Patent Application
20240263386
The present invention relates to a fiber treatment agent, a first fiber treatment agent, a second fiber treatment agent, a composition containing the first fiber treatment agent, a dilute liquid of the fiber treatment agent, a method for treating fiber, and a fiber.
In a spinning and drawing step or a finishing step for, for example, synthetic fibers, a fiber treatment agent may be adhered to the fiber surfaces from a standpoint of reducing friction of the fibers.
Known oil agents for fiber are disclosed in Patent Documents 1 to 4.
However, further improvement of the friction characteristic in a wet state of fibers with a fiber treatment agent adhered thereto has been sought.
A fiber treatment agent for solving the above problem contains a fatty acid (A), an organic phosphoric acid ester compound (B), and a (poly)oxyalkylene derivative (C). The fatty acid (A) is at least one selected from the group consisting of a fatty acid with 1 to 6 carbon atoms, a hydroxy fatty acid with 1 to 6 carbon atoms, and a salt thereof.
If the sum of the contents of the fatty acid (A), the organic phosphoric acid ester compound (B), and the (poly)oxyalkylene derivative (C) in the fiber treatment agent is taken as 100% by mass, the fiber treatment agent preferably contains the fatty acid (A) at a ratio of not less than 0.001% by mass and not more than 20% by mass.
The fiber treatment agent preferably contains a first fiber treatment agent, which contains the organic phosphoric acid ester compound (B), and a second fiber treatment agent, which contains the (poly)oxyalkylene derivative (C), and is preferably such that the fatty acid (A) is contained in either or both of the first fiber treatment agent and the second fiber treatment agent.
Preferably with the fiber treatment agent, if the sum of the contents of the organic phosphoric acid ester compound (B) and the fatty acid (A) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent contains the organic phosphoric acid ester compound (B) at a ratio of not less than 90% by mass and not more than 100% by mass and the fatty acid (A) at a ratio of not less than 0% by mass and not more than 10% by mass, and if the sum of the contents of the (poly)oxyalkylene derivative (C) and the fatty acid (A) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent contains the (poly)oxyalkylene derivative (C) at a ratio of not less than 90% by mass and not more than 100% by mass and the fatty acid (A) at a ratio of not less than 0% by mass and not more than 10% by mass.
The fiber treatment agent is preferably such that an acid value measured for the first fiber treatment agent by a potentiometric titration method is not less than 0.01 mg KOH/g and not more than 60 mg KOH/g.
The fiber treatment agent is preferably such that the fatty acid (A) is at least one selected from the group consisting of a fatty acid with 1 to 4 carbon atoms, a hydroxy fatty acid with 1 to 4 carbon atoms having a hydroxy group in its molecule, and an alkali metal salt thereof.
The fiber treatment agent is preferably such that the fatty acid (A) is at least one selected from the group consisting of a fatty acid alkali metal salt with 1 to 4 carbon atoms and a hydroxy fatty acid alkali metal salt with 1 to 4 carbon atoms having a hydroxy group in its molecule.
The fiber treatment agent is preferably such that the organic phosphoric acid ester compound (B) contains at least one selected from the group consisting of an alkyl phosphoric acid ester and a salt thereof, the alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms or a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms added with an alkylene oxide with 2 to 3 carbon atoms.
With the fiber treatment agent, the fiber is preferably a synthetic fiber.
With the fiber treatment agent, the fiber is preferably a polyester short fiber.
With the fiber treatment agent, the fiber is preferably a polyethylene terephthalate fiber.
With the fiber treatment agent, the fiber is preferably a short fiber.
A first fiber treatment agent for solving the above problem contains an organic phosphoric acid ester compound (E) and is used in combination with a second fiber treatment agent, which contains a (poly)oxyalkylene derivative (F). A fatty acid (D) is further contained in either or both of the first fiber treatment agent and the second fiber treatment agent. The fatty acid (D) is at least one selected from the group consisting of a fatty acid with 1 to 6 carbon atoms, a hydroxy fatty acid with 1 to 6 carbon atoms, and a salt thereof.
The first fiber treatment agent is preferably such that an acid value measured for the first fiber treatment agent by a potentiometric titration method is not less than 0.01 mg KOH/g and not more than 60 mg KOH/g.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and if the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent preferably contains the organic phosphoric acid ester compound (E) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and if the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent preferably contains the organic phosphoric acid ester compound (E) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent preferably contains the organic phosphoric acid ester compound (E) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent preferably contains the organic phosphoric acid ester compound (E) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
A second fiber treatment agent for solving the above problem contains a (poly)oxyalkylene derivative (F) and is used in combination with a first fiber treatment agent, which contains an organic phosphoric acid ester compound (E). A fatty acid (D) is further contained in either or both of the first fiber treatment agent and the second fiber treatment agent. The fatty acid (D) is at least one selected from the group consisting of a fatty acid with 1 to 6 carbon atoms, a hydroxy fatty acid with 1 to 6 carbon atoms, and a salt thereof.
When the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent preferably contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass.
When the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent preferably contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent preferably contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass.
When the first fiber treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second fiber treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent preferably contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
A composition containing first fiber treatment agent for solving the above problem contains the first fiber treatment agent and water.
