U.S. patent application number 09/920516 was filed with the patent office on 2002-03-28 for single fiber containing carbon powder inside the fiber, processed work and cotton work thereof, processed work and cotton work containing carbon powder on the fiber surface or in the fibers, and producing thereof.
Invention is credited to Takashima, Hisato.
Application Number | 20020037406 09/920516 |
Document ID | / |
Family ID | 18725715 |
Filed Date | 2002-03-28 |
United States Patent
Application |
20020037406 |
Kind Code |
A1 |
Takashima, Hisato |
March 28, 2002 |
Single fiber containing carbon powder inside the fiber, processed
work and cotton work thereof, processed work and cotton work
containing carbon powder on the fiber surface or in the fibers, and
producing thereof
Abstract
This invention relates to the single fiber having superior
deodorization and hygroscopicity since carbon powder is contained
inside thereof, the processed work and the cotton work thereof, and
the producing wherein there is no blocking on an injection nozzle
and a disagreeable smell does not occur when carbon powder is
contained to the processed work and the cotton work, and whereof
the single fiber wherein it is comprised by melting and spinning
out of synthetic resin pellet compounding 1-30 weight % of fine
carbon powder having 20 .mu.m or less as pigment, the processed
work and the cotton work wherein carbon powder is contained on the
fiber surface and/or inside of the fibers, the producing of the
processed work, wherein diluted solution of emulsion comprises at
least carbon powder, surfactant and water is sprayed or immersed to
the processed work and the work is dried with heating.
Inventors: |
Takashima, Hisato;
(Takatsuki-shi, JP) |
Correspondence
Address: |
Curtis L. Harrington & Associates
Suite 250
6300 State University Drive
Long Beach
CA
90815
US
|
Family ID: |
18725715 |
Appl. No.: |
09/920516 |
Filed: |
July 31, 2001 |
Current U.S.
Class: |
428/364 ;
428/394 |
Current CPC
Class: |
Y10T 428/2913 20150115;
Y10T 428/2967 20150115; D01F 6/62 20130101; Y10T 428/2927 20150115;
D01F 1/10 20130101 |
Class at
Publication: |
428/364 ;
428/394 |
International
Class: |
D02G 003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 1, 2000 |
JP |
2000-233149 |
Claims
1. A single fiber containing carbon powder inside the fiber,
wherein it is comprised by melting and spinning out of synthetic
resin pellet compounding 1-50 weight % of fine carbon powder having
20 .mu.m or less as pigment.
2. A single fiber wherein fine carbon powder has the size of 1.0
.mu.m and 6-15 weight % thereof is compounded.
3. The single fiber as claimed in claim 1, wherein said fine carbon
powder comprises at least one of Bintyo charcoal and carbon
black.
4. The single fiber as claimed in claim 2, wherein said fine carbon
powder comprises at least one of Bintyo charcoal and carbon
black.
5. The single fiber as claimed in claim 1, wherein said synthetic
resin pellet comprises recycled polyethylene terephthalate.
6. The single fiber as claimed in claim 2, wherein said synthetic
resin pellet comprises recycled polyethylene terephthalate.
7. The single fiber as claimed in claim 3, wherein said synthetic
resin pellet comprises recycled polyethylene terephthalate.
8. The single fiber as claimed in claim 4, wherein said synthetic
resin pellet comprises recycled polyethylene terephthalate.
9. The processed work wherein the single fiber as claimed in claim
1 is twisted to make knitting yam or weaving yam and then it
becomes knitting goods or textiles.
10. The processed work wherein the single fiber as claimed in claim
2 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
11. The processed work wherein the single fiber as claimed in claim
3 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
12. The processed work wherein the single fiber as claimed in claim
4 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
13. The processed work wherein the single fiber as claimed in claim
5 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
14. The processed work wherein the single fiber as claimed in claim
6 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
15. The processed work wherein the single fiber as claimed in claim
7 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
16. The processed work wherein the single fiber as claimed in claim
8 is twisted to make knitting yarn or weaving yarn and then it
becomes knitting goods or textiles.
