US 20070243783A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2007/0243783 A1
Kotani et al. (43) Pub. Date: Oct. 18, 2007
(54) CONJUGATED STRETCH YARN, GLOVES (30) Foreign Application Priority Data
AND STRETCH FABRC WITH OPENWORK
PATTERN Sep. 3, 2004 (JP)...................................... 2004-256.844
Nov. 29, 2004 (JP)...................................... 2004-343995
Publication Classification
(75) Inventors: Tetsuo Kotani, Osaka (JP); Yoshihiro
Matsui, Osaka (JP); Yuji Hamaguchi, (51) Int. Cl.
Osaka (JP); Mitsuo Miyajima, Osaka D04B L/18 (2006.01)
(JP); Yoshinobu Ohie, Osaka (JP): A4ID 9/00 (2006.01)
Masumi Goto, Osaka (JP) D04B 7/34 (2006.01)
Correspondence Address: D06O I/02 (2006.01)
MORRISON & FOERSTER LLP
(52) U.S. Cl. ................. 442/306; 2/159; 66/174: 8/114.6
1650 TYSONS BOULEVARD (57) ABSTRACT
SUTE 4OO
A composite elastic yarn includes a polyolefin-based elastic
MCLEAN, VA 22102 (US) fiber and a polyolefin-based inelastic fiber. A cross-linked
(73) Assignee: Toyo Boseki Kabushiki Kaisha, Osaka polyolefin-based elastic fiber, for example, is employed as
shi, Osaka (JP) the polyolefin-based elastic fiber, and a high molecular
weight polyethylene fiber having a weight average molecu
(21) Appl. No.: 11/660,914 lar weight of at least 10x10, for example, is employed as
the polyolefin-based inelastic fiber. Such a composite elastic
(22) PCT Filed: Aug. 30, 2005 yarn is Suitable for use as a glove material. The yarn may be
used to produce a stretchable fabric with a watermark-like
(86). PCT No.: PCT/UP05/15712 pattern including a cross-linked polyeolefin-based elastic
fiber and an inelastic fiber, and having a watermark-like
S 371(c)(1), pattern produced by complete or incomplete removal of the
(2), (4) Date: Feb. 23, 2007 inelastic fiber with partial burn-out printing.
US 2007/0243783 A1
CONJUGATED STRETCH YARN, GLOVES AND
STRETCH FABRIC WITH OPENWORK PATTERN
REFERENCE TO RELATED APPLICATIONS
0001. This is a national stage application under 35 USC
371 of International Application No. PCT/JP2005/015712,
filed Aug. 30, 2005, which claims priority from Japanese
Patent Application Nos. 2004-256.844 and 2004-343995,
filed Sep. 3, 2004, and Nov. 29, 2004, respectively, the entire
disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
0002 The present invention relates to a composite elastic
yarn with excellent chemical resistance and lightfastness,
suitable for application to objects where durability is
required. Such as Swimsuits, underwear, outerwear, diaper
covers, sanitary products, outdoor products like tents, and
industrial materials.
0003. The present invention further relates to a cut
resistant glove which has excellent chemical resistance,
lightfastness, and quick-drying properties, and is Suitably
used when handling iron plates with sharp edges or burrs;
dealing with glass; engaging in dangerous work using
knives, such as the processing of meat and cutting of large
fish; and the like.
0004 The present invention also relates to a stretchable
fabric with a watermark-like pattern having high stretch
ability, and a manufacturing method therefor.
BACKGROUND OF THE INVENTION
0005 Composite elastic yarns are widely used in Swim
Suits, leotards, underwear, outerwear, diaper covers, stretch
able parts of sanitary products, tent sheets and the like.
Conventional composite elastic yarns are covered yarns
wherein a general-purpose inelastic filament yarn, Such as
those made of polyester or polyamide, covers a polyurethane
elastic core yarn.
0006 Although polyurethane elastic fibers have high
stretchability, their chemical resistance and weatherability
are significantly inferior compared with general-purpose
yarns. For this reason, sufficient durability cannot be
achieved when polyurethane elastic fibers are used in gar
ments which are to be subjected to industrial cleaning
involving chlorine sterilization; in Swimming Suits; and in
materials which are exposed outdoors, such as car sheets. In
order to improve chemical resistance and weather resistance
of polyurethane elastic yarns, attempts at adding various
additive agents thereto have been made. However, the nature
of polyurethane elastic yarns remains Substantially
unchanged, and Such polyurethane elastic yarns cannot be
used especially under severe conditions (see, for example,
patent document 1 and patent document 2).
0007 Polyester fibers and polyamide fibers, which are
used as inelastic fibers in composite elastic yarns, have
chemical resistance and weatherability superior to those of
polyurethane elastic fibers. However, these fibers are inap
propriate for use as a material that is exposed to harsh
environments, such as prolonged outdoor exposure or indus
trial cleaning with chlorine or other chemicals, because they
hydrolyze and/or turn yellow under such conditions.
Oct. 18, 2007
0008 An example of a suitable application for composite
elastic yarns is use as a glove material. Excellent cut
resistance is required in gloves which are used when han
dling iron plates with sharp edges or burrs; dealing with
glass; and engaging in dangerous work using edged tools
Such as knives, including the processing of meat and cutting
of large fish. Known cut-resistant gloves are those made
from yarns of aramid fibers, metal fibers, glass fibers, and
the like. However, the use of gloves made of metal fiber
yarns is limited due to the poor flexibility of metal fiber
yarns and resulting difficulties in knitting, and also due to the
electrically conductive nature thereof. Glass fibers may
break in a glove, and the broken ends of the fibers occa
sionally project from the inner Surface of the glove and stick
into the hand. Aramid fibers are prone to lose their strength
by contact with strong acid or strong alkali, and further, if
exposed to natural light, the fibers are discolored and/or their
abrasion resistance is decreased.
