacterial agent, a bacteriostatic agent, or a combination thereof.
The adsorbent, deodorant, antibacterial agent, bacteriostatic agent cannot be clearly distinguished, and are not particularly limited. Examples of the agents include those containing, as main component, at least one selected from the group consisting of tetravalent metal phosphates, divalent metal hydroxides, silver oxides, zinc oxides, aluminum oxides, silicon oxides, zirconium oxides, silver ions, copper ions, and zinc ions.
Specifically, the agent may be selected from MIZUKANITE available from Mizusawa Industrial Chemicals, Ltd., LIONITE available from Lion Corporation, hydrotalcite compounds available from Kyowa Chemical Industry Co., Ltd., KESMON series and NOVARON series available from Toagosei Co., Ltd., KD-211GF available from Rasa Industries, Ltd., TZ-100 and SZ-100S available from Titan Kogyo, Ltd., and mixtures thereof, etc.
The average secondary particle diameter of the deodorant functional agent is preferably 0.1 to 2 m, more preferably 0.2 to 1.5 m. When the particle diameter is more than 2 m, for example, filter clogging or fluff yarn breakage is often caused in the melt spinning step, and yarn breakage is increased in the drawing step.
The amount of the deodorant functional agent used may be selected from a wide range as long as the qualities (the strength, elongation, and fluff) of the filament yam are not deteriorated. The ratio of the agent to the entire filament yarn is, for example, 0.1%
to 25% by mass, preferably 0.3% to 20% by mass, more preferably 0.5% to 10% by mass.
The deodorant functional agent may be attached to the island component polymer as described above as follows: 1. the deodorant functional agent is added in or immediately after the polymerization of the island component polymer; 2. a masterbatch containing a base of the island component polymer and the deodorant functional agent is prepared and used; or 3. the deodorant functional agent is added in an optional step (such as a polymer pellet preparation step or a melt spinning step) before completion of the spinning; etc. The method using the masterbatch is preferred from the viewpoint of preventing side reactions due to the catalytic activity in the polymerization, etc.
In the deodorant functional agent-containing extra fine multifilament of the invention, a plurality of the deodorant functional agents may be used in combination to improve the catalytic function.
The sea-island composite filament yarn used in the invention may be prepared by using a known sea-island composite spinneret as shown in Figs. 1 and 2. The island component and the sea component are extruded in the melt states, and the resultant fibers are melt-spun at a rate of 500 to 3500 mlminute and then subjected to a drawing treatment and a heat treatment without temporal winding.
As the number of the islands is larger, the fibers of the island component are thinner after dissolution in the sea. The number of the islands is preferably 100 to 1,000 per single yarn. When the number is less than 100, the resultant yam has a low island ratio and cannot show properties specific to the extra fine filament yarn. On the other hand, when the number is more than 1,000, costs for producing the spinneret are increased, and its processing accuracy is often deteriorated. The number is further preferably 500 to 1,000.
The dissolution rate of the sea component is preferably 30 to 5,000 times, more preferably 100 to 4,000 times as high as that of the island component. When the dissolution rate ratio is less than 30 times, in a cross-section of the filament yarn, the separate island component is partially dissolved in a surface portion, and the sea component is often not dissolved in a center portion. As a result, the thickness of the island component is made uneven to deteriorate the quality. On the other hand, when the dissolution rate ratio is more than 5,000 times, it is difficult to form the filament yarn.
The sea component polymer for forming the sea-island composite filament yarn may be any fiber forming polymer such as polyamide, polystyrene, polyethylene, or polyester, as long as a difference between it and the island component in the solvent dissolution rate is 30 times or more. Particularly polyesters are preferred in view of controlling the solvent solubility. For example, the sea component polymer may be a polymer soluble in an alkaline aqueous solution of potassium hydroxide, sodium hydroxide, etc., which is optimally a polylactic acid, a polyethylene glycol-based polyester copolymer, or a polyester copolymer of 5-sodium sulfonate isophthalate. It is particularly preferred that the sea-island composite filament yarn is knitted or woven, and the sea component is dissolved and removed by a known alkali weight loss apparatus to obtain the extra fine yarn. It should be noted that nylon 6 is soluble in formic acid, and polystyrene is soluble in an organic solvent such as toluene.
The island component polymer may be any fiber forming polymer such as polyamide, polystyrene, polyethylene, or polyester, and is preferably a polyethylene terephthalate.