17. The cotton work wherein the single fiber as claimed in claim 1
is cotton-opened.
18. The cotton work wherein the single fiber as claimed in claim 2
is cotton-opened.
19. The cotton work wherein the single fiber as claimed in claim 3
is cotton-opened.
20. The cotton work wherein the single fiber as claimed in claim 4
is cotton-opened.
21. The cotton work wherein the single fiber as claimed in claim 5
is cotton-opened.
22. The cotton work wherein the single fiber as claimed in claim 6
is cotton-opened.
23. The cotton work wherein the single fiber as claimed in claim 7
is cotton-opened.
24. The cotton work wherein the single fiber as claimed in claim 8
is cotton-opened.
25. A processed work wherein carbon powder is contained on at least
one of a surface and an inside of the fibers.
26. A cotton work wherein carbon powder is contained on at least
one of a surface and an inside of the fibers.
27. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 9.
28. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 10.
29. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 11.
30. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 12
31. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 13.
32. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 14.
33. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 15.
34. The processed work wherein carbon powder is contained on at
least one of the surface and the inside of the processed work as
claimed in claim 16.
35. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 17.
36. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 18.
37. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 19.
38. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 20.
39. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 21.
40. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 22.
41. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 23.
42. The cotton work wherein carbon powder is contained on at least
one of the surface and the inside of the cotton work as claimed in
claim 24.
43. A process of producing a processed work comprising the steps
of: at least one of spraying or immersion of a diluted solution of
emulsion to the processed work, said diluted solution of emulsion
comprising at least carbon powder, surfactant and water; and drying
said work with heating.
44. A process of producing a cotton work comprising the steps of:
taking cotton-opening process, measuring process, loading process,
laminating process and needle punching process; at least one of
spraying or immersion of a diluted solution of emulsion to the
processed work, said diluted solution of emulsion comprising at
least carbon powder, surfactant and water; and drying said work
with heating.
Description
FIELD OF THE INVENTION
[0001] This invention relates to the single fiber containing carbon
powder inside the fiber, the processed work and the cotton work
thereof, the processed work and the cotton work containing carbon
powder on the fiber surface or in the fibers, and producing
thereof. Its work is to provide the single fiber having superior
deodorization and hygroscopicity and the processed work and the
cotton work thereof; in addition, to provide the producing wherein
there is no blocking on an injection nozzle and disagreeable smell
and so on does not occur when carbon powder is contained to the
processed work and the cotton work.
[0002] Incidentally, in the present invention, the cotton work
means cotton after the single fiber spun is cotton-opened spun,
cushion material, nonwoven fabric and so on. Further, the processed
work in this invention means textile or knitting goods processed
from weaving yarn twisted or knitting yarn.
PRIOR ART
[0003] Accompanying with progress of technology, the new material
is born one after another, and the material of the goods needed for
our daily life has been changed considerably with a decade ago.
While the new material has new function and/or it gives easiness of
use and convenience, it may cause unexpected situation. For
example, a series of condition called Sick-house syndrome is given
as the problem in recent years, and it is considered that
detrimental organic compounds, such as formaldehyde contained in
the glue used for wallpaper etc. in general home are one of
causes.
[0004] Then, in order to eliminate such a detrimental substance in
general home and to eliminate smell of a pet, tobacco and so on,
deodorization function into the material comprising wallpaper,
curtain and so on is given. Moreover, giving the deodorization
function is done into the other materials, for example, such
function is given into the fiber comprising clothes and
bedclothes.
[0005] As an art giving the deodorization function into fiber, for
example, the cotton, fiber and wallpaper added charcoal and for
producing thereof are disclosed in Japan patent publication
Tokukaihei 11-229219. This art is what solvent blended acrylic
resin and charcoal is sprayed or immersed to cotton or a fiber so
that deodorization function is given with adding charcoal into
cotton, a fiber or so on.
[0006] However, the following problems existed in the art indicated
in Japan patent publication Tokukaihei 11-229219.