0009 High-tenacity polyethylene fibers are also
employed as cut-resistant glove materials. Although high
tenacity polyethylene fibers do not exhibit the above-de
scribed defects, because these fibers are poor in stretchabil
ity, the stretchability of the knitted fabric of a glove obtained
therefrom is imparted only by its knitting structure. Stretch
ability of the glove is thus occasionally insufficient for some
uses; the glove cannot be easily put on or taken off, and also,
the adherence thereof to the skin may be inadequate.
0010 Composite yeans comprising a polyurethane elastic
yarn as a core yarn have been developed in an attempt to
improve the stretchability of high-tenacity polyethylene
fibers. However, as mentioned above, the chemical resis
tance and weatherability of polyurethane elastic yarns are far
worse than those of general-purpose yarns. When a glove is
made thin and light using Such a high-tenacity polyethylene
fiber so as to enhance wearing comfort, the exposure of the
core yarn, composed of a polyurethane elastic fiber, becomes
great. As a result, the adverse characteristics of polyurethane
elastic fibers as described above significantly degrade the
physical properties of the glove.
0011 Quick-drying properties are required in gloves for
use in activities using water and in outdoor leisure activities,
because wet gloves give a strong feeling of discomfort to the
wearer and also undermine workability. However, conven
tional gloves do not possess a quick-drying nature.
0012. As described above, a cut-resistant glove which
provides a comfortable fit and has excellent chemical resis
tance, weatherability, and quick-drying properties has not
yet been achieved.
0013 In recent years, there has been a high demand for
designs on underwear, Swimsuits and the like, and it has
been accordingly desired to apply burn-out printing to
stretchable fabrics from which these products are made.
0014) A well-known example of a burn-out printing
method is opal finishing. Opal finishing is a method wherein
a fabric is first obtained as a union fabric or union knit
containing an acid-resistant fiber. Such as silk fibers, polya
mid-based fibers and polyester-based fibers, and a vegetable
fiber which is easily carbonized by acid, such as cotton fibers
and rayon fibers. The obtained fabric is then printed with a
carbonizing paste made of Sulfuric acid, aluminium sulfate
or the like, and the vegetable fiber at the printed portion is
US 2007/0243783 A1
then carbonized and accordingly removed, thereby forming
a watermark-like pattern. According to one conventional
technique of this method, for example, an union fabric or
union knit is made by weaving or knitting a polyester-based
fiber having relatively high acid resistance with a cellulose
fiber having poor acid resistance, the fabric or knit thus
obtained is processed with acid, and the cellulose fiber is
thereby burnt out, resulting in the formation of a watermark
like design on the fabric (patent document 3). Another opal
finishing method is known for giving a watermark-like
pattern to a fabric made of different kinds of polyester fibers
having different degrees of alkali solubility (patent docu
ment 4).
0015. As mentioned above, as materials for stretchable
fabrics, covered yarns are widely used which are obtained by
covering a polyurethane elastic core yarn with a general
purpose inelastic filament yarn made of polyester, polya
mide or the like. However, watermark-like pattern formation
by opal finishing is not possible on Such a fabric because, as
with the above-described general-purpose inelastic filament
yarns, polyurethane elastic fibers have poor acid resistance.
Moreover, polyurethane fibers easily turn yellow and thus
are not suitable as materials for fabrics on which to form a
watermark-like pattern.
0016 Patent document 1 JP 2001-08 1632 A
0017 Patent document 2.JP 1994-081215 A
0.018 Patent document 3 JP 2002-61070 A
0.019 Patent document 4.JP 1993-263375 A
SUMMARY OF THE INVENTION
0020. The present invention aims to solve the above
described problems. The first object of the invention is to
provide a composite elastic yarn with excellent chemical
resistance and weather resistance.
0021. The second object of the invention is to provide a
cut-resistant glove with high resistance to chemicals and
weathering.
0022. The third object of the invention is to provide a
stretchable fabric with a watermark-like pattern, and a
manufacturing method therefor.
Means for Solving the Problem
0023 (i) When an elastic fiber and an inelastic fiber in a
composite elastic yarn are both polyolefin-based fibers. Such
a composite elastic yarn is highly resistant to chemicals and
weathering. A cross-linked polyolefin-based fiber is prefer
ably employed as Such an elastic fiber.
0024 (ii) When the inelastic fiber in such a composite
elastic yarn is for example a high-tenacity polyethylene
filament, a composite elastic yarn with extremely high
tenacity is provided. A glove made of a fabric comprising
Such a composite elastic yarn ensures a comfortable fit and
demonstrates excellent cut resistance, chemical resistance,
and weather resistance. Furthermore, a glove manufactured
using Such a composite yarn has quick-drying properties.
0025 (iii) When a fabric is obtained by weaving or
knitting a composite elastic yarn made of an elastic
yarn comprising a cross-linked polyolefin fiber and an
inelastic yarn not comprising any polyolefin fiber,
Oct. 18, 2007
because cross-linked polyolefin fibers are highly resis
tant to chemicals, a watermark-like pattern can be
formed on Such a fabric by dissolving the inelastic yarn
by opal finishing.
0026. The present invention has been accomplished
based on these findings, and provides composite elastic
yarns and so forth as described below.
0027. Item 1. A composite
p elastic yvarn comprising
p 9. a
polyolefin-based elastic fiber and a polyolefin-based
inelastic fiber.
0028) Item 2. A composite elastic yarn according to
Item 1, wherein the polyolefin-based elastic fiber is a
cross-linked polyolefin-based elastic fiber.
0029) Item 3. A composite elastic yarn according to
Item 1, wherein the polyolefin-based inelastic fiber is a
high-molecular-weight polyethylene fiber having a
weight average molecular weight of at least 10x10.
