FIBER BUNDLE FOR ARTIFICIAL HAIR, AND PROCESS FOR ITS PRODUCTION
To provide a fiber bundle for artificial hair which has a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency. The fiber bundle for artificial hair is a fiber bundle obtained by crimping fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method and has a crimp wave shape satisfying the following formula: 1 mm≦R≦20 mm wherein R is the distance between the top and the bottom of the crimp wave shape. Further, in the fiber bundle for artificial hair, the fibers (A) are vinyl chloride fibers obtained by melt-spinning a vinyl chloride resin composition.
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The present invention relates to a fiber bundle for artificial hair to be used for head decoration, particularly to a fiber bundle for artificial hair suitable for braids.
BACKGROUND ARTAmong fiber bundles for artificial hair to be used for head decoration, such as wigs, weaves, hair pieces, braids, extension hairs, accessory hairs, etc., a fiber bundle for artificial hair to be used for braids is required to have a special performance for the purpose of its use.
A braid, e.g. one having crimping applied by gear-crimping, may be woven into hair at a beauty shop or the like, and further, depending upon the style, curling may be imparted by hot water to complete the decoration.
Fibers for doll hair have been proposed as fibers having bulky crimping applied (Patent Document 1). However, such fibers for doll hair are not one having a good balance of properties required for a braid.
Patent Document 1: JP-A-11-309275
DISCLOSURE OF THE INVENTION Object to be Accomplished by the InventionIt is an object of the present invention to provide a fiber bundle for artificial hair having a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency.
Means to Accomplish the ObjectThe present inventors have conducted an extensive study to accomplish the above object and as a result, have found it possible to obtain a fiber bundle for artificial hair having a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency by applying crimping under the following conditions to fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method.
That is, the present invention provides the following.
(1) A fiber bundle for artificial hair, which is a fiber bundle obtained by crimping fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method and which has a crimp wave shape satisfying the following formula:
1 mm≦R≦20 mm
wherein R is the distance between the top and the bottom of the crimp wave shape.
(2) The fiber bundle for artificial hair according to the above (1), wherein the fibers (A) have a fineness of monofilament of from 20 to 100 decitex.
(3) The fiber bundle for artificial hair according to the above (1) or (2), wherein the fibers (A) are vinyl chloride fibers obtained by melt-spinning a vinyl chloride resin composition.
(4) The fiber bundle for artificial hair according to the above (3), wherein the vinyl chloride resin composition comprises a vinyl chloride resin and from 0.5 to 10 parts by mass, per 100 parts by mass of the vinyl chloride resin, of a chlorinated vinyl chloride resin.
(5) The fiber bundle for artificial hair according to the above (4), which further contains a thermal stabilizer.
(6) The fiber bundle for artificial hair according to the above (5), wherein the thermal stabilizer is at least one member selected from the group consisting of a Ca—Zn type thermal stabilizer, a hydrotalcite type thermal stabilizer, a tin type thermal stabilizer and a zeolite type thermal stabilizer.
(7) The fiber bundle for artificial hair according to any one of the above (1) to (6), wherein the cross-sectional shape of the fibers (A) is a Y-shape, a H-shape, a U-shape, a C-shape or a X-shape.
(8) The fiber bundle for artificial hair according to any one of the above (1) to (7), wherein the crimping is gear-crimping.
(9) The fiber bundle for artificial hair according to any one of the above (1) to (8), which is for head decoration.
(10) A braid using the fiber bundle for artificial hair as defined in the above (9).
(11) A process for producing a fiber bundle for artificial hair comprising the following sequential steps (a) to (e):
(a) a step of mixing a vinyl chloride resin composition comprising a vinyl chloride resin and a thermal stabilizer,
(b) a step of melt-spinning the vinyl chloride resin composition from a spinneret at a spinneret temperature of from 160 to 190° C.,
(c) a step of stretching the melt-spun fibers (A) in an atmosphere at a stretching temperature of from 90 to 120° C. at a stretching ratio of from 200 to 400%.
(d) a step of subjecting the stretched fibers (A) to thermal relaxing treatment in an atmosphere of air at a temperature of from 110 to 140° C. until the entire length of the fibers becomes from 60 to 95% of the length before the treatment, and
(e) a step of gear-crimping the fibers (A) treated for thermal relaxing, at a gear surface temperature of from 30 to 100° C. at a crimping rate of from 0.5 to 10 m/min.