[0007] First, it is what solvent blended acrylic resin and charcoal
is sprayed or immersed to cotton or a fiber so that charcoal is
adhered to cotton or a fiber, but since acrylic resin is used as a
binder, there is the problem that an injection nozzle is blocked so
that it is difficult to manufacture preferably when it is
manufactured continuously for a long time. Moreover, either method
of the case in splaying or the case in immersing, viscosity of
solvent increases because of the acrylic resin as a binder so that
it is possible to adhere charcoal near the surface of cotton or a
fiber, but there is a problem that it is hard to adhere charcoal
inside of cotton or a fiber. Incidentally, a disagreeable smell was
emanated during the manufacture since resin is used, and the safety
of the manufactured product was not enough.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a model sectional view of the processed work
containing carbon, related to the present invention.
[0009] FIG. 2 is a model sectional view of the processed work
containing carbon, related to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] First, the single fiber containing carbon powder inside of
the fiber, related to the present invention will be described.
[0011] The single fiber containing carbon powder inside of the
fiber, related to the present invention contains carbon powder
beforehand inside of the fiber.
[0012] As a fiber used in the single fiber containing carbon powder
inside of the fiber, related to the present invention, it is mainly
chemical fiber, and all chemical fibers, such as recycled fiber,
half-synthetic fiber, synthetic fiber, and inorganic fiber, can be
used as chemical fiber. Concretely, as recycled fiber, cellulose
recycled fiber, such as rayon and cuprammonium, recycled silk
thread, milk protein fiber, soybean protein fiber, corn protein
fiber, protein recycled fiber, such as peanut protein fiber, and
other alginic acid fibers, natural rubber, etc. can be exemplified.
As half-synthetic fiber, acetate, a promix, chloride rubber,
hydrochloric acid rubber, etc. can be exemplified. As synthetic
fiber, polyamide fiber, polyester fiber, polyacrylics nitril fiber,
polyvinyl alcohol fiber, polypropylene fiber, polyvinyl chloride
fiber, polyethylene fiber, polyethylene terephthalate fiber,
polyvinylidene chloride fiber, polyurethane fiber, polyalkylene
paraoxibenzoate fiber, polychlal fiber, fluoric fiber, estamid
fiber, polyfluoro ethylene fiber, polyvinylidene cyanide fiber,
polyurea fiber, etc. can be exemplified. Further, as an inorganic
fiber, a glass fiber, a metal fiber, etc. can be exemplified.
Moreover, optional additives, such as antibacterial agent, a
bacteriostat, a catalyst, a coloring prevention agent, a
heat-resistant agent, a flame retardant, an oxidization prevention
agent and an inorganic subtlety particle may be added by the above
described fiber if necessary.
[0013] Incidentally, in this invention, synthetic fiber in these
chemical fibers is used preferably, and polyester fiber,
polyacrylics nitril fiber, polypropylene fiber, polyvinyl chloride
fiber, polyethylene fiber, polyethylene terephthalate fiber, and
polyvinylidene chloride fiber in particular are used more
preferably.
[0014] More particularly preferably, using the recycled
polyethylene terephthalate resin regenerated from used good made of
polyethylene terephthalate is preferable. Since synthetic resin
pellet: recycled article becomes to blacken even if carbon powder
is not contained, 1.0 .mu.m or less, more preferably 0.01-1.0 .mu.m
of fine carbon powder 6-15 weight % is contained, transparent
single fiber is prepared from pure synthetic resin pellet, and tone
of collar can be adjusted by those content. If the content of the
carbon powder is less than 6 weight %, no effect by carbon powder
because of blending can be obtained; and if over 15 weight % is
compounded, single fiber intensity will be weak; therefore, neither
case is preferable. Moreover, this is because that if particle
diameter is over 1.0 .mu.m, it will be hard to add into single
fiber made of recycled polyethylene terephthalate resin.