0030) Item 4. A composite elastic yarn according to
Item 3, wherein the high-molecular-weight polyethyl
ene fiber is a high tenacity multifilament fiber with a
tenacity of 20 cn/dtex or more and an resistance of
incipient tension of 200 ch/dtex or more.
0031) Item 5. A composite elastic yarn according to
Item 1, comprising 1 to 50 wt.% of the polyolefin
based elastic fiber.
0032. Item 6. A composite elastic yarn according to
Item 1, which is a covered yarn formed by covering the
polyolefin-based elastic fiber with the polyolefin-based
inelastic fiber.
0033 tem 7. A gl
Item glove partially
iall or wholly
holl composedd of
o
a woven fabric or knitted fabric comprising the com
posite elastic yarn of Item 1.
0034) Item 8. A glove according to Item 7, wherein a
portion comprising the composite elastic yarn of Item
1 contains at least 30 wt.% of the composite elastic
yarn.
0035) Item 9. A method for manufacturing a glove,
comprising weaving or knitting the composite elastic
yarn of Item 1.
0036) Item 10. Use of the composite elastic yarn of
Item 1 as a material for gloves.
0037) Item 11. Use of the composite elastic yarn of
Item 1 for manufacturing gloves.
0038. Item 12. A stretchable fabric with a watermark
like pattern, the stretchable fabric comprising a cross
linked polyolefin-based elastic fiber and an inelastic
fiber, and having a watermark-like pattern produced by
complete or incomplete removal of the inelastic fiber
with partial burn-out printing.
0039) Item 13. A stretchable fabric according to Item
12, wherein the inelastic fiber is at least one kind of
natural fiber selected from the group consisting of
cotton fibers, hemp fibers, kenaffibers, natto(fermented
soybean) fibers, soy protein fibers, wool fibers, silk
fibers, cashmere fibers, and mohair fibers.
0040 Item 14. A stretchable fabric according to Item
12, wherein the inelastic fiber is at least one kind of
US 2007/0243783 A1
chemical fiber selected from the group consisting of
rayon fibers, cuprammonium rayon fibers, acetate
fibers, promix fibers, polylactic acid fibers, polyester
based fibers, polyamide-based fibers, polyolefin-based
fibers, and acrylic fibers.
0041) Item 15. A stretchable fabric according to Item
12, wherein the inelastic fiber comprises at least one
kind of natural fiber selected from the group consisting
of cotton fibers, hemp fibers, kenaf fibers, fermented
soybean fibers, soy protein fibers, wool fibers, silk
fibers, cashmere fibers, and mohair fibers; and at least
one kind of chemical fiber selected from the group
consisting of rayon fibers, cuprammonium rayon fibers,
acetate fibers, promix fibers, polylactic acid fibers,
polyester-based fibers, polyamide-based fibers, poly
olefin-based fibers, and acrylic fibers.
0042. Item 16. A stretchable fabric according to Item
12, wherein the burn-out printing is opal finishing.
0043 Item 17. A stretchable fabric according to Item
12, comprising 3 to 20 wt.% of the cross-linked
polyolefin-based elastic fiber.
0044) Item 18. A method for manufacturing a stretch
able fabric with a watermark-like pattern, comprising
applying partial burn-out printing to a fabric compris
ing a cross-linked polyolefin-based elastic fiber and an
inelastic fiber, thereby completely or partially remov
ing the inelastic fiber of a processed portion of the
fabric to make a watermark-like pattern.
0045. In the composite elastic yarn of the present inven
tion, a polyolefin-based fiber is employed for elastic and
inelastic fibers, and accordingly, excellent chemical resis
tance and weatherability are provided. Furthermore, when,
for example, a high-molecular-weight polyethylene fiber or
like high tenacity fibers are used as an inelastic fiber, the
resulting composite yarn as a whole has extremely high
tenacity.
0046) The composite elastic yarn of the present invention
is thus especially suitable as a material for gloves that are
used for handling sharp-edged tools or like activities that
might cause injuries. Materials conventionally employed for
cut-resistant gloves include aramid fibers, metal fibers, glass
fibers and the like. However, gloves produced with these
materials have problems such as difficulties in knitting,
inconveniences caused by conductivity, and the danger that
fibers might break and pierce the hand. In this regard, gloves
produced from the composite elastic yarn of the present
invention are advantageous as the fibers therein have excel
lent flexibility which leads to an ease in knitting, possess
electrical insulating properties, and do not easily break.
0047. Furthermore, the present invention provides a
stretchable fabric having a watermark-like pattern thereon,
which has not been achieved before. More specifically, the
stretchable fabric of the invention comprises an elastic fiber
and an inelastic fiber, and the elastic fiber is a cross-linked
polyolefin-based fiber which is highly resistant to chemicals;
due to Such a structure, the watermark-like pattern is formed
thereon by destroying the inelastic fibers with a burn-out
printing method. Unlike urethane-based elastic fibers, cross
linked polyolefin-based fibers do not yellow easily, and thus
a watermark-like design with high transparency can be
maintained over long-term use. The stretchable fabric of the
Oct. 18, 2007
invention is of beautiful appearance and has excellent
stretchability, and hence is suitable for a wide range of uses,
including applications to underwear and sportswear.
DETAILED DESCRIPTION OF THE
INVENTION
0048. The present invention will be described in more
detail hereinafter.
(I) Composite Elastic Yarn
0049. The composite elastic yarn of the present invention
comprises a polyolefin-based elastic fiber and a polyolefin
based inelastic fiber.