EFFECTS OF THE INVENTIONAccording to the present invention, it is possible to obtain a fiber bundle for artificial hair having a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency.
R: Distance between the top and the bottom of the crimp wave shape
BEST MODE FOR CARRYING OUT THE INVENTIONIn the present invention, crimping means, for example, gear-crimping to continuously impart a wave form by sandwiching fibers between two gear rolls, or a method to impart a wave shape by continuously pushing fibers heated by e.g. steam into e.g. a stuffing box. By such a method, a wave form suitable for the desired product is imparted, whereby the processability into braids, extension hairs, etc. will be improved, and it is possible to obtain a fiber bundle for artificial hair having the gloss of fibers properly adjusted.
Gear-crimping is a method to apply crimping by passing the fiber bundle between two meshing high temperature gears, wherein the material of gears to be used, the wave shape and size of gears, the number of gear teeth, etc. are not particularly limited. The crimp wave shape may be changed by the material or fineness of fibers, the pressure condition between the gears, etc.
In the present invention, the crimp wave shape can be controlled by the gear surface temperature or the crimping rate. These crimping conditions are not particularly limited, but the gear surface temperature is preferably from 30 to 100° C., more preferably from 40 to 80° C., and the crimping rate is preferably from 0.5 to 10 m/min, more preferably from 1.0 to 8.0 m/min. If the gear surface temperature is lower than 30° C., the crimping tends to be weak, and a crimp wave shape may not sometimes be imparted. On the other hand, if the gear surface temperature exceeds 100° C., the crimping is likely to be imparted so much that R in the crimp wave shape tends to be large. If the crimping rate is less than 0.5 m/min, R in the crimp wave shape may sometimes be large. On the other hand, if the crimping rate exceeds 10 m/min, the crimping is likely to be weak, and no adequate crimp wave shape may sometimes be imparted.
On the other hand, it is preferred to apply preheating to the fiber bundle before passing it through the gears, whereby a more stabilized productivity and a more uniform crimp wave shape may be obtained. If crimping is intensive, bulkiness and weaving efficiency may be good, but yarn separability tends to deteriorate. On the other hand, if the crimping is weak, yarn separability may be good, but the bulkiness and weaving efficiency tend to deteriorate.
At the time of gear-crimping, the total fineness of the fiber bundle is not particularly limited, but is preferably from 100,000 to 2,000,000 decitex, more preferably from 500,000 to 1,500,000 decitex. If the total fineness of the fiber bundle is less than 100,000 decitex, the productivity in gear-crimping tends to be poor, and yarn breakage may result by the gear-crimping. On the other hand, if the total fineness of the fiber bundle exceeds 2,000,000 decitex, it tends to be difficult to obtain a uniform crimp wave shape.
In the fiber bundle for artificial hair of the present invention, the crimp wave shape shown in
1 mm≦R≦20 mm
wherein R is the distance between the top and the bottom of the crimp wave shape.
The distance R in the crimp wave shape is from 1 to 20 mm, preferably from 3 to 15 mm. If the distance R in the crimp wave shape is less than 1 mm, no adequate effect of gear-crimping will be obtained, whereby the bulkiness tends to be small, and further, intertwining among fibers in the fiber bundle tends to be little, and fibers tend to be slippery one another, thus leading to poor weaving efficiency. On the other hand, if R exceeds 20 mm, the crimp wave shape tends to be rough, and fibers tend to be caught by figures when they are to be separated, whereby the yarn separability tends to be poor.
In the present invention, the KES method is an abbreviation of Kawabata evaluation system and is one to measure the repulsive forces at various curvatures when a fiber structure is bent by means of a KES flexural property-measuring machine (manufactured by KATO TECH CO., LTD), as disclosed by Tokio Kawabata in the Journal of the Textile Machinery Society of Japan (Textile Engineering), vol. 26, No. 10, p 721-728 (1973). And, an average value of repulsive forces of monofilament within a curvature ranges of from 0.5 to 1.5 cm−1, is measured. By measuring the repulsive force by monofilament, the rigidity of the fiber bundle can be predicted.
A method of controlling the flexural rigidity value by the KES method can be attained, for example, by controlling the spinneret temperature at the time of the melt-spinning.