Incidentally, the process comprising steps of: heating synthetic
resin single fiber; opening such single fiber partially; and
blending carbon powder therein, or the process wherein carbon
powder is adhered to the surface in the spinning process of single
fiber can be adapted.
[0015] For the carbon powder used in the present invention, either
of white carbon obtained by that material wood is burned at
750-1200.degree. C. and is carbonized at 350-520.degree. C. or
black carbon obtained by that material wood is burned at
400-750.degree. C. and is carbonized at 250-450.degree. C. can be
used preferably, furthermore carbon black made from petroleum can
be used. For example, as white carbon, charcoal that material wood
is oak kind or Japanese oak kind belonging to the beech family
(Fagaceae), Japanese oak genus (Quercus), such as Bintyo charcoal
that material wood is Ubamegashi (Quercus phillyraeoides) burned
around 1200.degree. C. or charcoal that material wood is conifer,
such as Japan cedar (Cryptomeria japonica), Japanese cypress
(Chamaecyparis obtusa), Japanese red pine (Pinus densiflora),
Japanese black pine (Pinus thunbergii), can be exemplified.
Moreover, as black carbon, charcoal that material wood is Kunugi
(Quercus acutissima), Konara (Quercus serrta Thunb), etc. can be
exemplified. Furthermore, charcoal using the bamboos belonging to
the rice plant family (Gramineae) or activated carbon can be used
preferably. In the present invention, charcoal or charcoal of
bamboo is used preferably in particular, Bintyo charcoal is used
more preferably.
[0016] Although the particle diameter of the carbon powder used is
not limited in particular, 0.1-20 .mu.m is preferable for example,
preferably 0.5-10 .mu.m, more preferably 0.5-5 .mu.m. If it is less
than 0.1.mu.m, the number of processes for pulverization will
increase, and if it is over 20 .mu.m, the intensity of fiber may
fall; therefore neither of the cases is preferable. However, carbon
powder having 0.1 .mu.m or less is prepared and then may be
contained if needed.
[0017] Incidentally, when carbon black is used as carbon powder,
the particle diameter of the carbon black is not limited
especially, but it should be 0.01-1 .mu.m. This is because that it
is difficult to prepare less than 0.01 .mu.m of the particle
diameter, and it is also difficult to prepare over 1 .mu.m of the
particle diameter.
[0018] Further, in the present invention, it is possible to use two
kinds or more of the carbon powder described above. Using both
charcoal or charcoal of bamboo, such as Bintyo charcoal, and carbon
black is preferable in particular. This is because that charcoal
and/or bamboo charcoal is superior in hygroscopicity and
deodorization, but it is difficult to color substantially uniformly
since the particle diameter is relatively large. Making the
particle diameter small is desirable, but in this case, said effect
will decrease. Thus, by blending fine particle diameter of carbon
black, it will be superior in hygroscopicity and deodorization and
it will be possible to color substantially uniformly. When both
charcoal and/or charcoal of bamboo and carbon black are used, the
compounding ratio is not limited especially, but charcoal and/or
charcoal of bamboo and carbon black=1:0.5-4, preferably 1:1-3, more
preferably 1:1.5-2.5, in weight ratio.
[0019] If the compound amount of carbon black is less than 0.5
weight times of the compound amount of charcoal and/or charcoal of
bamboo, no effect because of compounding carbon black can be
obtained; and if the compound amount of carbon black is over 4
weight times of the compound amount of charcoal and/or charcoal of
bamboo, hygroscopicity and deodorization will be inferior;
therefore neither case is preferable.
[0020] In order to contain the charcoal powder and/or carbon black
into single fiber beforehand, the necessary quantity of carbon
powder is compounded with the synthetic resin being the materials
as described above, a pellet is made, and this is span into single
fiber. Incidentally, the method of spinning may be any of melt
spinning, dry spinning, wet spinning, and emulsion spinning, and
the method suitable for the synthetic resin used should be
adopted.
