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-fiber Less than 0.1 dtex: called ultra micro-fiber Less than 0.01 dtex: called super ultra micro-fiber
0.01 0.01 dtex
0.02
Applications of Micro-fiber Shin-Gohsen (Complex fiber) Silky touch Rose petal touch Peach skin touch Powder touch
*5) Reduction of Fluid resistance Hydro-plane property Non-adherent Non-adherent of Sea plants and animals
*6) Response property to Environment Chemical reactive property Response property to electricity
*1)
Artificial Leather (Suede, Smooth) Artificial Fur High touch materials Flexibility Fissionability Aesthetic property
*2) Wiping property Filtration property
*3) Absorption property Water Repellent property
Development of Micro-Fiber Ultra micro-fiber
*7) Reinforcement property Disposition property
Garments, Bug, Shoes, Cap, Sports goods, Furniture, Car seat, Wall Cloth, Display tool, Polishing material
*4) Application using Specific Property High strength High Smoothing
*8) Compatibility to living body
*1) Application of high touch materials *5) Reduction of Fluid resistance: Ski and Skate wear, Jump suits, Swimming race wear
*6) Application to Response property to environment Chemical reactive property Response property to electricity High speed response gel fiber Heat resistance/chemical resistance Squeezing roll Artificial muscle Micro-scissors/ tweezer (for Catheter) Morter-less drive
Garments, bag, shoes, cap, Glove for golf, Golf bag Furniture, Car sheet, Wall Cloth, Display tool, Polishing material, Video deck, Tape recorder, Piano, Water absorption roll, Mouse pad
2) Application of Wiping and filtering property Wiping 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 Down Healthy underwear, Anti-vermin Anti-vermin bed cloth etc.
3) Application of Absorption and Water repellent property Water 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 usages Polishing cloth, Sound control cloth, Environmental control cloth for making sensitivity mood Vivid 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 property Ion 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 body Artificial 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 Electron Microscope
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Production Method
Soluble to solvent
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 Random type ： Meltblow spinning Flash spining Fiblisation Polymer blend spinning Tuck spinning Burst spinning Bacterium spinning Others
Insoluble to solvent
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After fter Sep Separat aratio ion n
:General Dyeing Process Pre-treatment Polyester Micro-fiber
・ Weight Reducing Finishing ・ Relax Scouring ・ Heat Setting
・ Dyeing
Examples of Dyeing process (Without Weight Reducing, Relaxing process) Example 1; Desizing—Rinsing—Drying—Pre-heat Desizing—Rinsing—D rying—Pre-heat setting—Dyeing—Drying setting—Dyeing—Drying--Finishing --Finishing Example 2; Desizing—Rinsing—Dyeing—Drying—Finishing
Example 3; Desizing—Rinsing—Drying—Softening—Dryin Desizing—Rinsing—Drying—Softening—Drying—Raising g—Raising finishing—Setting --Dyeing—Softening--Finishing Example 4; Desizing—Rinsing—Drying—Pre-heat Desizing—Rinsing—D rying—Pre-heat setting—Dyeing—Softening—D setting—Dyeing—Softening—Drying rying — Raising finishing—Rinsing--Finishing finishing—Rinsing--Finishing
Weight Reducing Finishing 1)
2)
Purpose a) Roughing on the face of fabrics b) Softening by slender of yarn (less solidness) c) Loosing the organization of of fabrics and giving drape drape property
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) Proced cedures ； Many variations, such as Atmospheric pressure method, High pressure method, Continuous process, Hanging method b) 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 dyeing e) 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 k nitting 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 Handling
Atmosphere Boiling method Immense to NaOH soln. and boiling in loop method
-Batch
X
◎
◎
Amount
large
Control
◎
easiest
wise
Atmosphere boiling method -Batch With Accelerator wise ） Jet dyeing machine
X
High pressure 130℃ method -Batch ） Jet dyeing machine wise
△
△
△—○
medium
○
High Pressure 130℃ method -Batch with Accelerator wise ） Jet dyeing machine
○--△
X△--
△—○
least
○
Continuous Pad-batch roll( Semi-method continuo .us
○
◎
◎
large
○
Continuous Pad-steam method methodcontinuo continuo us
◎
○
○--◎
medium
○
Continuous Pad- cylinder dry continuo method us
◎
△—○
△
large
△—○
○
○
small
○
easy
Calculation Method of Caustic Soda
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 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
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 Soap Soapin ing g 95℃ X 20 20 min. min. Not Not to to use use acid acid in this this cas case. e. 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 １：３０ Liquor ratio 130℃ X 60 min.