Although the reason is not clearly understood, the flexural rigidity can be made low by lowering the spinneret temperature. The control of the flexural rigidity can also be attained by changing the monofilament fineness of the fibers. By reducing the monofilament fineness, the flexural rigidity can be made low. Further, in the case of a cross sectional shape with high bulkiness, the flexural rigidity tends to be high, and in the case of a cross sectional shape with low bulkiness, the flexural rigidity tends to be low. The cross sectional shape with high bulkiness may, for example, be a Y-shape, a H-shape, a U-shape, a C-shape or a X-shape. The cross sectional shape with low bulkiness may, for example, be an elliptical, circular or cocoon shape.
Here, with respect to the cross sectional shape, the Y-shape is a shape resembling alphabetical letter Y with an axis divided into three directions as viewed in its cross section; the H-shape is a shape resembling alphabetical letter H as viewed in its cross section; the U-shape is a shape resembling alphabetical letter U as viewed in its cross section; the C-shape is a shape resembling alphabetical letter C with the circumferential surface of a thin-walled cylindrical fiber partly cut out in the longitudinal direction, as viewed in its cross section; the X-shape is a shape resembling alphabetical letter X with radially extending four protrusions as viewed in its cross section; elliptical is an oval shape as viewed in its cross section; circular is a circular shape as viewed in its cross section; and the cocoon shape is a shape resembling the shape of a cocoon formed by a combination of two cylinders extending in parallel as viewed in its cross section.
The flexural rigidity per fiber as measured by the KES method is from 0.7 to 2.5 gf·cm2, preferably from 1.0 to 2.0 gf·cm2. If the flexural rigidity as measured by the KES method is less than 0.7 gf·cm2, the rigidity to maintain curling tends to be inadequate, whereby the curl-retention performance tends to be poor, and the hot water-curling efficiency tends to be deteriorated. On the other hand, if the flexural rigidity as measured by the KES method exceeds 2.5 gf·cm2, the rigidity tends to be so high that the fibers tend to have a hard touch, and the weaving efficiency tends to be deteriorated. The cross sectional shape of the fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method, is preferably a Y-shape, a H-shape, a U-shape, a C-shape or a X-shape. Such a cross sectional shape has a high symmetry and, with the same fineness, has a relatively larger porosity than e.g. a circular cross sectional shape, whereby the rigidity is high, and it is suitable for obtaining more uniform curling efficiency.
In a case where a soft touch is more important for the fiber bundle for artificial hair of the present invention, a fiber bundle for artificial hair is preferred which has a flexural rigidity of from 0.7 to less than 1.4 gf·cm2 as measured by the KES method and which satisfies that the distance R in the crimp wave shape is within a range of less than from 1 to 4 mm. Further, in a case where the bulkiness is more important, a fiber bundle for artificial hair is preferred which has a flexural rigidity of from 1.4 to less than 2.5 gf·cm2 as measured by the KES method and which satisfies that the distance R in the crimp wave shape is within a range of from 4 to less than 20 mm.
In the present invention, the fibers (A) preferably have a fineness of monofilament of from 20 to 100 decitex, more preferably from 35 to 80 decitex. If the fineness of monofilament is less than 20 decitex, such fibers tend to be so soft that their stiffness tends to be inadequate, but also they tend to be poor in the retention of the crimp wave shape, and their commercial value is likely to be low. On the other hand, if the fineness of monofilament exceeds 100 decitex, the flexural rigidity tends to be large whereby the texture will be rough and hard, and the weaving efficiency is likely to be poor. The rigidity varies depending upon the material and cross sectional shape of the fibers, and the optimum fineness should be selected for each material.
In the present invention, the synthetic resin which may be used as the fibers (A), includes all synthetic resins which can be formed into fibers, such as a vinyl chloride resin, a modacrylic resin, an acrylic resin, a polyethylene terephthalate resin, a polypropylene resin, a nylon resin, a polylactic acid type resin and a polyvinyl alcohol resin. Among them, a vinyl chloride resin is particularly preferred in view of the properties such as the strength, gloss, color hue, flame retardancy, touch, thermal shrinkage property, etc.
The vinyl chloride resin to be used in the present invention, may be one obtained by bulk polymerization, solution polymerization, suspension polymerization, emulsion polymerization or the like. However, it is preferred to use one produced by suspension polymerization, in consideration of e.g. the initial coloration of the fibers.