A dilute liquid of fiber treatment agent for solving the above problem contains the fiber treatment agent and water.
A dilute liquid of fiber treatment agent for solving the above problem contains the first fiber treatment agent and the second fiber treatment agent.
The dilute liquid of fiber treatment agent has a ratio between the contents of the first fiber treatment agent and the second fiber treatment agent of preferably such that the first fiber treatment agent/the second fiber treatment agent is not less than 1/9 and not more than 9/1.
A method for treating a fiber for solving the above problem includes applying to a fiber a dilute liquid of fiber treatment agent, obtained by adding the first fiber treatment agent and the second fiber treatment agent to water.
A fiber for solving the above problem has the first fiber treatment agent and the second fiber treatment agent adhered thereto.
The present invention succeeds in improving the friction characteristic in a wet state of fibers with a fiber treatment agent adhered thereto.
A first embodiment that embodies a fiber treatment agent according to the present invention (also referred to hereinafter simply as treatment agent) will now be described.
The treatment agent of the present embodiment contains a fatty acid (A), an organic phosphoric acid ester compound (B), and a (poly)oxyalkylene derivative (C).
The fatty acid (A) is at least one selected from the group consisting of a fatty acid with 1 to 6 carbon atoms, a hydroxy fatty acid with 1 to 6 carbon atoms, and a salt thereof.
By the fatty acid (A) being the above-described compound, the friction in a wet state of fibers with the treatment agent adhered thereto can be improved. In other words, the friction characteristic in the wet state can be improved.
A fatty acid with 1 to 6 carbon atoms that constitutes the fatty acid (A) may be a known fatty acid and may be a saturated fatty acid or an unsaturated fatty acid. It may also be of straight chain form or have a branched chain structure. It may also be a monobasic fatty acid or a dibasic fatty acid.
Specific examples of the fatty acid with 1 to 6 carbon atoms include methanoic acid, ethanoic acid (acetic acid), butanoic acid, propanoic acid (propionic acid), pentanoic acid, hexanoic acid, and butanedioic acid (succinic acid).
A hydroxy fatty acid with 1 to 6 carbon atoms that constitutes the fatty acid (A) may be a known hydroxy fatty acid and may be a saturated hydroxy fatty acid or an unsaturated hydroxy fatty acid. It may also be of straight chain form or have a branched chain structure. It may also be a monobasic hydroxy fatty acid or a dibasic hydroxy fatty acid.
Specific examples of the hydroxy fatty acid with 1 to 6 carbon atoms include hydroxyethanoic acid, hydroxypropanoic acid (lactic acid), hydroxybutanoic acid, hydroxypentanoic acid, hydroxyhexanoic acid, citric acid, and 2,3-dihydroxybutanedioic acid (tartaric acid).
A salt that constitutes the fatty acid (A) may be a known salt and is preferably a metal salt. Examples of the metal salt include an alkali metal salt and an alkaline earth metal salt. Among these, an alkali metal salt is more preferable.
Examples of an alkali metal that constitutes the alkali metal salt include sodium, potassium, and lithium.
Examples of an alkaline earth metal that constitutes the alkaline earth metal salt include calcium, magnesium, beryllium, strontium, and barium.
The fatty acid (A) is preferably at least one selected from the group consisting of a fatty acid with 1 to 4 carbon atoms, a hydroxy fatty acid with 1 to 4 carbon atoms having a hydroxy group in its molecule, and an alkali metal salt thereof. Among these, by the fatty acid (A) being an alkali metal salt of a fatty acid with 1 to 4 carbon atoms or an alkali metal salt of a hydroxy fatty acid with 1 to 4 carbon atoms having a hydroxy group in molecule, the friction characteristic in the wet state can be improved further.
One type of the fatty acid (A) may be used alone or two or more types of the fatty acids (A) may be used in combination as appropriate.
Examples of the organic phosphoric acid ester compound (B) include an alkyl phosphoric acid ester, an alkenyl phosphoric acid ester, an alkyl phosphoric acid ester or alkenyl phosphoric acid ester having a polyoxyalkylene group, and a salt of any of these. An alkyl group constituting the alkyl phosphoric acid ester or an alkenyl group constituting the alkenyl phosphoric acid ester is not particularly limited and may be of straight chain form or have a branched chain structure. A branching position in the branched chain structure is not particularly limited and may be an α-position or a β-position.
The number of carbon atoms of the alkyl group or the alkenyl group is not particularly restricted and is preferably 1 to 30, and more preferably 12 to 22.
Specific examples of the alkyl group include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a decyl group, an undecyl group, a dodecyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, an octadecyl group, an icosyl group, an isobutyl group, an isopentyl group, an isohexyl group, an isoheptyl group, an isooctyl group, an isodecyl group, an isoundecyl group, an isododecyl group, an isotridecyl group, an isotetradecyl group, an isopentadecyl group, an isohexadecyl group, an isoheptadecyl group, an isooctadecyl group, and an isoicosyl group.
