Polyester Microfiber
Transcript of Polyester Microfiber
Features of Micro-fiber or (Fine-Denier Fiber)
Effects of Fabrics: Soft touch Excellent Drape property Freshness Comfortable High Exhaustion of oil and others etc.
*1) Shin-Gohsen is a mixture (blending) of many kinds of Micro-Fiber (Fine-denier) Polyester filament, following new touch were obtained. Peach skin touch Rayon touch (Rose pedal touch) New silky touch New woolen touch
Definition of Micro-fiber (Fine denier)
Less than 1 dtex (φ10 μm): difficult to spin industrially, called ultra fine fiber or micro-fiberLess than 0.1 dtex: called ultra micro-fiberLess than 0.01 dtex: called super ultra micro-fiber
1 dtex 10 dtex0.1 dtex0.01 dtex 2 3 50.2 0.3 0.50.02 0.03 0.05
Regular FiberMicro FiberSuperMicro FiberSuper Ultra
Micro Fiber
Applications of Micro-fiber
Artificial Leather(Suede, Smooth)
Artificial Fur High touch materials
Shin-GohsenSilky touch
Rose petal touchPeach skin touch
Powder touch
*1) Garments, Bug, Shoes, Cap, Sports goods,Furniture, Car seat,
Wall Cloth, Display tool,Polishing material
*5) Reduction of Fluid resistanceHydro-plane property
Non-adherent of Sea plants and animals
FlexibilityFissionability
Aesthetic property*2) Wiping propertyFiltration property
*3) Absorption propertyWater Repellent property
*4) Application using Specific Property
High strengthHigh Smoothing
*8) Compatibility to living body
*6) Response property to Environment
Chemical reactive propertyResponse property to electricity
*7) Reinforcement propertyDisposition property
Development of Micro-Fiber
Ultra micro-fiber
(Complex fiber)
*1) Application of high touch materialsGarments, bag, shoes, cap,
Glove for golf, Golf bagFurniture, Car sheet,
Wall Cloth, Display tool,Polishing material,
Video deck, Tape recorder, Piano,Water absorption roll, Mouse pad
2) Application of Wiping and filtering propertyWiping cloth, Wiper for spectacles,
Cleansing cloth, Greasy sweat cloth,Dust cloth, Mouse pad,
High performance Air filter,Filtering cloth/ Filtering materials,
Anti-dusting wear, Anti-dusting mask, Battery Separator,
Side cloth for Quilt DownHealthy underwear,
Anti-vermin bed cloth etc.
*5) Reduction of Fluid resistance: Ski and Skate wear, Jump suits, Swimming race wear
*6) Application to Response property to environmentChemical reactive propertyResponse property to electricity High speed response gel fiberHeat resistance/chemical resistance Squeezing rollArtificial muscleMicro-scissors/ tweezer (for Catheter)Morter-less drive
3) Application of Absorption and Water repellent propertyWater permeable/ Water repellent Woven/ Knitted fabrics,Water permeable/ Water repellent Construction materials,
Water absorbable/ Oil absorbable materials, Water Absorbable towel, Water absorbable roller,
Stamp pad, Typing ribbon, Oil/ Water separation fabrics
4) Special usagesPolishing cloth, Sound control cloth,
Environmental control cloth for making sensitivity moodVivid printing , Map fabrics,
Distinction fabrics, Bar code fabrics, Hot melt adhesive materials,
Air bug for automobile, Information built-in fiber, Handy garments (Low bulky, Collapsible),
Signet stamp pad, Writing pad,Cushion materials, Recycling Battery materials
*7) Application to Reinforcement and Disposition propertyIon exchangeable fiber; In-vitro Circulatory artificial liver,
Ammonia gas absorption filter, Image guide,Fiber reinforced plastics, Fibriled paper,
Super electro conductive fiber with metal complex
*8) Using for Compatible living bodyArtificial blood tube, Artificial bone,
Separation materials of blood, Cell culture carrier,Base material for enzyme fixation, Artificial tendon