The vinyl chloride resin is not particularly limited and may be a conventional homopolymer of vinyl chloride or conventional various types of copolymer resins. As such a copolymer resin, a conventional copolymer resin may be used, and typical examples include a copolymer resin of vinyl chloride with a vinyl ester, such as a vinyl chloride/vinyl acetate copolymer resin or a vinyl chloride/vinyl propionate copolymer resin; a copolymer resin of a vinyl chloride with an acrylate, such as a vinyl chloride/butyl acrylate copolymer resin or a vinyl chloride/2-ethylhexyl acrylate copolymer resin; a copolymer resin of vinyl chloride with an olefin, such as a vinyl chloride/ethylene copolymer resin or a vinyl chloride/propylene copolymer resin; and a vinyl chloride/acrylonitrile copolymer resin. It is particularly preferred to use, for example, a homopolymer resin as a homopolymer of vinyl chloride, a vinyl chloride/ethylene copolymer resin or a vinyl chloride/vinyl acetate copolymer resin. In such a copolymer resin, the content of the vinyl chloride comonomer is not particularly limited and may be determined depending upon the required quality such as the molding processability, yarn properties, etc. Particularly preferably, the content of the vinyl chloride comonomer is from 2 to 30%, more preferably from 2 to 20%.
The viscosity-average polymerization degree of the vinyl chloride resin to be used in the present invention is preferably from 600 to 2,500, more preferably from 600 to 1,800. If the viscosity-average polymerization degree is less than 600, the melt viscosity tends to be low, and the obtained fibers are likely to be susceptible to heat shrinkage. On the other hand, if it exceeds 2,500, the melt viscosity becomes high, and the nozzle pressure becomes high, whereby safe production tends to be difficult. Here, the viscosity-average polymerization degree is one obtained by dissolving 200 mg of the resin in 50 ml of nitrobenzene and measuring the specific viscosity of this polymer solution in a 30° C. constant temperature tank by means of an Ubbelohde viscometer, followed by calculation in accordance with JIS K6720-2.
In the present invention, a chlorinated vinyl chloride resin is further incorporated, whereby slippage of fibers of the fiber bundle from one another can be suppressed, and the weaving efficiency at the time of processing into a braid may, for example, be improved.
With respect to the content of the chlorinated vinyl chloride resin, the chlorinated vinyl chloride resin is preferably from 0.5 to 10 parts by mass, more preferably from 1 to 5 parts by mass, per 100 parts by mass of the vinyl chloride resin. If the chlorinated vinyl chloride resin is less than 0.5 part by mass, the effect to suppress slippage of fibers of the fiber bundle from one another tends to be small. On the other hand, if the chlorinated vinyl chloride resin exceeds 10 parts by mass, the surface roughness of the obtained fibers (A) tends to be high, whereby the texture tends to be hard, and it is likely to damage hands at the time of weaving the fiber bundle, and thus the weaving efficiency tends to be poor.
The viscosity-average polymerization degree of the chlorinated vinyl chloride resin to be used in the present invention is preferably from 450 to 800, more preferably from 500 to 600. If the viscosity-average polymerization degree is less than 450, the melt viscosity tends to be low, and the obtained fibers (A) are likely to be susceptible to heat shrinkage. On the other hand, if it exceeds 800, the melt viscosity tends to be high, and the nozzle pressure tends to be high, whereby safe production is likely to be difficult. Here, the viscosity-average polymerization degree is one calculated by the same method as described above.
The vinyl chloride resin composition of the present invention may contain known additives which are commonly used for a vinyl chloride resin composition, depending upon the particular purpose. The additives may, for example, be a thermal stabilizer, a plasticizer, a lubricant, a compatibilizing agent, a processing aid, a reinforcing agent, an ultraviolet absorber, an antioxidant, an antistatic agent, a filler, a flame retardant, a pigment, an initial coloration-improving agent, an electrical conductivity-imparting agent, a surface treating agent, a photostabilizer and a perfume.
As the thermal stabilizer to be used in the present invention, a conventional one may be used. Particularly, it is preferred to use at least one member selected from the group consisting of a Ca—Zn type thermal stabilizer, a hydrotalcite type thermal stabilizer, a tin type thermal stabilizer and a zeolite type thermal stabilizer. Such a thermal stabilizer is used to prevent thermal decomposition during the molding or to improve the color of fibers and long-run properties. It is particularly preferred to use a Ca—Zn type thermal stabilizer and a hydrotalcite type thermal stabilizer in combination, whereby the balance of the molding processability and yarn properties is excellent. Such a thermal stabilizer is used in an amount of preferably from 0.1 to 5.0 parts by mass, more preferably from 0.3 to 3.0 parts by mass, per 100 parts by mass of the vinyl chloride resin.