The shape of the deodorant functional agent-containing extra fine filament yam of the invention in the length direction is not particularly limited. Thus, the filament yarn may be a yarn having a substantially constant diameter in the length direction, a thick and thin yam having a diameter variation in the length direction, or another yarn.
The photocatalyst-containing extra fine filament yarn may comprise a short or long fiber, and may be a spun yarn, a multifilament yarn, or a composite yarn of short and long fibers.
The filament yam of the invention may be subjected to an optional processing or treatment such as a false-twist processing, an air entanglement treatment (e.g. an interlacing processing), a crimping processing, an antishrink treatment, an anticrease treatment, a hydrophilization processing, a waterproofing processing, or an antidyeing processing, depending on the application or fiber type.
The deodorant functional agent-containing extra fine filament yam of the invention may contain a common additive in addition to the deodorant functional agent depending on the fiber type. Examples of such additives include antioxidants, flame retardants, antistatics, colorants, lubricants, insect repellents, tick repellents, antifungals, ultraviolet absorbents, and flatting agents.
The deodorant functional agent-containing extra fine filament yam of the invention can be used in various fibrous products. Examples of such products include yarns, clothes (such as woven fabrics, knitted fabrics, and nonwoven fabrics), pile clothes (such as woven pile fabrics and knitted pile fabrics), apparel clothes and other wears produced therefrom, interior products, bedclothes, and food packing materials. Specific examples thereof include apparel clothes and other wears such as underwears, sweaters, jackets, pajamas, summer kimonos (yukatas), white garments, slacks, socks, gloves, stockings, aprons, masks, towels, handkerchiefs, supporters, headhands, caps, shoe insoles, and padding clothes, and further include carpets, curtains, shop curtains (norens), wallpapers, sliding screen papers (shoji papers), sliding paper doors (fusumas), fiber blinds, artificial houseplants, fabrics for chairs, tableclothes, electric apparatus covers, straw mats (tatamis), fillings (e.g. cotton fillings) and side fabrics for Japanese beddings (futons), sheets, blankets, futon covers, pillows, pillow cases, bedcovers, fillings for beds, mats, hygiene materials, toilet seat covers, wiping clothes, and filters for air cleaners and air conditioners.
For example, under irradiation of a solar light, a fluorescent lamp, an ultraviolet ray lamp, etc., the deodorant functional agent-containing extra fine filament yarn of the invention and the fibrous product containing the filament yam can decompose various odorous components and make the components odorless rapidly over a long period. The odorous components include basic odorous components (such as ammonia and amines), acidic odorous components (such as acetic acid), and neutral odorous components (such as fonmalin and acetaldehyde). Thus, the filament yarn can efficiently remove even an odor containing many odorous components, such as a cigarette odor, and thereby is useful for deodorizing rooms and cars. In addition, the filament yarn is useful also for deodorizing aldehydes such as formalin or acetaldehyde generated from furnitures and new building materials.
In the light irradiation, the light wavelength may be selected depending on the photocatalyst. The light wavelength is not limited as long as the photocatalyst can be activated, and the light generally contains an ultraviolet ray. The titanium oxide used as the photocatalyst can show a sufficiently effective catalytic activity even under a solar light or a fluorescent lamp light. The light irradiation.is generally carried out in the presence of oxygen or an oxygen-containing matrix such as air.
Examples The present invention will be described more specifically with reference to Examples and Comparative Examples below. It is to be understood that the invention is not limited to Examples, and various modifications may be made therein without departing from the scope of the invention. Characteristic values described in Examples were measured as follows.
(1) Deodorizing function Deodorizing function was evaluated using a deodorization rate by the following method.
Using ammonia as an odorous component, 3 L of a gas having an initial odorous component concentration of 100 ppm was enclosed together with 1 g of a cylindrically knitted sample in a Tedlar bag. In the case of using a photocatalyst as a deodorant functional agent, the sample was irradiated with an ultraviolet ray lamp at 1.2 mW/cm2=hr.
After 24 hours, the residual odorous component concentration in the container was measured by a detecting tube. A blank examination was carried out in the same manner except for not using the sample. The deodorization rate was calculated using the following equation.