Specific examples of the alkenyl group include a butenyl group, a pentenyl group, a hexenyl group, a heptenyl group, an octenyl group, a nonenyl group, a decenyl group, an undecenyl group, a dodecenyl group, a tridecenyl group, a tetradecenyl group, a pentadecenyl group, a hexadecenyl group, a heptadecenyl group, an octadecenyl group, an icosenyl group, an isobutenyl group, an isopentenyl group, an isohexenyl group, an isoheptenyl group, an isooctenyl group, an isononenyl group, an isodecenyl group, an isoundecenyl group, an isododecenyl group, an isotridecenyl group, an isotetradecenyl group, an isopentadecenyl group, an isohexadecenyl group, an isoheptadecenyl group, an isooctadecenyl group, and an isoicosenyl group.
A phosphoric acid that constitutes the organic phosphoric acid ester compound (B) is not particularly limited and may be orthophosphoric acid or a polyphosphoric acid, such as diphosphoric acid.
If an organic phosphoric acid ester salt is used as the organic phosphoric acid ester compound (B), examples of such a salt include a phosphoric acid ester amine salt and a phosphoric acid ester metal salt.
Examples of the metal salt include an alkali metal salt or an alkaline earth metal salt. Specific examples of an alkali metal that constitutes the alkali metal salt include sodium, potassium, and lithium. Examples of an alkaline earth metal that constitutes the alkaline earth metal salt include a metal corresponding to being a Group II element, for example, calcium, magnesium, beryllium, strontium, and barium.
An amine that constitutes the amine salt may be any of a primary amine, a secondary amine, and a tertiary amine. Specific examples of the amine that constitutes the amine salt include (1) aliphatic amines, such as methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, N—N-diisopropylethylamine, butylamine, dibutylamine, 2-methylbutylamine, tributylamine, octylamine, and dimethyllaurylamine, (2) aromatic amines or heterocyclic amines, such as aniline, N-methylbenzylamine, pyridine, morpholine, piperazine, and derivatives of the above, (3) alkanolamines, such as monoethanolamine, N-methylethanolamine, diethanolamine, triethanolamine, isopropanolamine, diisopropanolamine, triisopropanolamine, dibutylethanolamine, butyldiethanolamine, octyldiethanolamine, and lauryldiethanolamine, (4) polyoxyalkylene alkyl aminoethers, such as polyoxyethylene lauryl aminoether and polyoxyethylene stearyl aminoether, and (5) ammonia.
If an organic phosphoric acid ester compound with an alkylene oxide chain added is used, an alkylene oxide with 2 to 4 carbon atoms is preferable. Specific examples of the alkylene oxide include ethylene oxide, propylene oxide, and butylene oxide. A lower limit of the number of added moles of the alkylene oxide is set as appropriate and is preferably not less than 0.1 moles, more preferably not less than 1 mole, and even more preferably not less than 2 moles. An upper limit of the number of added moles is set as appropriate and is preferably not more than 50 moles, more preferably not more than 40 moles, and even more preferably not more than 30 moles. A range in which the above upper limit and lower limit are arbitrarily combined are also assumed. The number of added moles of the alkylene oxide represents the number of moles of the alkylene oxide with respect to 1 mole of an aliphatic alcohol compound in the charged raw materials.
One type of the alkylene oxide may be used alone or two or more types of the alkylene oxides may be used in combination as appropriate. If two or more types of the alkylene oxide are used, the addition form thereof may be any of block addition, random addition, and a combination of block addition and random addition and is not particularly limited.
Among the above, it is preferable for the organic phosphoric acid ester compound (B) to contain at least one selected from the group consisting of an alkyl phosphoric acid ester and a salt thereof, the alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms or a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms added with an alkylene oxide with 2 to 3 carbon atoms. By using such compound, a card passing property of the fibers with the treatment agent adhered thereto can be improved.
The organic phosphoric acid ester compound (B) is preferably an alkali metal salt of an alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms or a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms added with an alkylene oxide with 2 to 3 carbon atoms.
It is more preferably a potassium metal salt of an alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms or a residue in which a hydroxyl group is removed from an aliphatic alcohol with 12 to 22 carbon atoms added with an alkylene oxide with 2 to 3 carbon atoms.
It is even more preferably a potassium salt of an alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 16 to 22 carbon atoms or a residue in which a hydroxyl group is removed from an aliphatic alcohol with 16 to 22 carbon atoms added with an alkylene oxide with 2 to 3 carbon atoms. It is especially preferably a potassium salt of an alkyl phosphoric acid ester having in its molecule a residue in which a hydroxyl group is removed from an aliphatic alcohol with 16 to 22 carbon atoms.
One type of the organic phosphoric acid ester compound (B) may be used alone or two or more types of the organic phosphoric acid ester compounds (B) may be used in combination as appropriate.
Examples of the (poly)oxyalkylene derivative (C) include a compound having an alkylene oxide added to an alcohol or a carboxylic acid and an ether-ester compound having an alkylene oxide added to an ester compound of a carboxylic acid and a polyhydric alcohol.
The alcohol or carboxylic acid may be an alcohol or carboxylic acid of an aliphatic system with a straight chain form or having a branched chain or may be an alcohol or carboxylic acid of an aromatic system. It may also be a saturated alcohol or carboxylic acid or an unsaturated alcohol or carboxylic acid. It may also be an alcohol or carboxylic acid that is monovalent or divalent or higher.