Example 4 ； Jigger dyeing machine Scouring by Jigger Heat setting Weight Reduction Neutralization Soaping NaOH 3% Accelerator 0.05% 95-98℃ Passing 6-8 times
Rinsing
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
Example 8 ； Pad Roll method NaOH 150-300 g/l Pad Batching up (Rolling) Φ70-80 cm Cove Coverr with with vin vinyl yl-s -she heet et,, and and hol holdi ding ng at at 80℃ X 6-7 6-7 hrs 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 acid Acid rinsing ； Removal of auxiliary 、 If insufficient removal of them, it will cause tarring problem at dyeing Acetic 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 ted at 90 90℃ x 20 20 min.
ax Scouring Purpose a( Removing impurities, thickener, oil coatings ； These materials causes uneven dyeing, if they are not removed eno b( Giving swelling of fabrics ； Adding the higher added value and improvement, such as Bulky property, Stretch property, Soft handling etc.
Care points a) Rope creasing, broken creasing b) Utilization of beating effects c) Heating-up speed and higher temperature treatment
Technical Points a) It is necessary to treat the the fabrics in tensionless condition b) Treatment condition must be differ by 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.
4) Example of recipe
90-- 10 90 100℃ 0℃ 30 min.
60℃ 60 ℃
20 min.
Nonionic Nonionic detergent detergent 1 g/ l S oda ash 1 g/ l
60℃ Hot rinsingrinsing- cold rinsing rinsing
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% 100% Poly Polyes este terr fabr fabric ics s 180— 180—21 210 0℃ for for 30 sec. sec. Text Textur ured ed fabr fabric ics s 150— 150—17 170 0℃ for for 30 sec. sec. T/C, T/R blended fabrics 190—220 for 30 sec. Modified Polyester: 100% 100% Poly Polyes este terr fabr fabric ics s Text Textur ured ed fabr fabric ics s
180— 180—21 210 0℃ for for 30 sec. sec. 150— 150—17 170 0℃ for for 30 sec. sec.
In some cases for polyester textured fabrics steam set is applied: Text Textur ured ed fabr fabric ics s 130± 130±10 10℃ for for 5—10 5—10 min. min.
Denier Number and Surface condition of Filament
Denier No. and Surface area
g / 2 m n r
Denier number and Relative dyeing depth
Dyeing Speed on Micro- Fiber
Dyeing on Complex Fiber (Mixture of Regular- / Micro-) Dyeing rate of the dye in same bath
( % e t a r g
Surface depth of the fabrics in same bath
Dyeing Technologies must be considered for Micro-fiber Based on ： Thin yarn
Bigger surface area
Dyeing Speed Absorption of Dye is higher Dyeing speed is higher Level Dyeing Dyeing speed is higher Difficult to even dyeing Deep shades Bigger surface area Difficult to get heavy shade Barriness Blended different yarn Different dyeing Causes barriness problem Reproducibility Blended different yarn Different dyeing Lowering reproducibility Handling Thin yarn Soft touch Lower Fastnesses Thin yarn Bigger surface area Easily dye go out from surface Rubbing and erasing problem Bigger surface area Fibriled fiber taken out easily Anti-creasing Thin yarn Bigger surface area Easily creasing mark, rope mark
Dyeing Properties of Micro-Fiber ・ 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, antipilling agent, anti-slipping agent, moisture management agent which must be taken care of not to deteriorate of fastnesses,
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
Examples of General Dyeing Procedure Dyeing Recipe;
for pa
Dye X %owf Dispersing Agent 1 g/l pH 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 condition Sequestering agent 1 g/l Penetrating agent 1 g/l Leveling agent 1 g/l
80℃
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 micro-fi bers
Shade Deepening Technology 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 Method Many 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; (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 o f the fiber
Development of Porous Polyester (Micro-creator ）
Creators are made by Plasma, Before Dyeing or After Dyeing
Modified Polyester with dye site in fabrics
CH=CH2
Co-polymerization of stylene monomer with sulfuric group
SO3Na
Combination Technology: Exhaustion Rate of Dye by Blending
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
Principal of Fluorescent Whitening
%
Quenching Effects
100 % Whi Amount of Agent
Typical Commercial Products for Polyester Blancophor EBL Daitophor EFL Fluolite XMF Hostalux PE Mikawhite ATN, HTN, HTS, STN, BBN Mikephor ETN Palanil White G, R Tinopal ERT, ET Uvitex ERN, EBF , EBX, EMT, EM-V, EDR, EBH, EBB, EVB, EFT Many of Modified Products
Dyeing Temperature: 120-130℃ Time : 30-60 min. Color shade: Greenish-----Reddish