Deodorization rate (%) = l00x(Co-C1)/Co Co: Concentration measured after 24 hours in blank examination C1 : Concentration measured after 24 hours in Tedlar bag containing sample (2) Number of exposed particles A photograph of a side of drawn yarns arranged in parallel was taken at 5000 magnification using a scanning electron microscope. The number of particles exposed between cracked fiber surfaces per 25 m2 was counted, and the average value was calculated at n=10.
(3) Number of portions thicker than single yarn diameter.
In the same manner as the measurement of the exposed particle number, using the above photograph, the number of portions clearly thicker than the average single yarn diameter per 25 m2 was counted, and the average value was calculated at n=10.
(4) Average secondary particle diameter of deodorant functional agent The average secondary particle diameter of the deodorant functional agent can be measured by various methods. For example, the particle diameter can be measured using a dynamic light scattering particle size distribution measuring apparatus. For example, MICROTRAC UPA (model 9340-UPA150) manufactured by Nikkiso Co., Ltd. may be used as the particle size distribution measuring apparatus.
[Example I]
A polyethylene terephthalate having an intrinsic viscosity of 0.64 (at 35 C, in orthochlorophenol) was used as a base polymer, 10% by weight of a masterbatch was chip-blended with the base polymer, and the resultant was melted at 285 C by an extruder.
The masterbatch was prepared using 10 parts by weight of a deodorant functional agent (a titanium oxide photocatalyst ST 01 available from Ishihara Sangyo Kaisha, Ltd.), which had an average secondary particle diameter of 1.2 gm measured by MICROTRACUPA
(model 9340-UPA150) manufactured by Nikkiso Co., Ltd.
A modified polyethylene terephthalate copolymerized with 4 wt% of a polyethylene glycol (PEG) having an average molecular weight of 4000 and a melt viscosity of 1600 poise at 285 C and 8 mol% of 5-sodium sulfoisophthalate (SIP) as a sea component was melted by another extruder.
The photocatalyst-containing polyester was used as an island component, and each of the melted polymers were extruded at a sea/island component weight ratio of from a spinneret having an island number of 836 at a spinning temperature of 285 C.
The extruded polymers were pulled at a spinning speed of 1000 m/minute, and drawn at a preheating temperature of 90 C, a heat setting temperature of 140 C, and a draw ratio of 4.0 without temporal winding. The resultant was winded at 3950 m/minute to obtain a 56-dtex/I0-fil drawn yarn.
A cylindrically knitted sample was prepared using the obtained drawn yam, and its weight was reduced by 30% at 55 C by a 2.5% aqueous NaOH solution. As a result of observing a cross-section of the filament yarn, a uniform aggregate of extra fine fibers was formed, and the extra fine single yarn fibers had an average diameter of 690 nm.
Furthermore, thick and thin portions containing the deodorant functional agent particles thicker than the fiber diameter were found on the side surface of the filament yarn. The deodorant functional agent particles thinner than the fiber diameter were directly observed in cracks on the yarn surface. As a result of evaluating the deodorizing function of the cylindrically knitted sample, the sample exhibited a deodorization rate of 100%. The results are shown in Table 1.
[Example 2]
Production and evaluation were carried out in the same manner as Example 1 except for changing the extrusion amount to prepare extra fine single yam fibers having an average diameter of 385 nm. The results are shown in Table 1.
[Comparative Example 1]
Production and evaluation were carried out in the same manner as Example I
except for not using the photocatalyst masterbatch. The results are shown in Table 1.
[Comparative Example 2]
Production and evaluation were carried out in the same manner as Example 1 except for using another spinneret in the spinning to prepare extra fine single yarn fibers having an average diameter of 2510 nm. The results are shown in Table 1.
[Comparative Example 3]
Production and evaluation were carried out in the same manner as Example I
except for significantly reducing the extrusion amount to prepare extra fine single yam fibers having an average diameter of 153 nm. However, the resultant single yarn fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 3]
Production and evaluation were carried out in the same manner as Example 1 except that LIONITE PC available from Lion Corporation (average secondary particle diameter 3 m) was used instead of the above photocatalyst and crushed into an average particle diameter of 1.9 gm using a jet mill manufactured by Seishin Enterprise Co., Ltd.
(model STJ-200). The results are shown in Table 1.