0050. As polyolefin-based fibers are highly resistant to
chemicals and weathering, fabrics obtained by weaving or
knitting the composite elastic yarn of the invention do not
easily discolor, and furthermore, the initial fabric properties
can be maintained even under harsh conditions, such as
exposure to outdoor conditions or to industrial cleaning
using chemicals. Moreover, because polyolefin-based fibers
have low densities, a stretchable fabric obtained therefrom is
lightweight even when thick. Furthermore, as polyolefins are
hydrophobic materials, the composite elastic yarn and
stretchable fabric comprising the same of the invention
allow quick and easy drying.
0051 Although the form of the composite elastic yarn of
the invention is not limited, in terms of cut resistance of the
resulting fabric, a covered yarn wherein an elastic fiber is
uniformly covered with an inelastic fiber is preferable. Such
a covered yarn can be manufactured with a covering
machine, or alternatively, it may also be produced by draft
ing an elastic yarn and at the same time plying and twisting
it with an inelastic fiber.
0052 The proportion of elastic fiber in the composite
elastic yarn of the present invention is usually 1 wt.% or
more, preferably 5 wt.% or more, and more preferably 10
wt.% or more. The upper limit of the proportion of elastic
fiber is usually 50 wt.% or less, and preferably 30 wt.% or
less. The specified range can achieve sufficient stretchability
and recoverability, along with practically sufficient tenacity.
0053 An "elastic fiber” as used herein signifies a fiber
having an elasticity generally accepted as being rubber
elasticity, such as, for example, a fiber wherein, after 50%
elongation is applied (i.e., when stretched to 1.5 times), at
least 50% of the elongation is recovered.
0054 Examples of such polyolefin-based elastic fibers
include cross-linked polyolefin-based elastic fibers. Cross
linked polyolefins are obtainable by cross-linking of sub
stantially linear olefins, and their branch points are Substan
tially uniformly distributed over the main chain. Such cross
linked polyolefins can be produced by chemical cross
linking using radical initiators, coupling agents and/or the
like, after polymerization of olefin-based monomers. Cross
linking may also be formed, after polymerization, by irra
diation of energetic beams such as electron beams, B-rays,
and Y-rays. Considering the stability of the end products,
cross-linking by energetic beam irradiation is preferable.
0055. A desirable degree of cross-linking is such that, for
example, the Xylene extract measured according to ASTM
D-2765 is 70 wt.% or less (i.e., a gel content of 30 wt.%
or more), and preferably 40 wt.% or less (i.e., a gel content
of 60 wt.% or more).
US 2007/0243783 A1
0056 Ethylene can be mentioned as an example olefin.
0057 Specific examples of cross-linked polyolefins
include cross-linked low density polyethylenes in which an
C-olefin has been copolymerized, and the cross-linked poly
olefins disclosed in JP 2002-515530 A.
0.058 Due to their cross-linked structure, cross-linked
polyolefin-based elastic fibers have excellent stretchability,
chemical resistance, weatherability, and heat resistance.
0059. In the present invention, an “inelastic fiber' indi
cates a fiber without so-called rubber elasticity, such as
polyesters, polyamides, polyethylenes, polypropylenes, and
other known fibers which do not recover from elongation.
Examples thereof include fibers wherein, when 50% elon
gation is applied (i.e., when stretched to 1.5 times), less than
50% of the elongation is recovered.
0060 Usable inelastic fibers are, for example, fibers
made of high-molecular-weight polyethylene having a
weight average molecular weight of 1x10° or more. The
polyethylene fiber or filament is preferably a filament with
high tenacity and high elasticity, and especially preferable
thereof is a high-tenacity multifilament having a tenacity of
at least 20 cn/dtex and a resistance of incipient tension of at
least 200 cn/dtex, since a glove made of such a multifila
ment has excellent cut resistance. In addition, high-tenacity
and high-elastic polyethylene filaments have low Surface
friction coefficients and their abrasion resistance is thus
excellent. Therefore, when employed as a glove material,
lightness together with a comfortable fit can be achieved.
0061 The tenacity and resistance of incipient tension of
a polyethylene filament are measured according to the
methods described in the Examples.
0062) When materials etc. for the composite elastic yarn
of the present invention are suitably selected from the
above-specified ranges, the chemical resistance of the result
ing yarn is such that the strength retention therein after
chlorine treatment is 85% or more, and preferably 90% or
more. The conditions for chlorine treatment and the mea
Suring method for strength retention are as shown in the
Examples. The durability of a fabric with such strength
retention is practically sufficient to endure cleaning under
harsh conditions, chlorine sterilization, and the like.
0063. When materials etc. are suitably selected from the
above-specified ranges, the composite elastic yarn of the
present invention provides weatherability such that yellow
ing (Ab value) after light irradiation is 5% or less, preferably
3% or less, and more preferably 1% or less. The method of
evaluating yellowing is as described in the Examples. Yarns
with such a Ab value are not likely to yellow even when used
in harsh conditions, such as longtime outdoor exposure.
(II) Glove
0064 Due to its excellent stretchability, the above-de
scribed composite elastic yarn of the present invention is
Suitable as a material for gloves. A use of the present
invention is thus the use of the composite elastic yarn of the
invention as a glove material.
0065. The glove of the present invention is partially or
entirely composed of a woven or knitted fabric comprising
the above-described composite elastic yarn of the invention.
Oct. 18, 2007
0066. The cut-resistant glove of the present invention can
be obtained by knitting yarns including the composite elastic
yarn of the invention. It may also be manufactured by
cutting and sewing a fabric obtained by weaving the com
posite elastic yarn of the present invention.
0067. The glove of the present invention may contain, in
addition to the composite elastic yarn of the invention,
synthetic fibers such as polyesters, nylons, and acrylics;
natural fibers such as cotton and animal hair, and regener
ated fibers such as rayon. The fibers in the fabric may be in
the form of filaments or spun yarns.