Specific examples of the alkylene oxide with 2 to 4 carbon atoms include ethylene oxide, propylene oxide, and butylene oxide. A lower limit of the number of added moles of the alkylene oxide is set as appropriate and is preferably not less than 0.1 moles, more preferably not less than 1 mole, and even more preferably not less than 3 moles. An upper limit of the number of added moles is set as appropriate and is preferably not more than 50 moles, more preferably not more than 40 moles, and even more preferably not more than 30 moles. By this numerical value range, the friction characteristic can be further improved. A ranges in which the above upper limit and lower limit are arbitrarily combined are also assumed. The number of added moles of the alkylene oxide represents the number of moles of the alkylene oxide with respect to 1 mole of alcohol compound or carboxylic acid compound in the charged raw materials.
One type of the alkylene oxide may be used alone or two or more types of the alkylene oxide may be used in combination as appropriate. If two or more types of the alkylene oxide are used, an addition form thereof may be any of block addition, random addition, and a combination of block addition and random addition and is not particularly limited.
Specific examples of the (poly)oxyalkylene derivative (C) include polyoxyethylene alkyl ethers, polyoxyethylene alkenyl ethers, polyoxyethylene alkyl esters, polyoxyethylene alkenyl esters, polyoxyethylene alkyl phenyl ethers, polyoxyalkylene alkyl amino ethers, polyoxyalkylene alkenyl amino ethers, salts of polyoxyalkylene alkyl amino ethers and inorganic acids, and salts of polyoxyalkylene alkenyl amino ethers and inorganic acids.
One type of the (poly)oxyalkylene derivative (C) may be used alone or two or more types of the (poly)oxyalkylene derivatives (C) may be used in combination as appropriate.
If the sum of the contents of the fatty acid (A), the organic phosphoric acid ester compound (B), and the (poly)oxyalkylene derivative (C) in the treatment agent is taken as 100% by mass, the treatment agent contains the fatty acid (A) at a ratio of preferably not less than 0.001% by mass and not more than 20% by mass.
In one aspect of the present embodiment, the content of the fatty acid (A) in the treatment agent is, for example, 0.01 parts by mass or more, 0.05 parts by mass or more, 0.1 parts by mass or more, 0.5 parts by mass or more, 1 part by mass or more, 2 parts by mass or more, or 3 parts by mass or more with respect to 100 parts by mass of the treatment agent. Likewise, the content of the fatty acid (A) in the treatment agent is, for example, 5 parts by mass or less, 3 parts by mass or less, 2 parts by mass or less, 1 part by mass or less, 0.5 parts by mass or less, 0.1 parts by mass or less, or 0.05 parts by mass or less with respect to 100 parts by mass of the treatment agent.
The method for measuring the contents of the respective ingredients is not particularly limited, and the contents of ionic ingredients may be measured by, for example, the following method. That is, the treatment agent is heated for 2 hours at 105° C. to obtain a nonvolatile content. Sufficient dilution with pure water is performed such that the content of ionic ingredients in the nonvolatile content becomes not more than 500 ppm. Ion chromatography analysis is performed using the dilute liquid.
The treatment agent is preferably arranged so that during preservation, it includes a first fiber treatment agent that contains the organic phosphoric acid ester compound (B) and a second fiber treatment agent that contains the (poly)oxyalkylene derivative (C). In other words, it is preferable that the treatment agent is stored in a state of being separated into a first fiber treatment agent and a second fiber treatment agent. The fatty acid (A) is preferably contained in either or both of the first fiber treatment agent and the second fiber treatment agent.
If the sum of the contents of the organic phosphoric acid ester compound (B) and the fatty acid (A) in the first fiber treatment agent is taken as 100% by mass, the first fiber treatment agent contains the organic phosphoric acid ester compound (B) at a ratio of preferably not less than 90% by mass and not more than 100% by mass and the fatty acid (A) at a ratio of preferably not less than 0% by mass and not more than 10% by mass.
If the sum of the contents of the (poly)oxyalkylene derivative (C) and the fatty acid (A) in the second fiber treatment agent is taken as 100% by mass, the second fiber treatment agent contains the (poly)oxyalkylene derivative (C) at a ratio of preferably not less than 90% by mass and not more than 100% by mass and the fatty acid (A) at a ratio of preferably not less than 0% by mass and not more than 10% by mass.
By specifying the contents of the respective ingredients in the first fiber treatment agent and the second fiber treatment agent to be within the above ranges, the treatment agent can be improved in stability during preservation, in other words, formulation stability.
The operation and effects of the fiber treatment agent of the first embodiment will now be described.
Next, a second embodiment that embodies a first fiber treatment agent according to the present invention (referred to hereinafter as first treatment agent) will be described. Differences from the first embodiment will mainly be described below.
The first treatment agent of the present embodiment contains an organic phosphoric acid ester compound (E). The organic phosphoric acid ester compound (E) is the same as the organic phosphoric acid ester compound (B) described in the description of the first embodiment.