[0021] The compound amount of carbon powder will be 1-50 weight %
to the synthetic resin used. If the compound amount of carbon
powder is less than 1 weight %, the effect by compounding carbon
powder is not acquired, and if over 50 weight % is compounded, the
intensity of the fiber may fall; therefore neither of the cases is
preferable. Particularly preferably, 6-15 weight % thereof is
compounded. Incidentally, when pellet is spun and single fiber is
made, carbon powder may be compounded. In this case, the compound
amount of carbon powder is not limited especially, but it will be
7-20 weight %.
[0022] Moreover, although the thickness of the single fiber to be
spun is not limited, it will be 5-20 deniers and 10-15 deniers will
be preferable.
[0023] Thus, by containing carbon powder inside the fiber
beforehand, the single fiber containing the carbon powder inside
the fiber, related to the present invention can be obtained.
Furthermore, such single fiber can be processed to any optional
form. For example, after twisting such single fiber and making
knitting yarn or weaving yarn, a processed work can be obtained by
making knitting goods or textiles. Moreover, after such single
fiber is cotton-opened, optional cotton work, such as cotton,
nonwoven fabric, and cushion material, can be obtained.
Incidentally, when making the processed work or the cotton work, it
can be formed just from single fiber compounded carbon powder, or
fibers not compounded carbon powder, for example natural fibers
whereof: vegetable fibers such as cotton, kapok and hemp; animal
fibers such as silk, wool and goat hair: for instance, Angora wool
goat hair, cashmere and so on, can be compounded properly in
addition to chemical fibers described above.
[0024] The single fiber manufactured as above, and the processed
work and cotton work manufactured from such single fiber have
superior deodorization and hygroscopicity without falling carbon
powder since carbon powder is contained beforehand inside the
fiber. Furthermore, there is no restriction in the use, and
flexibility is high.
[0025] Next, the concrete producing of the single fiber containing
the carbon powder inside the fiber and cotton work comprised of
such single fiber, related to the present invention will be
described with exemplifying the case that nonwoven fabric is
processed with using recycled polyethylene terephthalate fiber as
fiber.
[0026] First, recycled synthetic resin which is for material of
fiber, in this case: recycled pellet obtained by blending particle
diameter 1-0.1 .mu.m of the ratio 1:2 for charcoal powder and
carbon black and by adding necessary quantity; for example, 5
weight % thereof into polyethylene terephthalate, is melted. By
spinning this and making to the necessary thickness, 10 deniers for
example, the single fiber which containing carbon powder inside PET
fiber can be manufactured.
[0027] Next, after said manufactured single fiber is cotton-opened,
necessary quantity is measured, and then it is formed to
sheet-shape and is layered until it becomes necessary thickness so
that the web is made. Finally the web is pierced with needle punch,
the single fiber in the web is pushed in, and it is intertwined so
that a nonwoven fabric can be manufactured. Incidentally, the
method of manufacturing a nonwoven fabric is not limited
particularly, but can be manufactured by well-known methods, such
as a method of gluing fibers using glue or a stitching method, a
spray fiber method, and a spun-bond method besides said needle
punch method.
[0028] Next, the processed work and the cotton work containing the
carbon powder on the fiber surface or in the fibers, related to the
present invention will be explained with reference to drawing. FIG.
1 and FIG. 2 are model sectional views of the processed work
containing carbon powder on the fiber surface or in the fibers,
related to the present invention.
[0029] The processed work and cotton work containing carbon powder
on the fiber surface or in the fibers, related to the present
invention (hereinafter, just called the processed work containing
carbon and the cotton work containing carbon) have a
characteristics whereof carbon powder (3) is contained in the
fibers: with concentrating on the surface of the processed work (2)
as the processed work containing carbon (1) shown in FIG. 1; or
with dispersing on the surface and the inside of the processed work
(2) as the processed work containing carbon (1) shown in FIG.
2.
[0030] The processed work (2) used in the processed work containing
carbon (1) is the textiles or knitting goods manufactured from at
least one or more kinds of yarn manufactured by spinning,
manufacturing yarn, spinning yarn, twisting yarn of one kind or two
kinds or more of fibers described later. Further, the cotton work
used in the cotton work containing carbon, related to the present
invention is cotton obtained by cotton-opening of the single fiber,
cushion material, a nonwoven fabric or so on manufactured by
spinning of one kind or two kinds or more of fibers described
later.