0068. In order to achieve high resistance to abrasion,
about 1- to about 4-dtex polyester multifilaments and similar
nylon filaments are preferable. Polypropylene filaments are
especially preferable due to their high lightfastness, excel
lent chemical resistance and low specific gravity.
0069. The proportion of composite elastic yarn is usually
at least 30 wt.% of all the yarns used in the glove, preferably
at least 50 wt.%, and more preferably at least 70 wt.%. Such
a proportion provides Sufficient cut resistance as is required
in a glove for injury-prone activities involving glass, knives
and the like.
0070 The thus-obtained glove is usable as is. If neces
sary, a urethane-based resin or ethylene-based resin may be
applied thereto for the purpose of providing non-slip per
formance.
(III) Stretchable Fabric with a Watermark-Like Pattern
0071. The stretchable fabric with a watermark-like pat
tern of the present invention comprises a cross-linked poly
olefin-based elastic fiber and an inelastic fiber, on which a
watermark-like design is provided by complete or incom
plete removal of the inelastic fiber with partial burn-out
printing.
0072 The definition of elastic fiber is as given above. The
cross-linked polyolefin-based elastic fiber is also as
described above.
0073. The definition of inelastic fiber is also as above.
The kind of inelastic fiber is not limited as long as it is
destroyable by a burn-out printing process which does not
destroy cross-linked polyolefin-based elastic fibers. Such an
inelastic fiber may be a natural fiber, chemical fiber, or a
combination thereof.
0074 Examples of natural fibers include cotton fibers,
hemp fibers, kenaf fibers, fermented-soybean fibers, soy
protein fibers, wool fibers, silk fibers, cashmere fibers,
mohair fibers and the like. Cotton fibers, silk fibers, wool
fibers, soy protein fibers and the like are preferably
employed for a natural inelastic yarn, as these fibers achieve
a fine hand and texture and high moisture absorbency.
Cottons fibers, silk fibers and the like are especially prefer
able.
0075 Examples of chemical fibers include rayon fibers,
cuprammonium rayon fibers, acetate fibers, promix fibers,
polylactic acid fibers, polyester-based fibers, polyamide
based fibers, polyolefin-based fibers, vinylon-based fibers,
acrylic fibers and the like. Polylactic acid fibers, polyester
based fibers, polyamide-based fibers and the like are pref
erably selected as a chemical inelastic fiber, due to their
US 2007/0243783 A1
excellent solubility. Polyester-based fibers and polylactic
acid fibers are especially preferable.
0.076 Such inelastic fibers can be used singly or as a
combination of two or more kinds. In order to obtain a fabric
which combines practicality and a beautiful appearance, it is
preferable to use an inelastic yarn, wherein a natural fiber
which generally has low acid resistance and a chemical fiber
which generally has high acid resistance are combined in the
form of a co-twisted yarn, filament mixed yarn, composite
spun yarn or covered yarn. With Such a structure, it is
possible to selectively remove natural fibers by the applica
tion of sulfuric acid or the like. Not only cross-linked
polyethylene elastic fibers but also other chemical fibers are
left undestroyed, whereby beautiful watermark-like patterns
can be achieved. Particularly suitable combinations are
cotton or silk natural fibers with polyester-based or poly
lactic acid chemical fibers.
0.077 Such an inelastic fiber is served to a cross-linked
polyolefin-based elastic fiber to weave or knit. The method
for combining elastic and inelastic fibers is not limited;
examples of usable fabrics include union fabric, union knit,
examples of usable yarns include co-twisted yarns, filament
mixed yarns, composite spun yarns, covered composite
yarns, and the like. A covered yarn wherein a cross-linked
polyolefin-based elastic fiber is covered with an inelastic
fiber is preferably employed. Because the elastic fiber is
almost completely covered with the inelastic fiber in such a
covered yarn, a fabric obtained by weaving or knitting this
yarn is a high-tenacity fabric with a pleasant hand and
texture.
0078. The role of an elastic fiber in a fabric is to provide
stretchability, and the proportion of elastic fiber in the fabric
is preferably 20 wt.% or less, and more preferably 15 wt.%
or less. The lower limit is preferably at least 3 wt.%, and
more preferably at least 5 wt.%. When elastic fibers are used
in Such a range, the resulting product does not have a
plastic-like hand and texture, as is particular to elastic yarns.
Furthermore, the surface of such a fabric is smooth. More
over, as the elastic fiber is unlikely to be exposed at the
fabric Surface, the fabric has no irritatingly glossy appear
ance. The above-specified range is also advantageous
because these fibers are expensive. Use of an elastic fiber
within Such a range can achieve practically sufficient stretch
ability in a resulting fabric.
0079 The fabric of the invention contains a cross-linked
polyolefin-based elastic fiber, and thus has good stretchabil
ity. The elongation of the fabric under constant load in the
direction of the extension of the elastic fiber is preferably
10% or more, and the recovery therefrom is preferably 60%
or more. It is more preferable that the elongation under
constant load be 15% or more and the recovery be 70% or
more. Such a range leads to a fabric having practically
sufficient stretchability. Moreover, when a fabric with such
a range is made into various shapes and affixed to something,
a sufficient flexibility is assured. Although no upper limit to
elongation under constant load is given, a limit of about
900% is usually preferable in terms of handleability. Meth
ods for measuring elongation under constant load and recov
ery therefrom are as indicated in the Examples. When the
warp yarns and weft yarns are both made of elastic fibers, the
term "elongation under constant load signifies the mean of
the elongations under constant load in both directions.
Oct. 18, 2007
0080 Such stretchability can be attained by suitably
selecting the kinds of elastic and inelastic fibers, and the
proportions thereof in a fabric within the above-given
ranges.