The hydrotalcite type thermal stabilizer is specifically a hydrotalcite compound, and more specifically, it may be a composite salt compound comprising magnesium and/or an alkali metal, and aluminum, or zinc, magnesium and aluminum, and may be one having crystal water dehydrated. The hydrotalcite compound may be natural one or synthesized one. The method for preparing a synthesized product may be a conventional method.
The fibers (A) and the fiber bundle for artificial hair of the present invention are produced by carrying out the following steps (a) to (e) sequentially:
(a) a step of mixing a vinyl chloride resin composition comprising a vinyl chloride resin and a thermal stabilizer,
(b) a step of melt-spinning the vinyl chloride resin composition from a spinneret at a spinneret temperature of from 160 to 190° C.,
(c) a step of stretching the melt-spun fibers (A) in an atmosphere at a stretching temperature of from 90 to 120° C. at a stretching ratio of from 200 to 400%.
(d) a step of subjecting the stretched fibers (A) to thermal relaxing treatment in an atmosphere of air at a temperature of from 110 to 140° C. until the entire length of the fibers becomes from 60 to 95% of the length before the treatment, and
(e) a step of gear-crimping the fibers (A) treated for thermal relaxing, at a gear surface temperature of from 30 to 100° C. at a crimping rate of from 0.5 to 10 m/min.
In the step (a) of mixing the vinyl chloride resin composition of the present invention comprising a vinyl chloride resin and a thermal stabilizer, a conventional mixing machine such as a Henschel mixer, a supermixer or a ribbon blender may, for example, be used. The mixed vinyl chloride resin composition can be used as a powder compound or a pellet compound obtained by melt-kneading the powder compound.
The powder compound can be produced under conventional usual conditions. Either hot blending or cold blending may be used, but it is preferred to use hot blending by raising the resin temperature at the time of blending to a level of from 105 to 155° C., preferably from 105 to 135° C., in order to reduce the volatile content in the vinyl chloride resin composition.
The pellet compound can be produced in the same manner as in a usual production of a vinyl chloride pellet compound. For example, a pellet compound may be made by using a kneading machine such as a single screw extruder, a counter-rotating twin screw extruder, a conical twin screw extruder, a corotating twin screw extruder, a cokneader, a planetary gear extruder or a roll kneader. The conditions for producing the pellet compound are not particularly limited, but it is preferred to set the resin temperature to be at most 185° C., preferably at most 180° C. It is optionally possible to install a stainless steel mesh or the like having a fine aperture in the kneading machine to remove foreign matters which may be included in the pellet compound, to employ a means to remove “chips”, etc. which may be included during cold cutting, or to carry out hot cutting. Particularly preferably a hot cutting method may be used which is substantially free from inclusion of “chips”.
A conventional extruder may be used to form the vinyl chloride resin composition into a non-stretched fiber yarn. For example, a single screw extruder, a counter-rotating twin screw extruder or a conical twin screw extruder may, for example, be used. It is particularly preferred to use a single screw extruder having a bore diameter of from 35 to 85 mm or a conical twin screw extruder having a bore diameter of from about 35 to 50 mm. If the bore diameter is excessively large, the extrusion amount tends to be large, and the nozzle pressure tends to be too large, or the flow-out speed of the non-stretched yarn tends to be so high that winding tends to be difficult, such being undesirable.
Now, with respect to the step (b) of melt-spinning the vinyl chloride resin composition in the present invention, the fineness of monofilament of the non-stretched yarn is preferably adjusted to be at most 300 decitex, more preferably at most 250 decitex. If the fineness of the non-stretched yarn exceeds 300 decitex, it will be required to increase the stretching ratio at the time of the stretching treatment in order to obtain the fibers (A) having fine fineness, and the fibers (A) having fine fineness after the stretching treatment will be glossy, whereby it tends to be difficult to maintain the level of a medium gloss to 70% gloss state.