[0031] Moreover, as the processed work (2) used in the processed
work containing carbon (1), the processed work comprising the
single fiber containing carbon powder inside the fiber, as
described the above, can be used, and as the cotton work used in
the cotton work containing carbon, the cotton work comprising the
single fiber containing carbon powder inside the fiber, as
described the above, can be used In addition to the chemical fibers
described above, natural fiber can be used as the fiber comprising
the processed work containing carbon (1) and the cotton work
containing carbon. As natural fiber: vegetable fibers such as
cotton, kapok and hemp; and animal fibers such as silk, wool and
goat hair: for instance and Angora wool goat hair, cashmere and so
on, can be exemplified. Optional additives, such as antibacterial
agent, a bacteriostat, a catalyst, a coloring prevention agent, a
heat-resistant agent, a flame retardant, an oxidization prevention
agent and an inorganic subtlety particle may be compounded to said
fiber if necessary.
[0032] As the carbon powder (3) used in the processed work
containing carbon (1) and the cotton work containing carbon, the
same kind of carbon powder as the carbon powder described above can
be used. Further, the particle diameter of the carbon powder (3)
used in the processed work containing carbon (1) and cotton work,
related to the present invention is not limited, but 0.1-500 .mu.m
is preferable and 0.5-50 .mu.m is more preferable. This is because
that if it is less than 0.1 .mu.m, the number of processes for
pulverization will increase, and if it is over 500 .mu.m of the
partial diameter, it may fall from processing work (2) and cotton
work; therefore, neither of the cases is preferable.
[0033] Incidentally, when carbon black is used as carbon powder,
the particle diameter is not limited especially, but it will be
0.01-1 .mu.m. This is because it is difficult prepare less than
0.01 .mu.m of particle diameter, and it is also difficult prepare
over 1 .mu.m of particle diameter.
[0034] Further, in the present invention, it is possible to use two
kinds or more of the carbon powder described above. Using both
charcoal or charcoal of bamboo, such as Bintyo charcoal, and carbon
black is preferable in particular. This is because that charcoal
and/or bamboo charcoal is superior in hygroscopicity and
deodorization, but it is difficult to color substantially uniformly
since the particle diameter is relatively large. Making the
particle diameter small is desirable, but in this case, said effect
will decrease. Thus, by blending fine particle diameter of carbon
black, it will be superior in hygroscopicity and deodorization and
it will be possible to color substantially uniformly. When both
charcoal and/or charcoal of bamboo and carbon black are used, the
compounding ratio is not limited especially, but charcoal and/or
charcoal of bamboo and carbon black=1:0.5-4, preferably 1:1-3, more
preferably 1:1.5-2.5, in weight ratio.
[0035] If the compound amount of carbon black is less than 0.5
weight times of the compound amount of charcoal and/or charcoal of
bamboo, no effect because of compounding carbon black can be
obtained; and if the compound amount of carbon black is over 4
weight times of the compound amount of charcoal and/or charcoal of
bamboo, hygroscopicity and deodorization will be inferior;
therefore neither case is preferable.
[0036] Moreover, the content of carbon powder (3) will be adjusted
properly so as the total amount of carbon powder in the processed
work containing carbon (1) and the cotton work containing carbon is
1-20 weight %
[0037] In order to make the processed work containing carbon (1)
and the cotton work containing carbon, related to the present
invention by containing said carbon powder (3) to processed work
(2) and cotton work, the diluted solution of emulsion prepared from
carbon powder (3) and water using the surfactant is sprayed or
immersed to the above-described processed work (2) and cotton
work.