0081 Portions of the fabric of the present invention have
a watermark-like design. The watermark-like design is
formed by completely or incompletely removing the inelas
tic fiber by burn-out printing. In other words, the method of
the present invention for manufacturing a stretchable fabric
with a watermark-like pattern is a method which forms a
watermark-like pattern on a fabric comprising a cross-linked
polyolefin-based fiber and an inelastic fiber by partially,
completely, or incompletely destroying the inelastic fiber.
0082) Opal-finishing can be mentioned as an example of
a method for burn-out printing. This method comprises the
steps of printing a fabric with a paste containing Sulfuric
acid; aluminium Sulfate; sodium sulfate; one or more alka
line metal hydroxides, carbonates, and/or bicarbonates; and/
or sodium hydroxide, and applying heat to the printed fabric
to remove inelastic fibers which have inferior chemical
resistance.
0083. The stretchable fabric of the present invention can
be obtained by applying partial burn-out printing to a fabric
comprising a cross-linked polyolefin-based elastic fiber and
an inelastic fiber, and completely or incompletely removing
the inelastic fiber therein, thereby forming a watermark-like
design on the fabric.
EXAMPLES
0084. The following examples illustrate the present
invention in further detail, but the scope of the invention is
not limited by these examples.
(I) Example of Glove Production Using Composite Elastic
Yarn.
<Evaluation of Chlorine Resistance Ability>
0085. The evaluation was conducted using a testing
device as disclosed in JP 2000-97933. A for evaluating
chlorine resistance of a Swimsuit. The device comprises:
0.086 (1) a water tank for immersion of a test sample:
a sample-holding means to hold the sample; a buffer
tank for measuring the chlorine concentration and pH
of the solution contained in the water tank; an adjust
ment tank for adjusting the chlorine concentration and
pH of the solution in the water tank; and a controlling
system for adjusting the chlorine concentration and pH
of the solution in the water tank to a set value, based on
the measured values of chlorine concentration and pH;
wherein
0087 the chlorine concentration and pH of a solution
are adjusted to a set value in the adjustment tank by the
controlling system, and the Solution is then circulated
in the water tank; and the device further comprising:
0088 (2) a water temperature-controlling system for
adjusting the solution temperature in the water tank to
a set value; and wherein
0089 (3) the sample-holding means is supported by a
sample-moving means, and is movable at a constant
speed in relation to the Solution in the water tank; and
US 2007/0243783 A1
0090 (4) the sample-holding means is supported by a
Swimsuit-moving means whose installation angle to the
water flow is variable.
0091. Using this testing device, changes in pH of a
chlorine Solution due to immersion of a sample therein are
Suppressed, and conditions in the water tank wherein the
sample is immersed are uniformly maintained. Furthermore,
the Swimsuit sample receives a water stream, which models
the situation of Swimming. As a result, measurements at
conditions similar to real-life dynamic situations can be
made, whereby a practical chlorine resistance evaluation is
possible.
1) Preparation of Sodium Hypochlorite Solution
0092 50 ml of sodium hypochlorite (antiformin: manu
factured by Nacalai Tesque, Inc.) was obtained, and pure
water was added thereto to make the whole quantity 51.
2) Preparation of Acetic Acid Solution
0093 50 ml of acetic acid (manufactured by Nacalai
Tesque, Inc.) was obtained, and pure water was added
thereto to make the whole quantity 51.
3) Installation of Specimen
0094. Using the composite elastic yarn, a tubular-knitted
fabric specimen was obtained, and fixed in an unstretched
state with a pin line on a frame made of stainless steel.
4) Test Conditions
0.095 The test conditions are as follows.
0096 Effective chlorine concentration: 3.0 ppm
O097 pH: 7.5
0098 Temperature: 30° C.
0099 Fabric rotation speed: 17.6 rad/s
0100 Fabric installation position: 50 cm away from the
rotation axis
(Rotating with the above rotation speed at the above instal
lation position, the specimen receives a water stream at a
rate of about 1.4 m/s)
0101 Current angle to the fabric: 90°
0102) Operating (rotation) conditions: intermittent opera
tion with 10 seconds of operation and 10 seconds of
Stoppage
0103) Operating time: 288 hours
0104. The processed sample was fully washed with water
and dried at a room temperature.
<Measurement of Strength Retention>
0105. A plain-knitted fabric was manufactured by knit
ting a composite elastic yarn with a 16-guage tubular
knitting machine having a diameter of 3.5 inches. The
obtained fabric was processed for 30 minutes with boiling
water, and then Subjected to a severe test pursuant to test
methods for color fastness to bleaching with hypoclorite
defined in JIS-L-0856 (2002) (sodium hypochlorite solution
A). After drying the specimen, the composite elastic yarns
therein were raveled out, and elastic yarns were taken out
therefrom and then subjected to an S-S test to measure the
breaking tenacity (d2).
Oct. 18, 2007
0106 For a product evaluation, a product was first rav
eled out to take out the composite elastic yarns, and the
elastic yarns were separated therefrom and Subjected to an
S-S test (d1). Separately, a similar product was treated with
chlorine in the same manner as above, and elastic yarns were
isolated after raveling out of the product, an S-S test carried
out, and the breaking tenacity measured (d2). Strength
retention (%) was calculated using the formula (d2)/(d1)x
100.
<Evaluation of Lightfastness.>
0.107 Using a high-energy sunshine fade meter (carbon
arc) manufactured by Suga Test Instruments Co., Ltd., light
irradiation treatment was applied to a tubular-knitted fabric
made of a composite elastic yarn under the following
conditions.
0108 Temperature: 90° C.
01.09) Irradiation time: 90 hours
Next, using a SPECTROPHOTOMETER CM-3700d
manufactured by MINOLTA, the degree of discolora
tion was evaluated using the Ab value.