Size / Scale of Disperse Dye and Polyester fiber
Optical MicroscopeElectron Microscope Naked eye
Visible ray
Dis
trib
utio
n of
Par
ticle
siz
e of
Dis
pers
e dy
e
Mol
ecul
ar s
ize
of D
ispe
rse
dye
Vaca
ncy
amon
g m
olec
ular
of P
ES p
olym
er
Vaca
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amon
g PE
S fil
amen
t
Thic
knes
s of
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o fil
amen
t
Bul
ky P
artic
le s
ize
in s
peck
Mes
h of
Fab
rics
(500
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Visi
ble
Spec
k si
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Cau
sing
Clo
gby
Coa
gula
ted
Part
icle
1 dtex 10 dtex0.1 dtex0.01 dtex 2 3 50.2 0.3 0.50.02 0.03 0.05
Regular FiberMicro FiberSuperMicro FiberSuper Ultra
Micro Fiber
Filament type : Island-in-a sea type fiber Separate type conjugate spinning Improved orthodox spinning type Weight reducing type Super draw type Drawing by Laser heating
Production Method
Random type : Meltblow spinning Flash spining Fiblisation Polymer blend spinning Tuck spinning Burst spinning Bacterium spinning Others
Before Separation After Separation
Sepa
rate
type
Dis
solv
ed R
emov
e ty
pe
Soluble to solvent Insoluble to solvent
General Dyeing Process:
・ Weight Reducing Finishing・ Relax Scouring・ Heat Setting
・ Dyeing
Pre-treatment Polyester Micro-fiber
Examples of Dyeing process(Without Weight Reducing, Relaxing process)
Example 1; Desizing—Rinsing—Drying—Pre-heat setting—Dyeing—Drying--Finishing
Example 2; Desizing—Rinsing—Dyeing—Drying—Finishing
Example 3; Desizing—Rinsing—Drying—Softening—Drying—Raising finishing—Setting --Dyeing—Softening--Finishing
Example 4; Desizing—Rinsing—Drying—Pre-heat setting—Dyeing—Softening—Drying — Raising finishing—Rinsing--Finishing
Weight Reducing Finishing
1) Purpose a) Roughing on the face of fabrics b) Softening by slender of yarn (less solidness) c) Loosing the organization of fabrics and giving drape property
2) Care points a) Reduction rate: Generally 10-30% and taken care of over reduction b) Not to happen Uneven reduction parts c) Deterioration of strength of fabrics by over reducing d) Yellowing of fabrics e) Removal of decomposed polyester f) Troubles caused by Accelerator for weight reduction g) Wastewater treatment problem, especially accelerator
3) Technical points
a) Procedures ; Many variations, such as Atmospheric pressure method, High pressure method, Continuous process, Hanging methodb) Stable reduction rate ; Caustic soda 4-20% c) Using accelerator (quaternary ammonium salt)— Control on Kinds of accelerator and Amounts Control of treatment temperature, time and liquor ratio (95-130 ℃ 、 1:20—1:60 )d) Uneven weight reduction relates to uneven dyeinge) Management of raw fabrics---- Scouring condition, uniform padding, pick-up rate, moisture rate, f) Other care points ; ・ Less uneven scouring ・ Yellowing by residual accelerator ・ Removing oligomer, decomposed polyester---causing logging at beam
dyeing, staining on dyeing machine and broken the knitting needle ・ Lowering the yarn strength ・ Residual accelerator causes Tarring trouble with disperse dye ・ Lowering color reproducibility by Residual accelerator ・ Wastewater treatment, increasing BOD, and influence to activated sludge
Procedures and Characteristics of Procedures
Process
Operation
Strength
HandlingAmountControl
Atmosphere Boiling methodImmense to NaOH soln. and
boiling in loop method
Batch-wiseX◎◎large◎
easiest
Atmosphere boiling method With Accelerator
(Jet dyeing machine)Batch-wiseX○○small○
easy
High pressure 130℃ method)Jet dyeing machine)Batch-