Further, at the time of melt-spinning, it is preferred to carry out spinning under a nozzle pressure of at most 50 MPa, preferably at most 45 MPa. If the nozzle pressure exceeds 50 MPa, the load exerted to a thrust portion of the extruder tends to be excessive, whereby a trouble of the extruder is likely to occur. Further, “a resin leakage” is likely to result at a portion connected to the turn head, the die, etc.
In the present invention, the melt-spinning can be carried out by attaching to the forward end portion of the die (spinneret), nozzles having, for example, a C-shape in cross section similar to the cross sectional shape C of the fibers (A).
When the quality aspect such as the curling property as a fiber bundle for head decoration is taken into consideration, it is preferred to produce a non-stretched yarn having a fineness of monofilament of at most 300 decitex by having the vinyl chloride resin composition melted and extruded in the form of strands from multi type nozzle holes (number of nozzle holes is from 50 to 300, preferably from 60 to 280, and number of nozzle rows is from 1 to 5, preferably from 2 to 5) where a plurality of nozzle holes each having a cross sectional area of at most 0.5 mm2, are arranged in rows in the die. Specifically, a pellet compound or the like of a resin composition is melt-spun, for example, by means of a single screw extruder at a spinneret temperature of from 160 to 190° C., more preferably from 165 to 185° C., whereby a non-stretched yarn is obtainable.
Further, in the step (c) of stretching the melt-spun fibers (A), the non-stretched yarn obtained by the above melt spinning is subjected to stretch treatment/thermal treatment by a known method to obtain fibers (stretched yarn) having a fineness of at most 100 decitex. With respect to the conditions for the stretching treatment, stretching is carried out in an atmosphere at a stretching treatment temperature of from 90 to 120° C., preferably from 95 to 115° C. at a stretching ratio of from about 200 to 400%, preferably from about 220 to 360%. If the stretching treatment temperature is lower than 90° C., the strength of the fibers tend to be low, and yarn breakage is likely to occur. On the other hand, if it exceeds 120° C., the texture of the fibers tends to be a slippery texture like plastics, such being undesirable. Whereas, if the stretching ratio is less than 200%, development of the strength of fibers tends to be inadequate, and if it exceeds 400%, yarn breakage is likely to occur during the stretching treatment, such being undesirable.
Further, the step (d) of subjecting the stretched fibers (A) to thermal relaxing treatment is carried out.
The stretched fibers (A) is subjected to thermal relaxing treatment in an atmosphere of air maintained at a temperature of from 110 to 140° C., preferably from 115 to 135° C. until the length becomes from 60 to 100%, preferably from 65 to 90%, of the length before the thermal relaxing treatment, whereby the thermal shrinkage can be lowered. Such thermal relaxing treatment may be carried out continuously or separately from the stretching treatment.
Thereafter, the fibers (A) treated for thermal relaxing are subjected to the step (e) of gear-crimping at a gear surface temperature of from 30 to 100° C., preferably from 40 to 90° C., at a processing rate of from 0.5 to 10 m/min, preferably from 0.8 to 8 m/min. As the material for gears, not only brass, but also iron, copper, stainless steel or the like, may be used. Particularly preferred is brass or iron.
Further, in the present invention, conventional techniques relating to melt-spinning, such as techniques relating to various nozzle cross sectional shapes, techniques relating to heating cylinders, techniques relating to stretching treatment, techniques relating to thermal treatment, etc., may be used freely in combination.
When the fiber bundle for artificial hair of the present invention is incorporated in the total fibers in an amount of at least 90%, preferably at least 95%, of the total number of fibers, it is possible to obtain a fiber bundle for head decoration including one for a braid or one for extension hair excellent in handling efficiency in manual operation.
The fiber bundle for artificial hair of the present invention is one to be used for hair decoration such as a hair pieces, a braid, an extension hair or a doll hair. However, the fiber bundle subjected to crimping such as gear crimping is particularly suitable for a braid, an extension hair or the like among various hair decorations.
EXAMPLESNow, the present invention will be described in further detail with reference to Examples and Comparative Examples. However, it should be understood that the present invention is by no means thereby restricted, since such Examples and Comparative Examples are merely exemplary.
In Table 1, “Flexural rigidity” was measured by KES (Kawabata evaluation system)-FB2 pure bending testing machine (manufactured by KATO TECH CO., LTD). The sample was one fiber having a length of 9 cm, and it was passed through a jig having a diameter of 0.2 μm, whereupon a pure bending test was carried out at a deformation speed of 0.2 cm−1 within a curvature range of −2.5 to +2.5 cm−1, and an average value of repulsion forces with a monofilament within a curvature range of from 0.5 to 1.5 cm−1, was measured.