0110. Ab=b1-b2
0.111 b1: b value of the fabric prior to light irradiation
0112 b2: b value of the fabric after light irradiation
<Evaluation of Quick-Drying Properties.>
0113 Glove samples were placed in tap water for 10
minutes, and spin-dried with a domestic washing machine
for 5 minutes. Three monitors wore the processed gloves and
evaluated their degree of comfort.
<The Method of Measuring Tenacity and Resistance of
Incipient Tension>
0114 Tenacity and elastic modulus were measured as
follows. Using a Tensilon manufactured by Orientec Co.,
Ltd., a specimen of 200 mm (length between chucks) was
stretched at the rate of 100% elongation/minute. While the
specimen was being stretched, the stress thereof was mea
sured at an atmosphere temperature of 20° C. and a relative
humidity of 65%, and a strain-stress curve was thereby
obtained. The stress at the breaking point was defined as
tenacity (cN/dtex). Elastic modulus was calculated from the
tangent of the maximum slope, near the origin of the curve.
10 measurements were taken, and the mean value thereof
was employed.
Example 1-1
0.115. A yarn made of a 70-dtex monofilament manufac
tured by melt-spinning an O-olefin-copolymerized polyeth
ylene was cross-linked using an electron beam, obtaining a
cross-linked polyolefin fiber (herein after referred to as fiber
(A)) (product name: DOWXLA, manufactured by Toyobo
Co., Ltd.). Two specimens of the obtained fiber (A) were put
together, drafted to 1.55 times, and plied and twisted
together with a 440-dtex multifilament fiber (herein after
referred to as fiber (B)), which is an ultra-high-molecular
weight polyethylene fiber (product name: SK60, manufac
tured by Toyobo Co., Ltd.) having a tensile strength of 27
cN/dtex and a resistance of incipient tension of 900 cn/dtex,
to obtain a composite elastic yarn (herein after referred to as
fiber (X)) wherein the number of twists was 200 T/M. A
US 2007/0243783 A1 Oct. 18, 2007

glove was manufactured with a fashioning Stitch machine of textures (edited by The Textile Machinery Society of
using only the obtained composite elastic yarn. Japan), chapter IV, "Nuno no rikigakuteki tokusei no Sokutei
Measurement of dynamic characteristics of a fabric.
Example 1-2 Specimens having a width of 20 cm and a length of 5 cm
0116. Using one specimen of fiber (A) instead of two, a were taken from a fabric both in the warp and weft directions
composite elastic yarn (herein after referred to as fiber (Y)) and stretched in the lengthwise direction at a constant rate of
was obtained in otherwise the same manner as in Example 4.00x10 m/sec to a maximum load of 100 gf/cm. The
1-1. Using a fashioning Stitch machine, yarn (Y) was knitted elongation at the maximum load was measured. The
with a polypropylene fiber-processed yarn having 84 dtex, stretched specimens then underwent a deformation recover
36 filaments, and a glove thereby obtained. ing process. The elongation recovery was defined as the ratio
of the difference between the degree of elongation and the
Example 1-3 degree of deformation at Zero stress after the deformation
0117 Using a nylon filament yarn having 77 dtex, 24 recovery relative to the degree of elongation. In case of a
filaments instead of the polypropylene fiber-processed yarn, tubular-knitted fabric, the course direction was employed.
a glove was manufactured in otherwise the same manner as For a woven fabric, elongation and recovery in the direction
in Example 1-2. Wet coating with a urethane resin was in which the elastic yarn was stretched (when stretched both
applied to the palm side of the obtained glove. in the warp and weft directions, the mean value of the two)
were observed.
Comparative Example 1-1
0118 Using an 88-dtex polyurethane-urea elastic fiber Example 2-1
(product name: ESPA, manufactured by Toyobo Co., Ltd.:) 0.122 A plane knitted fabric was obtained by knitting,
instead of fiber (A), a glove was produced in otherwise the using a plane knitting machine, a 44-dtex cross-linked
same manner as in Example 1-1. Because of the high density polyolefin-based elastic yarn (product name: DOWXLA,
of the elastic yarn, the obtained composite elastic yarn
lacked lightness, and furthermore, it was poor in chlorine manufactured by of Toyobo Co., Ltd.) with a composite
resistance and lightfastness. spun yarn of 60 cotton yarn count comprising a polyester
fiber having 56 dtex, 68 filaments and a cotton yarn of 100's,
Comparative Example 1-2 and cut at the center. Using a screen printing machine
0119 Using an aramid fiber in place of fiber (B), a glove (product name: ICHINOSE #7000-type, manufactured by
was produced in otherwise the same manner as in Example Toshin Kogyo Co., Ltd.), a preliminary floral pattern was
1-1. The obtained composite elastic yarn easily discolored, printed on the obtained fabric, and a Sulfate-containing paste
and its lightfastness was poor. was applied to the patterned portion. The fabric was then
heat-treated at 105° C. for 2 minutes with a heater, steam
0120) The results of the evaluation of the gloves obtained treated at 130° C. for 30 minutes, washed with water, and
in the above examples are shown in Table 1 below. dried. Due to this operation, cotton fibers which are poorly
TABLE 1.
Ex. 1-1 Ex. 1-2 Ex. 1-3 Comp. Ex. 1-1 Comp. Ex. 1-2
Elastic fiber (dtex) Ethylene-based Ethylene-based Ethylene-based Urethane-based Ethylene-based
140 70 70 88 140
Inelastic fiber Polyethylene Polyethylene Polyethylene Polyethylene Aramid
(dtex) 440 440 440 440 440
fiber for union Polypropylene Nylon
knit(dtex) 84 77
Proportion of 100 85 86 100 1OO
composite elastic
yarn (%)
Discoloration Ad 1 1 3 10 15
Strength retention 95 95 95 47 95
(%)
Quick-drying Excellent Excellent Fair Good Fair
properties
Overall evaluation Excellent Excellent Good Poor Poor

(II) Production Example for Stretchable Fabric with Water
mark-Like Pattern
<Elongation under Constant Load and Recovery There
from>
0121 A fabric was tested for elongation in the warp and
weft directions under constant load and for recovery there
from, in accordance with the methods described in “Fuai
hyokanohyojunnka to kaiseki Standardization and analysis
acid resistant were selectively dissolved and removed,
thereby giving a plain knitted fabric featuring a clear floral
watermark-like design.