wise△△○—△medium○
High Pressure 130 method℃with Accelerator
(Jet dyeing machine)Batch-wise△--○--△X○—△least○
Continuous Pad-batch (roll) method
Semi--contin
uous.○◎◎large○
Continuous Pad-steam method contin
uous◎○○--◎medium○
Continuous Pad- cylinder dry method contin
uous◎○—△△large○—△
Calculation Method of Caustic Soda
Merits of high Pressure method : Even weight reduction Uniform reduction at any woven organization Available to smaller amounts of caustic soda Shorten the treatment time
Merits by using accelerators; Shortening time Homogenize among lot to lot variation Reduction of caustic soda amount
Weight reduction rate (%)=(192 X weight of NaOH) / (2 X 40) / weight of fabrics X 100 = 192 / 80 X using amount % owf of NaOH 192 : Molecular Weight of PES 、 2 X 40 : Molecular Weight of NaOH Weight of NaOH : gram number
Examples of practical weight reduction recipe
Example 1 ; Jet dyeing machine NaOH 10-30 g/l Accelerator 0.5 g/l 95 X 60 min. ℃ ( Boil X 30—60 min. ) Liquor ratio 1 : 30 After treatment ; Sandzpan LKF (Sandoz) 430 ml / Disperon 100 (Takamatss Yusi) 1073 ml /1,200 l Soaping 95 X 20 min. Not to use acid in this case.℃
Example 2 ; NaOH 30 g/l Hydrosulfite 5 g/l 98—100 X 75 min.℃ Reduction rate ; 20%
Example 3 ; High Pressure method NaOH x % owf (by calculated upon equation) Accelerator 0.5-2 g/l Liquor ratio 1:30 130 X 60 min.℃
Example 4 ; Jigger dyeing machine Scouring by Jigger Heat setting Weight Reduction Rinsing Neutralization Soaping NaOH 3% Accelerator 0.05% 95-98℃ Passing 6-8 times
Example 5 ; Winch dyeing machine NaOH x % owf Accelerator 0.5-2 g/l Dispersing agent 2 g/l Boil X 60-110 min. Neutralization by Acetic acid 2 g/l 、 Dispalon 100 1 g/l Hot rinsing, and rinsing
Example 6 ; Pad Steam or Pad Dry Neutralization Hot rinsing and rinsing NaOH 10 % soln. Methanol or penetrating agent 0.5 g/l
Example 7 ; Boiling in loop method Winding Andon type of polyester NaOH 30-40 g/l Liquor ratio 1 : 30 95-97 X 2 hrs.℃
Example 8 ; Pad Roll method NaOH 150-300 g/l Pad Batching up (Rolling) Φ70-80 cm Cover with vinyl-sheet, and holding at 80 X 6-7 hrs.℃ Rotation by 1-12 r.p.m.
Example 9 ; Pad Steam method or Pad Dry method NaOH 300 g/l Neorate NA-30 (Nikka Chemical) 10 g/l 40% pick-up Steaming ; 130 30 min. or Baking ℃ ; 150 X 5 min.℃
Examples of commercial products as accelerator ; Olinax ( Meisei Chemical ) Sancleaner V9 ( Nikka Chemical ) Catiosol NS-11 (Takamatsu Yusi)
Rinsing after treatment :Rinsing Acid rinsing Soaping
Rinsing ; Removal of Na-salt of Tere-phtharic acidAcid rinsing ; Removal of auxiliary 、If insufficient removal of them, it will cause tarring problemat dyeingAcetic acid(90%) 2-3 ml/l 60 X 20 min.℃Soaping ; Removing auxiliary Example of soaping agent ; Marseilles Soap 2 g/l Dyedisper CD 2 g/l Mignol 802 3 g/l All treated at 90 x 20 min.℃
Relax Scouring 1) Purpose a) Removing impurities, thickener, oil coatings ; These materials causes uneven dyeing, if they are not removed enough b) Giving swelling of fabrics ; Adding the higher added value and improvement, such as Bulky property, Stretch property, Soft handling etc.
2) Care points a) Rope creasing, broken creasing b) Utilization of beating effects c) Heating-up speed and higher temperature treatment
3) Technical Points a) It is necessary to treat the fabrics in tensionless condition b) Treatment condition must be differ by the fabrics woven organization, by kinds of material, kinds of dyeing machine c) In generally it is said first with weak tension, and not to happen creasing at low temperature, then temperature increase and tensionless treatment and finally slow cooling.