In Table 1, “Specific volume” is an index for bulkiness of fibers. In the method for measuring the specific volume, fibers cut in a length of 100 mm and gear-crimped, were filled in a 56 cc container (100 mm×14 mm×40 mm) until the container became full, and the filled fibers were taken out and measured, whereupon the specific volume was calculated by the following formula and evaluated by the following evaluation standards.
Volume (cc) of container÷weight (g) of fibers=specific volume (cc/g)
Excellent: One having a specific volume of at least 20.0 (cc/g) and having very high bulkiness.
Good: One having a specific volume of from 15.0 to less than 20.0 (cc/g) and having high bulkiness.
No good: One having a specific volume of less than 15.0 (cc/g) and having low bulkiness.
In Table 1, “Combing efficiency” is an index for yarn separability at the time of weaving. 50 g of gear-crump fibers cut in a length of 1 m were taken and combed by a dog brush, whereby yarn breakage was observed for judgment. The less the yarn breakage, the smoother the combing, and the better the yarn separability. The evaluation was made by the following standards.
Excellent: One free from yarn breakage and excellent in combing efficiency.
Good: One having no problem with respect to the working efficiency and product quality although some yarn breakage is observed.
No good: Substantial number of yarn breakage is observed, and the operation efficiency at the time of weaving is poor.
In Table 1, “Weaving efficiency” is an index representing easiness in weaving. The weaving efficiency was evaluated from the degree of crimping under the following evaluation standards based on judgment by ten technicians (with practical experience of at least 5 years) for treatment of fibers for artificial hair.
Excellent: One evaluated by all of the technicians to be easy for weaving and thus being excellent in weaving efficiency.
Good: One evaluated by at least 80% of technicians to be easy for weaving and thus being good in weaving efficiency.
No good: One evaluated by at least 30% of technicians to be difficult for weaving and thus being poor in weaving efficiency.
In Table 1, “Curl retention” is an index representing hot water-curling efficiency. One gram of a fiber bundle having a length of 30 cm was wound on an aluminum pipe having a diameter of 20 mm and its forward end was fixed, and in that state, immersed in hot water at 80° C. for 15 seconds. Then, it was taken out and hanged in a state where the temperature was 23° C. and the humidity was 50%, for 24 hours, whereby the moving distance of the forward end between before and after the hanging was measured. The shorter the moving distance, the better the curling retention, thus representing that curling was properly exerted by hot water-treatment. The evaluation was made by the following evaluation standards.
Excellent: The moving distance is less than 1.0 cm.
Good: The moving distance is at least 1.0 cm and less than 1.5 cm.
No good: The moving distance is at least 1.5 cm.
Example 1Vinyl chloride type fibers (A) having the fineness of monofilament and the numerical value of the flexural rigidity as shown in Table 1 were obtained by sequentially carrying out (a) a step of mixing by a Henschel mixer a vinyl chloride resin composition prepared by blending 100 parts by mass of a vinyl chloride resin (TH-1000, manufactured by TAIYO VINYL CORP., viscosity average polymerization degree: 1030, apparent density: 0.54), 3 parts by mass of a hydrotalcite type composite stabilizer (CP-410A, manufactured by Nissan Chemical Industries, Ltd.) (thermal stabilizer component: 1.5 parts by mass), 0.5 part by mass of an epoxidized soybean oil (O-130P, manufactured by Asahi Denka Kogyo K.K.) and 0.8 part by mass of an ester lubricant (EW-100, manufactured by Riken Vitamin Co., Ltd.), (b) a step of melt-spinning the mixed resin composition by means of a spinneret having 120 nozzle holes with an X-form nozzle shape and a nozzle cross sectional area of 0.06 mm2 at a spinneret temperature of 170° C. at an extrusion rate of 10 kg/hr to obtain fibers with 150 decitex, (c) a step of stretching the melt-spun fibers 300% in an atmosphere of air at 100° C., and (d) a step of subjecting the stretched fibers to thermal relaxing treatment in an atmosphere of air at 120° C. until the entire length of fibers shrank to a length of 75% of the length before the treatment. Then, the fibers (A) were formed into a fiber bundle having a total fineness of 1,000,000 decitex and subjected to (e) a step of gear-crimping it by means of gears made of brass (diameter: 13 cm, distance between gear waves: 6 mm, depth of gear waves: 7 mm) at a gear surface temperature of 50° C. at a processing rate of 2.5 m/min. As a result, a fiber bundle for artificial hair was obtained which had the numerical value of R (the distance between the top and the bottom of the crimp wave shape) as shown in Table 1.