0123 Elongation and elongation recovery of the obtained
knitted fabric were 54% and 85%, respectively.
Example 2-2
0.124. The procedure of Example 2-1 was followed,
except that a vinylon fiber having 44 dtex, filaments was
US 2007/0243783 A1
used instead of the polyester fiber. As in Example 2-1, the
cotton fiber was dissolved and removed, and a plain-knitted
fabric provided with a beautiful floral watermark-like design
was obtained. Elongation and elongation recovery of this
knitted-fabric were 62% and 81%, respectively.
Comparative Example 2-1
0125 The procedure of Example 2-1 was repeated,
except for using a 44-dtex polyurethane elastic yarn (product
name: ESPA 465, manufactured by Toyobo Co., Ltd.)
instead of the 44-dtex cross-linked polyolefin-based elastic
yarn. The polyurethane elastic fiber was dissolved by acid,
and only the polyester fiber was left in the fabric. As a result,
the fabric contained holes, and no floral watermark-like
pattern was formed thereon. The elongation of this fabric
was 53%, whereas elongation recovery was low, at 42%.
0126 The composite elastic yarn of the present invention
exhibits excellent chemical resistance and highlightfastness,
and is thus Suitable for application to Swimsuits, underwear,
outerwear, diaper covers, sanitary products, tents and like
outdoor products, industrial materials and the like.
0127. When using high-tenacity fibers as inelastic fibers,
the obtained yarns are suitable as a material for gloves for
use in dangerous work Such as handling iron plates with
sharp edges or burrs, dealing with glass, and in dangerous
work using knives, such as the processing of meat and
cutting of large fish.
0128 Moreover, as the stretchable fabric of the present
invention features a beautiful appearance with a watermark
like pattern in addition to the excellent stretchability, it is
Suitable as a material for underwear and sportswear.
1. A composite elastic yarn comprising a polyolefin-based
elastic fiber and a polyolefin-based inelastic fiber.
2. A composite elastic yarn according to claim 1, wherein
the polyolefin-based elastic fiber is a cross-linked polyole
fin-based elastic fiber.
3. A composite elastic yarn according to claim 1, wherein
the polyolefin-based inelastic fiber is a high-molecular
weight polyethylene fiber having a weight average molecu
lar weight of at least 10x10.
4. A composite elastic yarn according to claim 3, wherein
the high-molecular-weight polyethylene fiber is a high
tenacity multifilament fiber with a tenacity of 20 cn/dtex or
more and a resistance of incipient tension of 200 cn/dtex or
O.
5. A composite elastic yarn according to claim 1, com
prising 1 to 50 wt.% of the polyolefin-based elastic fiber.
6. A composite elastic yarn according to claim 1, which is
a covered yarn formed by covering the polyolefin-based
elastic fiber with the polyolefin-based inelastic fiber.
Oct. 18, 2007
7. A glove partially or wholly composed of a woven fabric
or knitted fabric comprising the composite elastic yarn of
claim 1.
8. A glove according to claim 7, wherein a portion
comprising the composite elastic yarn of claim 1 contains at
least 30 wt.% of the composite elastic yarn.
9. A method for manufacturing a glove, comprising weav
ing or knitting the composite elastic yarn of claim 1.
10. (canceled)
11. A stretchable fabric with a watermark-like pattern, the
stretchable fabric comprising a cross-linked polyolefin
based elastic fiber and an inelastic fiber, and having a
watermark-like pattern produced by complete or incomplete
removal of the inelastic fiber with partial burn-out printing.
12. A stretchable fabric according to claim 11, wherein the
inelastic fiber is at least one kind of natural fiber selected
from the group consisting of cotton fibers, hemp fibers,
kenaf fibers, fermented soybean fibers, soy protein fibers,
wool fibers, silk fibers, cashmere fibers, and mohair fibers.
13. A stretchable fabric according to claim 11, wherein the
inelastic fiber is at least one kind of chemical fiber selected
from the group consisting of rayon fibers, cuprammonium
rayon fibers, acetate fibers, promix fibers, polylactic acid
fibers, polyester-based fibers, polyamide-based fibers, poly
olefin-based fibers, and acrylic fibers.
14. A stretchable fabric according to claim 11, wherein the
inelastic fiber comprises at least one kind of natural fiber
selected from the group consisting of cotton fibers, hemp
fibers, kenaf fibers, fermented soybean fibers, soy protein
fibers, wool fibers, silk fibers, cashmere fibers, and mohair
fibers; and at least one kind of chemical fiber selected from
the group consisting of rayon fibers, cuprammonium rayon
fibers, acetate fibers, promix fibers, polylactic acid fibers,
polyester-based fibers, polyamide-based fibers, polyolefin
based fibers, and acrylic fibers.
15. A stretchable fabric according to claim 11, wherein the
burn-out printing is opal finishing.
16. A stretchable fabric according to claim 11, comprising
3 to 20 wt.% of the cross-linked polyolefin-based elastic
fiber.
17. A method for manufacturing a stretchable fabric with
a watermark-like pattern, comprising applying partial burn
out printing to a fabric comprising a cross-linked polyolefin
based elastic fiber and an inelastic fiber, thereby completely
or partially removing the inelastic fiber of a processed
portion of the fabric to make a watermark-like pattern.