[0038] As surfactant used when preparing the diluted solution of
emulsion, any surfactant which can disperse like said carbon powder
(3) into water can be used. For example, such as alkylsulfate,
alkylphosphate, polycarboxylate, fatty acid salt,
alkylbenzylsulphonate, alkylsulfosuccinate,
alkyldiphenyletherdisulphonate, polyoxiethylene alkylsulfate,
allylalkylsulfate, polyoxiethylene alkylphosphate, naphthalene
sulfonic acid and formalin condensate can be exemplified.
[0039] Incidentally, water-soluble high polymers, such as
hydroxyethylcellulose, as the form stabilizer, sodium metaphosphate
and the like as dispersion adjuvant, and additives such as
antiseptic and colorant besides surfactant and carbon powder which
are indispensable components may be compounded properly and
optionally.
[0040] To prepare the diluted solution of emulsion from each
component explained as above, it can be prepared by blending
necessary amount of each component to water. Incidentally, if
dispersion of carbon powder is inferior with this method, all
additives such as carbon powder and surfactant are blended to a
little amount of water and are made to paste-shape beforehand, and
then may be diluted with remained water.
[0041] Moreover, content of surfactant is not limited especially,
but it is added to become 0.01-5 part by weight, more preferably
0.1-3 part by weight, when the total amount of compounded
components is set to 100 part by weight. This is because that: if
content of surfactant is less than 0.01 part by weight, carbon
powder can not be dispersed in water; and if more than 5 part by
weight is compounded, no further effect can be expected; therefore,
neither case is preferable.
[0042] Incidentally, content of water and carbon powder is not
limited especially, but it may adjusted to become 1:0.1-10 in
weight ratio, preferably 1:0.2-5, more preferably 1:0.5-2. This is
because both in the case that the compound amount of carbon powder
is less than 0.1 weight times of the compound amount of water and
in the case that the compound amount of carbon powder is over 5
weight times of the compound amount of water, dispersion of carbon
powder can not be improved.
[0043] After diluted solution of emulsion prepared from each
composition as explained above is sprayed to the processed work (2)
or the cotton work, or after diluted solution of emulsion is
immersed to the processed work (2) or the cotton work, and by being
dried, the processed work containing carbon powder (1) or the
cotton work, related to the present invention can be obtained.
[0044] Incidentally, drying after emulsion is applied is carried
out with heated drying. Heating temperature is not limited
especially, but it is at 100-200.degree. C., preferably at
120-170.degree. C. This is because that if it is less than
100.degree. C., it is impossible to dry sufficiently; and if
heating is at more than 200.degree. C., no further effect can be
obtained.
[0045] Next, concrete producing for the processed work and the
cotton work containing carbon powder, related to the present
invention will be explained with exemplifying the case used cotton,
as cotton work, comprised of polyester fibers.
[0046] First, after polyester fiber is cotton-opened, necessary
amount is measured. Next, it is loaded and formed to sheet-shape,
and then it is layered until it becomes necessary thickness and is
made to web. The web is pierced with a needle punch, fiber in the
web is pushed in, and it is intertwined so that cotton is
manufactured.
[0047] Next, diluted solution of emulsion prepared separately is
injected to such cotton thoroughly. Further, diluted solution of
emulsion may be immersed. Finally, by heated drying under the
temperature condition of approximately 150.degree. C., the cotton
work containing carbon powder, related to the present invention can
be obtained.
[0048] Since the processed work and the cotton work containing
carbon powder, related to the present invention contain carbon
powder on the fiber surface and/or inside fibers, they have
superior deodorization and hygroscopicity. Further, since carbon
powder is applied as diluted solution of emulsion to the processed
work and the cotton work, there is no fear of getting an injection
nozzle blocked when injecting; in addition, since it penetrates
inside of the processed work and the cotton work, carbon powder can
be dispersed not only near the surface of the processed work and
the cotton work but an inside thereof.
EXAMPLE
[0049] The present invention will be described in detail with
showing examples hereinafter. However, this invention is not
limited by the following examples at all.