90-100℃
60℃ 20 min.
30 min.
Nonionic detergent 1 g/ lSoda ash 1 g/ l
Hot rinsing-cold rinsing60℃
4) Example of recipe
Heat Setting:
1) Purpose a) To reduce the shrinkage of the fabrics at dyeing b) To avoid the fixation of creasing mark
2) General Treatment condition: 150-200 X 30sec.℃
3) Technical Points a) The higher temperature, the higher effect, though deteriorate of handling effect. b) Treatment temp. must be higher than dyeing temp. , and after heat set condition.
4) Examples of Setting Condition Regular Polyester: 100% Polyester fabrics 180—210 for 30 sec.℃ Textured fabrics 150—170 for 30 sec.℃ T/C, T/R blended fabrics 190—220 for 30 sec. Modified Polyester: 100% Polyester fabrics 180—210 for 30 sec.℃ Textured fabrics 150—170 for 30 sec.℃ In some cases for polyester textured fabrics steam set is applied: Textured fabrics 130±10 for 5—10 min.℃
Surfa
ce o
f yar
n m2
/g
1 2 3 5Denier
Denier No. and Surface area
1 2 3 4 5Denier
Surfa
ce o
f Dye
ing d
epth
Denier number and Relative dyeing depth
Denier Number and Surface condition of Filament
Dyeing Speed on Micro- Fiber
Dyeing Time / Temperature
ExhaustionRate
Micro-Fiber
ConventionalPolyester
Dyeing time or dyeing temperature
Thick yarn 3.0d
Thin yarn 0.1dRe
lative
dye
ing ra
te (%
)Su
rface
colo
r dep
th Thick yarn 3.0d
Thin yarn 0.1d
Dyeing time or dyeing temperature
Dyeing rate of the dye in same bath
Surface depth of the fabrics in same bath
Dyeing on Complex Fiber (Mixture of Regular- / Micro-)
Dyeing Speed Absorption of Dye is higher Dyeing speed is higherLevel Dyeing Dyeing speed is higher Difficult to even dyeingDeep shades Bigger surface area Difficult to get heavy shadeBarriness Blended different yarn Different dyeing Causes barriness problemReproducibility Blended different yarn Different dyeing Lowering reproducibilityHandling Thin yarn Soft touchLower Fastnesses Thin yarn Bigger surface area Easily dye go out from surfaceRubbing and erasing problem Bigger surface area Fibriled fiber taken out easilyAnti-creasing Thin yarn Bigger surface area Easily creasing mark, rope mark
Dyeing Technologies must be considered for Micro-fiber
Based on : Thin yarn Bigger surface area
・ Surface area of materials is 2-5 times higher than conventional type polyester by means of thickness of yearn.
・ Then dye must be used 2-5 times higher than conventional dyeing for getting same color value.
・ Resultantly fastnesses, such as washing, light, sublimation, rubbing are reduced.
・ Then it is basic points and must be taken care of removal of unfixed dye and auxiliaries from fiber.
・ The selection of dye must be carefully for consideration of level dyeing, reproducibility of color and fastnesses.
・ For Mechanical finishing processes, suede finishing process or raising finishing, it is necessary to use lubricant, smoothing agent or anti-electro static agent.
・ On the other hand, for to add performance or aesthetic( 審美的) finishing, it need finishing agents such as water-oil repellent agent, softening agent, anti-
pilling agent, anti-slipping agent, moisture management agent which must be taken care of not to deteriorate of fastnesses,
Dyeing Properties of Micro-Fiber
Level Dyeing Technology
The Causes of Uneven dyeing often Thin yarn Bigger surface area Higher Absorption of Dye Higher Dyeing speed
For Level dyeing methods on simple fiber Dyeing temperature ; Control of dyeing speed---Control of heating-up speed Higher dyeing temperature is better for level dyeing, for migration Dyeing machine operation : Control of fabrics cycling (speed up) Control of Circulation of fabrics and dyeing bath Longer liquor ratio Dyes and Auxiliary phase : Dye of Larger migration property Better compatible dye combination Auxiliary having higher migration ability
for pale
for mediium
for deep
80℃
100℃
130℃ X 10 min.