The first treatment agent is used in combination with a second fiber treatment agent (referred to hereinafter as second treatment agent) that contains a (poly)oxyalkylene derivative (F). The (poly)oxyalkylene derivative (F) is the same as the (poly)oxyalkylene derivative (C) described in the description of the first embodiment. A fatty acid (D) is further contained in either or both of the first treatment agent and the second treatment agent. The fatty acid (D) is the same as the fatty acid (A) described in the description of the first embodiment.
The first treatment agent has an acid value of preferably not less than 0.01 mg KOH/g and not more than 60 mg KOH/g measured by a potentiometric titration method. By the acid value being in the above numerical value range, emulsification failure of the first treatment agent can be suppressed. A method for measuring the acid value will be described later.
When the first treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and if the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first fiber treatment agent is taken as 100% by mass, it is preferable that the first treatment agent contains the organic phosphoric acid ester compound (E) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass. Further in this case, it is more preferable that the first treatment agent contains the organic phosphoric acid ester compound (E) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
When the first treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the organic phosphoric acid ester compound (E) and the fatty acid (D) in the first treatment agent is taken as 100% by mass, it is preferable that the first treatment agent contains the organic phosphoric acid ester compound (E) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass. Further in this case, it is more preferable that the first treatment agent contains the organic phosphoric acid ester compound (E) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
The operation and effects of the first treatment agent of the second embodiment will now be described. The present embodiment has the following effects in addition to the effects of the first embodiment.
A preservation form of the first treatment agent is not particularly limited, and it is preferably preserved or stored in a state of an aqueous liquid.
Next, a third embodiment that embodies the second treatment agent according to the present invention will be described. Differences from the first and second embodiments will mainly be described below.
The second treatment agent of the present embodiment contains a (poly)oxyalkylene derivative (F) described above. The second treatment agent is used in combination with the first treatment agent of the second embodiment. A fatty acid (D) described above is further contained in either or both of the first treatment agent and the second treatment agent.
When the second treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second treatment agent is taken as 100% by mass, it is preferable that the second treatment agent contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass. Further in this case, it is more preferable that the second treatment agent contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
When the first treatment agent contains the organic phosphoric acid ester compound (E) and the fatty acid (D) and the second treatment agent contains the (poly)oxyalkylene derivative (F) and the fatty acid (D) and if the sum of the contents of the (poly)oxyalkylene derivative (F) and the fatty acid (D) in the second treatment agent is taken as 100% by mass, it is preferable that the second treatment agent contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 90% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 10% by mass. Further in this case, it is more preferable that the second treatment agent contains the (poly)oxyalkylene derivative (F) at a ratio of not less than 95% by mass and not more than 99.999% by mass and the fatty acid (D) at a ratio of not less than 0.001% by mass and not more than 5% by mass.
The operation and effects of the second treatment agent of the third embodiment will now be described. The present embodiment has the following effects in addition to the effects of the first and second embodiments.
Next, a fourth embodiment that embodies a method for treating a fiber according to the present invention will be described.
The method for treating a fiber of the present embodiment is characterized by applying to a fiber a dilute liquid of fiber treatment agent (also referred to hereinafter as dilute liquid) that contains the fiber treatment agent of the first embodiment and water.
It is preferable that the dilute liquid is prepared by adding the first treatment agent of the second embodiment and the second treatment agent of the third embodiment to water. It is more preferable that the dilute liquid is prepared by adding a composition containing first fiber treatment agent (also referred to hereinafter as first treatment agent-containing composition), which contains the first treatment agent and water, and the second treatment agent to water. With a mode where the first treatment agent and the second treatment agent are used in combination, the mixing ratio of the first treatment agent and the second treatment agent can be changed arbitrarily. Therefore, even under different production conditions such as different production equipment and different climates (e.g., temperature and humidity), it is made easy to finely adjust a mixing ratio of the first treatment agent and the second treatment agent and prepare a fiber treatment agent or dilute liquid to obtain optimal spinning and drawing properties all the time. Stable fiber production is thereby made possible. The ratio between the contents of the first treatment agent and the second treatment agent, or more precisely, the mass ratio between nonvolatile contents thereof, is preferably such that the first treatment agent/second treatment agent is not less than 1/9 and not more than 9/1. By specifying to be in this range, handleability can be improved. The method for treating a fiber is a method in which the dilute liquid obtained as described above is applied to a fiber, for example, in a spinning or drawing step or a finishing step. The nonvolatile content is determined from the absolute dry mass of the object that has been heat-treated at 105° C. for 2 hours to sufficiently remove volatile substances.
In one aspect of the present embodiment, the concentration of the first treatment agent in the first treatment agent-containing composition is, for example, 20% by mass or more, 25% by mass or more, 30% by mass or more, 35% by mass or more, 40% by mass or more, 45% by mass or more, or 50% by mass or more. Likewise, the concentration of the first treatment agent in the first treatment agent-containing composition is, for example, 60% by mass or less, 50% by mass or less, 45% by mass or less, 40% by mass or less, 35% by mass or less, 30% by mass or less, or 25% by mass or less.
The dilute liquid is prepared, for example, by adding the first treatment agent or the first treatment agent-containing composition and the second treatment agent to water such that the nonvolatile concentration is not less than 0.01% by mass and not more than 10% by mass. A known method can be used as appropriate as a method for adding the first
treatment agent or the first treatment agent-containing composition and the second treatment agent to water, and steps 1 and 2 described below are preferably undertaken. By this method, the stability of the dilute liquid can be further improved.