Preparation of Samples on Examples 1 and 2
[0050] First, 8 weight % of carbon powder, which is blended with
particle diameter 0.1-1.0 .mu.m of carbon black powder and carbon
powder at ratio 1:2, was blended to the powder of used PET, which
is the material of recycled PET fiber so that pellet was made, and
then such pellet was melted with heating. Then it was spun so that
thickness approximately 15 deniers of PET fiber containing carbon
powder inside the fiber was made as sample of Example 1.
[0051] Next, after said manufactured sample of the Example 1 was
cotton-opened, it was formed to sheet-shape and was layered until
it becomes necessary thickness so that it was made to web. Finally,
the web was pierced with a needle punch, fiber in the web was
pushed in, and it was intertwined so that manufactured cotton was
made as sample of Example 2
Preparation of Sample on Example 3
[0052] First, polyester was cotton-opened, it was formed to
sheet-shape and was layered until it becomes necessary thickness so
that it was made to web. Then, the web was pierced with a needle
punch, fiber in the web was pushed in, and it was intertwined so
that cotton work was manufactured.
[0053] Next, emulsion prepared separately so as the ratio of
surfactant: water: carbon powder is 6:5:1, was injected thoroughly
to said manufactured cotton work. Finally, it was heated drying
under the temperature condition of approximately 150.degree. C.,
and the cotton work containing carbon powder was made as sample of
Example 3
[0054] Said prepared sample of the Example 1 contained carbon
powder inside the fiber. Furthermore, the intensity of such fiber
was not inferiority as compared with the fiber not compounded
carbon powder. Moreover, in usual use situation on the samples of
Examples 2 and 3, carbon powder was not fallen.
Test; Deodorization Test
[0055] The deodorization test was carried out using said prepared
sample of Example 3. The test method is as follows: 10.times.20 cm
of the sample of the Example 3 was put in 5 liters of a tetra bag
(the amount of gas in a container is 3 liters), which was prepared
so as the concentration of ammonia is set to 400 ppm, and the
concentration of ammonia in the container after required time was
passed under temperature condition of 20.degree. C. was measured
using the Kitagawa-type detection pipe. Moreover, the case using
formaldehyde with preparing so as initial concentration is set to
15.0 ppm was also measured as the same method. Incidentally, as
comparative example, change of the ammonia concentration and
formaldehyde concentration with putting in no sample of the
examples was also measured under the same condition. A result is
shown in Table 1.
1 TABLE 1 0 10 20 30 60 90 120 Sample min. min. min. min. min. min.
min. Ammonia Example 400 115 110 105 99.0 86.0 86.0 (ppm) Compar-
400 400 400 400 400 400 400 ative example Formalde- Example 15.0 --
-- 2.6 -- -- 0.4 hyde Compar- 15.0 -- -- 15.0 -- -- 15.0 (ppm)
ative example
[0056] As the result of Table 1, it is found that the processed
work containing carbon has superior deodorization to toxic
substances, such as ammonia and formaldehyde.
Effect of the Invention
[0057] As described above, since the single fiber containing carbon
powder inside the fiber, related to the present invention, and the
processed work and cotton work thereof contain carbon powder inside
of fiber beforehand, they have superior deodorization and
hygroscopicity, carbon contained will not be fallen, and they can
be formed to required form so that flexibility is high.
[0058] Moreover, the processed work and the cotton work containing
carbon powder on at least one of the fiber surface and inside
thereof, related to the present invention have superior
deodorization and hygroscopicity. In addition, since carbon powder
is contained without using high polymer binder, such as acrylic
resin, safety is very high.
[0059] Since the process of producing the processed work and the
cotton work comprise the steps of: at least one of spraying or
immersion of a diluted solution of emulsion to the processed work,
said diluted solution of emulsion comprising at least carbon
powder, surfactant and water; and drying said work with heating,
carbon powder can be contained without using high polymer binder,
such as acrylic resin. For this reason, a disagreeable smell does
not occur when manufacturing, and it can manufacture safely.
[0060] Moreover, since emulsion is used, carbon powder can be
contained even the inside of the processed work and the cotton
work.
* * * * *