95℃
120℃
130℃ X 20 min.
110℃
130℃ X 20 min.
Room temp.
Room temp.
Room temp
30 min.
25 min.
20 min.
Examples of General Dyeing Procedure
Dyeing Recipe;
Dye X %owfDispersing Agent 1 g/lpH adjuster pH 5.0—5.5 ex. Acetic acid and Na-Acetate 1-3 g/l or Ammonium sulfate 1-3 g/l
If necessary, add followings depending on material conditionSequestering agent 1 g/lPenetrating agent 1 g/lLeveling agent 1 g/l
Selection standards of Dyes for complex micro-fiber ;
・ Solid dyeing on mixed micro-yarn and regular yarn at 120 ℃ dyeing (Dyeing temperature for mixed is sometimes lower than simple fiber)・ Compatible of tri-chromatic colors・ Good levelness and good reproducibility on Blended different yarn
Different dyeing・ Good fastness・ Sometimes levelness and reproducibility are reverse properties. Which will be important for the purpose?・ Dyeing temperature is mostly at 120℃ on Shin-Gohsen (Complex fiber)
Kayalon Microester, Sumikaron MF, Kiwalon Plyester MR are specially developed for complex micro-fibers
The reason why micro-fiber looks pale
1) Higher Reflectance on the surface Refractive index of polyester is large, as the denier of yarn
decrease, the surface area increase rapidly. Then the reflectance on the surface increase.
2) Shorter Length of Passage inside the filament Light pass length in yarn is shorter comparing with yarn diameter,
then the absorbance of light in yarn becomes small.
Shade Deepening Technology
Shade Deepening MethodMany technicians at fiber maker, dye maker and auxiliary maker have tried to develop the shade deepening technology from their own situation.
1) Fiber maker; Modify the fiber property ・ Improvement of dyeing ability----- CD-PES etc. (Co-polymerization; Styrene sulfonic acid) ・ Modify the surface of yarn-----Development of Porous PES
2) Dye maker; Development of dyes ・ Development of New chromophor with higher color value ----- ex. Hetero-cyclic compounds ・ Application of dyeing technology---- Combination technology
3) Auxiliary maker; Development of dyeing auxiliary ・ Development of finishing agent (shade deepening agent ) like addition of oil on the surface of the fiber
Polyester filamentPolyester filament
Development of Porous Polyester(Micro-creator )
Creators are made by Plasma,Before Dyeing or After Dyeing
Modified Polyester with dye site in fabrics Co-polymerization of stylene monomer with sulfuric group
CH=CH2
SO3Na
Dyeing Concentration % owf
Fixing
Rat
e %
100 % line
Dye CDye B
Dye A
Dye A + B
Dye A + B + C
Exhaustion Rate of Dye by Blending
Dyeing Temp. and Time
Yellow A+B+C
Red D+E+FBlue G+H+I
Exha
ustio
n Ra
te
Combination Technology:
Compatibility of Dye
Fluorescent Whitening Technology
• Principal of whitening Effect , Bluing Effects• Whiteness and Amounts of Agent• Quenching Phenomenon• Machine Staining• Commercial Products for Polyester
Refle
ctan
ce %
Wave Length400 nm 700 nm
%
Fluorescent Whitenning agent
Blueing
Raw Material
100 % Surface of Snow fallen
Whitening Effect
Blue dye
Principal of Fluorescent Whitening
White
ness
% owfAmount of Agent
Quenching Effects
Quenching Effects
Typical Commercial Products for Polyester
Blancophor EBLDaitophor EFLFluolite XMFHostalux PE
Mikawhite ATN, HTN, HTS, STN, BBNMikephor ETN
Palanil White G, RTinopal ERT, ET
Uvitex ERN, EBF , EBX, EMT, EM-V, EDR, EBH, EBB, EVB, EFTMany of Modified Products
Dyeing Temperature: 120-130℃Time : 30-60 min.
Color shade: Greenish-----Reddish