Step 1 is a step of adding the first treatment agent or the first treatment agent-containing composition and the second treatment agent to a first water to prepare a mother liquid of the dilute liquid of fiber treatment agent with a nonvolatile concentration of more than 2% by mass but not more than 10% by mass. The order of adding the first treatment agent or the first treatment agent-containing composition and the second treatment agent to the first water is not particularly restricted. The first treatment agent or the first treatment agent-containing composition may be added to the first water first, and then the second treatment agent may be added thereto. Alternatively, the second treatment agent may be added to the first water first, and then the first treatment agent or the first treatment agent-containing composition may be added thereto. Alternatively, the first treatment agent or the first treatment agent-containing composition and the second treatment agent may be added to the first water at the same time. The temperature of the water for diluting is not particularly restricted. From a standpoint of improving stability of emulsion, it is preferable to first add the first treatment agent or the first treatment agent-containing composition to the first water and then add the second treatment agent thereto.
Step 1 preferably further includes steps of warming water of 20% to 70% by mass of an entire amount of the first water to 60° C. to 95° C., adding thereto the first treatment agent or the first treatment agent-containing composition and the second treatment agent, and thereafter further adding thereto the remaining 30% to 80% by mass of the first water that has been adjusted to 40° C. or less. By this method, the stability of the dilute liquid can be further improved. Even in this case, the order of adding the first treatment agent or the first treatment agent-containing composition and the second treatment agent to the water is not particularly restricted. The first treatment agent or the first treatment agent-containing composition may be added to the water first, and then the second treatment agent may be added thereto. Alternatively, the second treatment agent may be added to the water first, and then the first treatment agent or the first treatment agent-containing composition may be added thereto. Alternatively, the first treatment agent or the first treatment agent-containing composition and the second treatment agent may be added to the water at the same time. From a standpoint of improving the stability of emulsion, it is preferable to first add the first treatment agent or the first treatment agent-containing composition to the water and then add the second treatment agent thereto.
Alternatively, step 1 may include steps of warming water of 20% to 70% by mass of the entire amount of the first water to 60° C. to 95ºC, adding thereto the first treatment agent or the first treatment agent-containing composition, thereafter further adding thereto the remaining 30% to 80% by mass of the first water that has been adjusted to 40° C. or less, and lastly adding thereto the second treatment agent. By this method, the stability of the dilute liquid can be further improved.
Step 2 is a step of adding a second water to the mother liquid of the dilute liquid of fiber treatment agent prepared in step 1 to prepare a dilute liquid with a nonvolatile concentration of not less than 0.01% by mass and not more than 2% by mass.
The type of a fiber to which the dilute liquid is applied is not particularly restricted. This is because, by the dilute liquid applied to the fiber, the fiber treatment agent ultimately covers the fiber surface and improves the friction characteristic. Examples of the fiber to which the dilute liquid is applied include a synthetic fiber, a natural fiber, and a regenerated fiber.
The synthetic fiber is not particularly limited, and specific examples thereof include (1) a polyester fiber, such as polyethylene terephthalate (PET), polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polylactic acid, or a composite fiber containing these polyester resins, (2) a polyamide fiber, such as nylon 6 or nylon 66, (3) a polyacrylic fiber, such as polyacrylic or modacrylic, and (4) a polyolefin fiber, such as polyethylene or polypropylene. Specific examples of the natural fiber and the regenerated fiber include a cotton fiber, a bleached cotton fiber, a viscose rayon fiber, a high tenacity rayon fiber, a super high tenacity rayon fiber, a high wet modulus rayon fiber, a solvent spun rayon fiber, a polynosic fiber, a cupra fiber, and an acetate fiber. Among these, it is preferably applied to a polyester fiber or a polyolefin fiber that especially requires imparting of friction characteristic between fibers in the production process.
Use of the fiber is not particularly restricted. and example thereof include a short fiber, a spun yarn, and a nonwoven fabric. Applications as both short fiber use and long fiber use are possible and it is preferably applied to a short fiber. Short fibers correspond to those that are generally called staples and do not include long fibers that are generally called filaments. The length of the short fiber is not particularly restricted as long as it corresponds to that of short fibers in the art and, for example, is preferably not more than 100 mm. Among these, it is preferably applied to a polyester short fiber.
The ratio of adhering the dilute liquid to the fiber is not particularly limited, and the dilute liquid is adhered such that a solids content would ultimately be of a ratio of preferably not less than 0.1% by mass and not more than 3% by mass with respect to the fiber. By such arrangement, effects due to the respective ingredients can be exhibited effectively. The method for adhering the dilute liquid is not particularly limited, and a known method such as a roller oiling method, a guide oiling method using a metering pump, an immersion oiling method, or a spray oiling method can be used in accordance with, for example, type, form, or use of the fiber.
The fiber to which the dilute liquid is applied may be dried using a known method. Water or other solvent is volatilized by the drying and a fiber with the ingredients contained in the first treatment agent and the second treatment agent adhered thereto is obtained.
The operation and effects of the method for treating a fiber of the fourth embodiment will now be described. The present embodiment has the following effects in addition to the effects of the first to third embodiments.