[Comparative Example 4]
Production and evaluation were carried out in the same manner as Example 3 except for not crushing the LIONITE PC available from Lion Corporation (average secondary particle diameter 3 m). However, the resultant single yam fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 4]
Production and evaluation were carried out in the same manner as Example I
except that an adsorbent MIZUKANITE HF available from Mizusawa Industrial Chemicals, Ltd. (average secondary particle diameter 2.7 m) was used instead of the above photocatalyst and crushed into an average particle diameter of 1.9 pm using a jet mill manufactured by Seishin Enterprise Co., Ltd. (model STJ-200). The results are shown in Table 1.
[Comparative Example 5]
Production and evaluation were carried out in the same manner as Example 4 except for not crushing the MIZUKANITE HF available from Mizusawa Industrial Chemicals, Ltd. (average secondary particle diameter 2.7 m). However, the resultant single yarn fibers were extensively broken in the spinning and drawing, so that a sample usable for the deodorizing function evaluation could not be produced. The results are shown in Table 1.
[Example 5]
Production and evaluation were carried out in the same manner as Example I
except for using a deodorant KESMON NS- 10 available from Toagosei Co., Ltd.
(average secondary particle diameter 0.9 gm) instead of the above photocatalyst. The results are shown in Table 1.
[Example 6]
Production and evaluation were carried out in the same manner as Example 1 except for using an antibacterial agent NOVARON AG300 available from Toagosei Co., Ltd. (average secondary particle diameter 0.9 m) instead of the above photocatalyst.
The results are shown in Table 1.
The samples of Examples 2 to 6, as well as the sample of Example 1, included in the scope of the invention were excellent in the deodorizing function. In contrast, the photocatalyst was not used in Comparative Example 1, and the numbers of the exposed photocatalyst particles and the portions thicker than the fiber diameter were significantly small in Comparative Example 2, whereby the samples of Comparative Examples 1 and 2 were remarkably poor in the deodorizing function. The results are shown in Table 1.
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Claims (8)
1. A deodorant functional agent-containing extra fine multifilament, characterized in that (a) the multifilament comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, and b) the multifilament comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yam fibers, wherein 5 to 25 particles of the deodorant functional agent per 25 µm2 are not completely covered with a fiber polymer and are partially exposed on the surface of the multifilament.
2. A deodorant functional agent-containing extra fine multifilament according to claim 1, wherein the deodorant functional agent is a photocatalyst.
3. A deodorant functional agent-containing extra fine multifilament according to claim 1, wherein the deodorant functional agent is an adsorbent, a deodorant, an antibacterial agent, or a bacteriostatic agent.
4. A deodorant functional agent-containing extra fine multifilament according to any of claims 1 to 3, wherein the deodorant functional agent has an average secondary particle diameter of 0.1 to 2 µm.
5. A deodorant functional agent-containing extra fine multifilament according to any of claims 1 to 4, wherein the polymer constituting the fibers comprises a polyester-based polymer.
6. A deodorant functional agent-containing extra fine multifilament according to claim 2, wherein the photocatalyst is mainly composed of titanium oxide.
7. A deodorant functional agent-containing extra fine multifilament according to claim 3, wherein the adsorbent, deodorant, antibacterial agent, or bacteriostatic agent contains, as main component, at least one of metal ions selected from the group consisting of silver ions, copper ions, and zinc ions, at least one of metal oxides selected from the group consisting of silver oxides, zirconium oxides, zinc oxides, aluminum oxides, and silicon oxides, or at least one of tetravalent metal phosphates, and divalent metal hydroxides.
8. A method for producing a deodorant functional agent-containing extra fine multifilament, comprising removing a sea component from a sea-island composite filament yarn including the sea component and island component to obtain an extra fine multifilament containing an island component, characterized in that (a) the island component comprises extra fine single yarn fibers having an average diameter of 200 to 2000 nm, (b) the island component comprises at least a deodorant functional agent having a secondary particle diameter equal to or more than the diameter of the extra fine single yarn fibers, and (c) the sea-island composite filament yarn is prepared by melt spinning and direct drawing without temporal winding.