The above-described embodiments may be modified as follows. The above-described embodiments and modifications described below can be implemented upon being combined with each other within a range that is not technically inconsistent.
Examples will now be given below to describe the features and effects of the present invention more specifically, but the present invention is not limited to these examples. In the following description of working examples and comparative examples, parts means parts by mass and % means % by mass unless otherwise noted.
Treatment agents were prepared using the respective ingredients shown in Tables 1 to 4 and by a preparation method described below.
As the fatty acids (A), A-1 to A-7, a-1, and a-2 indicated in Table 1 were used.
The type, number of carbon atoms, and number of hydroxy groups of each fatty acid (A) are respectively indicated in the “Fatty acid (A)” column, the “Number of carbon atoms” column, and the “Number of hydroxy groups” column of Table 1.
As the organic phosphoric acid ester compounds (B), B-1 to B-7 indicated in Table 2 were used.
The type and number of carbon atoms of aliphatic alcohol residue of each organic phosphoric acid ester compound (B) are respectively indicated in the “Organic phosphoric acid ester compound (B)” column and the “Number of carbon atoms of aliphatic alcohol residue” column of Table 2.
Respective ingredients were weighed out to provide 0.1 parts of potassium acetate (A-1), 34.9 parts of octadecyl phosphoric acid ester potassium salt (B-1), and 65 parts of polyoxyethylene (10 moles) lauryl ether (C-1) as shown in Table 3. These were stirred and mixed to prepare a treatment agent of Example 1.
Treatment agents of Examples 2 to 54 and Comparative Examples 1 to 3 were prepared in accordance with the same procedure as the treatment agent of Example 1 such as to contain the respective ingredients at ratios indicated in Tables 3 and 4.
The type and content of each fatty acid (A), the type and content of each organic phosphoric acid ester compound (B), and the type and content of each (poly)oxyalkylene derivative (C) are respectively indicated in the “Fatty acid (A)” column, the “Organic phosphoric acid ester compound (B)” column, and the “(Poly)oxyalkylene derivative (C)” column of Tables 3 and 4.
Details of the (poly)oxyalkylene derivatives (C) indicated in Tables 3 and 4 or the (poly)oxyalkylene derivatives (F) indicated in Tables 5 and 6 to be described below are as follows.
((Poly)oxyalkylene derivatives (C) or (F))
Each treatment agent prepared in Experimental Part 1 was added under stirring to ion exchanged water of half of a predetermined amount warmed to approximately 80° ° C. and dissolved completely. After dissolution, warming was stopped and the remaining half of the ion exchanged water of approximately 25° C. was added all at once and stirring was performed until uniform to prepare a 5% dilute liquid of the treatment agent.
With each of the treatment agents of Examples 1 to 54 and Comparative Examples 1 to 3, the wet-state friction characteristic of fibers with the dilute liquid adhered thereto and the card passing property of fibers with the treatment agent adhered thereto were evaluated by the procedures described below.
The 5% dilute liquid of each treatment agent prepared in Experimental Part 2 was diluted with ion exchanged water of approximately 25° C. to prepare a 0.35% dilute liquid. 80 mL of the prepared 0.35% dilute liquid were placed in a vat made of metal of 60 mm width×230 mm length×20 mm height.
A weight of rectangular plate shape of 30 mm width×90 mm length×45 mm height and 1 kg weight was prepared. A polyester spunbonded nonwoven fabric of the same size as a bottom surface of the weight was attached to the bottom surface using double-sided tape. The weight was placed with its bottom surface side, with the nonwoven fabric adhered thereon, facing downward in the vat containing the 0.35% dilute liquid.
A tensile test of pulling the weight under an atmosphere of 20° C.×60% RH and a condition of horizontal speed of 100 mm/min was performed using a tensile tester (Autograph model AGS-X, manufactured by Shimadzu Corporation) equipped with a load cell with a maximum load capacity of 50 N. The results of evaluating the wet-state friction characteristic according to the following criteria are indicated in the “Production workability” column of Tables 3 and 4.
In other words, the friction characteristic of the fibers and the metal in the wet state was evaluated by the above-described method. Specifically, the friction characteristic of the fibers and a roller made of the metal in a spinning step or a drawing step was evaluated by the above-described method. The above evaluation of friction characteristic was performed within 12 hours of preparation of the 0.35% dilute liquid.
The 5% dilute liquid of each treatment agent prepared in Experimental Part 2 was diluted with ion exchanged water of approximately 25° ° C. to prepare a 0.3% dilute liquid. This 0.3% dilute liquid was adhered, by a spray oiling method such that an adhered amount excluding solvent would be 0.15% by mass, onto semi dull polyester staple fibers with a fineness of 1.3×10−4 g/m (1.2 denier) and a fiber length of 38 mm obtained in a drafts making step. After then drying for 2 hours with a hot air dryer at 80° C., overnight humidity adjustment under an atmosphere of 25° C. and 65% RH was performed to obtain polyester staple fibers with the treatment agent adhered thereto.