Applications Claiming Priority (3)
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| JP2008218079A JP5400330B2 (en) | 2008-08-27 | 2008-08-27 | Photocatalyst-containing ultrafine fiber and method for producing the same |
| JP2008-218079 | 2008-08-27 | ||
| PCT/JP2009/065137 WO2010024423A1 (en) | 2008-08-27 | 2009-08-25 | Ultrafine fibers containing deodorizing agent and manufacturing method therefor |
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| CA2734872C CA2734872C (en) | 2016-03-15 |
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| CA2734872A Expired - Fee Related CA2734872C (en) | 2008-08-27 | 2009-08-25 | Extra fine filament yarn containing deodorant functional agent and producing the same |
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| US (1) | US20110142900A1 (en) |
| EP (1) | EP2319964B1 (en) |
| JP (1) | JP5400330B2 (en) |
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| RU (1) | RU2500841C2 (en) |
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| KR20070001246A (en) * | 2004-04-27 | 2007-01-03 | 가부시키가이샤 구라레 | Deodorant suede-tone-leather-like sheet |
| JP2006265773A (en) * | 2005-03-24 | 2006-10-05 | Tmt Machinery Inc | Spinning method of polyester filament yarn |
| JP4586634B2 (en) * | 2005-05-26 | 2010-11-24 | 東レ株式会社 | Sea-island type composite fiber with excellent see-through property |
| CA2613854A1 (en) * | 2005-06-30 | 2007-01-11 | Kyowa Chemical Industry Co., Ltd. | Antibacterial agent composed of silver-containing aluminum sulfate hydroxide particles and use thereof |
| JP4880929B2 (en) * | 2005-07-07 | 2012-02-22 | 帝人テクノプロダクツ株式会社 | Composite structure and filter using the same |
| JP2007063714A (en) * | 2005-08-31 | 2007-03-15 | Toray Ind Inc | Ultrafine polyester fiber and cloth |
| WO2007078203A1 (en) * | 2006-01-03 | 2007-07-12 | Norwex Holding As | Anti-bacterial micro-fibre and production thereof |
| CZ303243B6 (en) * | 2006-06-30 | 2012-06-13 | Elmarco S. R. O. | Structure containing at least one layer of nanofibers and process for producing a nanofiber layer |
| JP5071097B2 (en) * | 2007-12-21 | 2012-11-14 | 東レ株式会社 | Sea-island polyester composite fiber |
-
2008
- 2008-08-27 JP JP2008218079A patent/JP5400330B2/en active Active
-
2009
- 2009-08-25 CA CA2734872A patent/CA2734872C/en not_active Expired - Fee Related
- 2009-08-25 BR BRPI0917680A patent/BRPI0917680A8/en not_active Application Discontinuation
- 2009-08-25 ES ES09810069.6T patent/ES2543454T3/en active Active
- 2009-08-25 KR KR1020117005764A patent/KR101599090B1/en active IP Right Grant
- 2009-08-25 WO PCT/JP2009/065137 patent/WO2010024423A1/en active Application Filing
- 2009-08-25 EP EP20090810069 patent/EP2319964B1/en active Active
- 2009-08-25 US US13/059,570 patent/US20110142900A1/en not_active Abandoned
- 2009-08-25 RU RU2011111489/05A patent/RU2500841C2/en not_active IP Right Cessation
- 2009-08-25 AU AU2009284902A patent/AU2009284902A1/en not_active Abandoned
- 2009-08-25 CN CN200980133283.4A patent/CN102131966B/en active Active
- 2009-08-27 TW TW098128867A patent/TWI491771B/en active
Also Published As
| Publication number | Publication date |
|---|---|
| CA2734872C (en) | 2016-03-15 |
| JP2010053470A (en) | 2010-03-11 |
| EP2319964A1 (en) | 2011-05-11 |
| BRPI0917680A8 (en) | 2018-08-14 |
| BRPI0917680A2 (en) | 2015-12-01 |
| KR20110044898A (en) | 2011-05-02 |
| CN102131966B (en) | 2013-01-23 |
| ES2543454T3 (en) | 2015-08-19 |
| KR101599090B1 (en) | 2016-03-02 |
| US20110142900A1 (en) | 2011-06-16 |
| AU2009284902A1 (en) | 2010-03-04 |
| JP5400330B2 (en) | 2014-01-29 |
| EP2319964B1 (en) | 2015-05-20 |
| TW201022494A (en) | 2010-06-16 |
| WO2010024423A1 (en) | 2010-03-04 |
| TWI491771B (en) | 2015-07-11 |
| RU2500841C2 (en) | 2013-12-10 |
| EP2319964A4 (en) | 2012-10-24 |
| CN102131966A (en) | 2011-07-20 |
| RU2011111489A (en) | 2012-10-10 |
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| EEER | Examination request |
Effective date: 20140313 |
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| MKLA | Lapsed |
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