30 g of the polyester staple fibers obtained were used and passed through a miniature carding machine (manufactured by Takeuchi Manufacturing Co., Ltd.) to prepare a fiber web. The card passing property was evaluated according to the following criteria based on the spun amount and circumstances of formation of neps or flies of the fiber web at the elapse of 20 seconds from input of all of the raw stock into the carding machine. The evaluation results are indicated in the “Spinning property” column of Tables 3 and 4.
The abovementioned neps shall mean particulate fiber lumps that formed inside the fiber web due to entanglement of fibers with each other in an interior of the carding machine. The abovementioned flies shall mean fibers that are blown up in the process of preparing the fiber web.
Respective ingredients were weighed out to provide 0.3 parts of potassium acetate (A-1) as the fatty acid (D) and 99.7 parts of octadecyl phosphoric acid ester potassium salt (B-1) as the organic phosphoric acid ester compound (E) as shown in Table 5. These were stirred and mixed to prepare a first treatment agent. Further, mixing with water was performed such as to achieve the concentration indicated in the “First treatment agent concentration” column of Table 5 to prepare a first treatment agent-containing composition (I-1).
As with the first treatment agent-containing composition (I-1), respective ingredients were weighed out to provide the contents shown in Tables 5 and 6. These were stirred and mixed to prepare first treatment agents. Further, mixing with water was performed such as to achieve the concentrations indicated in the “First treatment agent concentration” column of Tables 5 and 6 to prepare first treatment agent-containing compositions (I-2) to (I-57).
Measurement of acid value by a method described below was performed on the first treatment agents.
First, each first treatment agent-containing composition was dissolved in a mixed solvent of ethanol/xylene=1/2 (volume ratio) to prepare a sample solution. The prepared sample solution was set in a known potential difference measuring device and titrated with a 0.1 mol/L potassium hydroxide methanol standard solution. The acid value of the first treatment agent-containing composition was calculated using the following formula.
Acid value of first treatment agent-containing composition (KOH mg/g)=(R×f×56.11×0.1)/S
Next, the following formula was used to calculate an acid value of the first treatment agent with respect to the acid value of the first treatment agent-containing composition. That is, the acid value of the first treatment agent was determined by conversion from the acid value of the first treatment agent-containing composition.
Acid value of first treatment agent (KOH mg/g)=(U×100)/T
As shown in Table 7, polyoxyethylene (10 moles) lauryl ether (C-1) was used as the (poly)oxyalkylene derivative (F) and this was deemed to be a second treatment agent (II-1).
As with the second treatment agent (11-1), respective ingredients were weighed out to provide the content ratios shown in Tables 7 and 8. These were stirred and mixed to prepare second treatment agents (II-2) to (II-57).
Each of the first treatment agent-containing compositions or second treatment agents was stored for 1 week at 25° C. or 50° ° C. The appearance after the elapse of 1 week was observed and evaluated according to the following criteria. That is, formulation stability of the first treatment agent was evaluated with the first treatment agent-containing composition. The evaluation results are indicated in the “Formulation stability” column of Tables 5 and 6.
The method for preparing a fiber treatment agent using a first treatment agent-containing composition and a second treatment agent is not particularly limited. For example, the first treatment agent-containing composition and the second treatment agent may be weighed out to provide predetermined contents and while stirring one of either, the other may be added and mixed to perform preparation.
The method for preparing a dilute liquid of fiber treatment agent using a first treatment agent-containing composition and a second treatment agent is not particularly limited, and, for example, the following method can be used.
First, the first treatment agent-containing composition prepared in Experimental Part 4 is added under stirring to ion exchanged water of half of a predetermined amount warmed to approximately 80° C. and dissolved completely. After dissolution, the second treatment agent prepared in Experimental Part 5 is added thereto under stirring and dissolved completely. After dissolution, warming was stopped and the remaining half of the ion exchanged water of approximately 25° C. is added thereto all at once and stirring is performed until uniform. The dilute liquid can thereby be prepared.
A 5% dilute liquid of fiber treatment agent of Example 55 was prepared by the above-described method using the first treatment agent-containing composition (I-1), the second treatment agent (II-2), and ion exchanged water. The mass ratios of nonvolatile contents of the first treatment agent-containing composition and the second treatment agent are indicated in Table 9.
As with Example 55, 5% dilute liquids of fiber treatment agent of Examples 56 to 108 and Comparative Examples 4 to 6 were prepared by the above-described method using the first treatment agent-containing compositions and the second treatment agents shown in Table 9 and ion exchanged water.
The type of each first treatment agent-containing composition and the nonvolatile content ratio thereof and the type of each second treatment agent and the nonvolatile content ratio thereof are respectively indicated in the “First treatment agent-containing composition” column and the “Second treatment agent” column of Table 9.
The dilute liquids of fiber treatment agent of the respective examples obtained were used to evaluate the wet-state friction characteristic of fibers with the dilute liquid adhered thereto and the card passing property of fibers with the treatment agent adhered thereto as in Example 1. The evaluation results are respectively indicated in the “Production workability” column and the “Spinning property” column of Table 9.
The fiber treatment agent of the present invention can improve the friction characteristic in a wet state of fibers with the fiber treatment agent adhered thereto. It can also improve the card passing property of fibers with the fiber treatment agent adhered thereto.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-114219 | Jul 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/026830 | 7/6/2022 | WO |