Examples 2 and 3A fiber bundle for artificial hair was obtained in the same manner as in Example 1 except that the processing conditions for the gear-crimping in Example 1 were changed to obtain the numerical value of R as shown in Table 1.
Examples 4 and 5A fiber bundle for artificial hair was obtained in the same manner as in Example 1 except that the nozzle shape in the step (b) in Example 1 was changed to a H-shape in Example 4, or to a C-shape in Example 5, to obtain the flexural rigidity as shown in Table 1.
Examples 6 and 7A fiber bundle for artificial hair was obtained in the same manner as in Example 1 except that in the step (a) in Example 1, the chlorinated vinyl chloride resin (HA-15E, manufactured by TAIYO VINYL CORP.) was changed to have the content as shown in Table 1.
Comparative Examples 1 and 2A fiber bundle for artificial hair was obtained in the same manner as in Example 1 except that the processing conditions for the gear-crimping in Example 1 were changed to have the numerical value of R as shown in Table 1.
Comparative Examples 3 and 4A fiber bundle for artificial hair was obtained in the same manner as in Example 1 except that melt-spinning was carried out by changing the nozzle shape in the step (b) in Example 1 to elliptical in Comparative Example 3, or to a C-shape in Comparative Example 4 to have a fineness of 200 decitex, and the flexural rigidity and the fineness of monofilament were as shown in Table 1.
As is evident from Table 1, by the present invention, it is possible to obtain a fiber bundle for artificial hair which has a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency.
INDUSTRIAL APPLICABILITYThe fiber bundle for artificial hair of the present invention has a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency and thus is suitable for hair decoration such as a braid.
The entire disclosure of Japanese Patent Application No. 2006-337831 filed on Dec. 15, 2006 including specification, claims, drawings and summary is incorporated herein by reference in its entirety.
Claims
1. A fiber bundle for artificial hair, which is a fiber bundle obtained by crimping fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method and which has a crimp wave shape satisfying the following formula: wherein R is the distance between the top and the bottom of the crimp wave shape.
- 1 mm≦R≦20 mm
2. The fiber bundle for artificial hair according to claim 1, wherein the fibers (A) have a fineness of monofilament of from 20 to 100 decitex.
3. The fiber bundle for artificial hair according to claim 1, wherein the fibers (A) are vinyl chloride fibers obtained by melt-spinning a vinyl chloride resin composition.
4. The fiber bundle for artificial hair according to claim 3, wherein the vinyl chloride resin composition comprises a vinyl chloride resin and from 0.5 to 10 parts by mass, per 100 parts by mass of the vinyl chloride resin, of a chlorinated vinyl chloride resin.
5. The fiber bundle for artificial hair according to claim 4, which further contains a thermal stabilizer.
6. The fiber bundle for artificial hair according to claim 5, wherein the thermal stabilizer is at least one member selected from the group consisting of a Ca—Zn type thermal stabilizer, a hydrotalcite type thermal stabilizer, a tin type thermal stabilizer and a zeolite type thermal stabilizer.
7. The fiber bundle for artificial hair according to claim 1, wherein the cross-sectional shape of the fibers (A) is a Y-shape, a H-shape, a U-shape, a C-shape or a X-shape.
8. The fiber bundle for artificial hair according to claim 1, wherein the crimping is gear-crimping.
9. The fiber bundle for artificial hair according to claim 1, which is for head decoration.
10. A braid using the fiber bundle for artificial hair as defined in claim 9.
11. A process for producing a fiber bundle for artificial hair comprising:
- (a) mixing a vinyl chloride resin composition comprising a vinyl chloride resin and a thermal stabilizer,
- (b) melt-spinning the vinyl chloride resin composition from a spinneret at a spinneret temperature of from 160 to 190° C.,
- (c) stretching the melt-spun fibers (A) in an atmosphere at a stretching temperature of from 90 to 120° C. at a stretching ratio of from 200 to 400%.
- (d) subjecting the stretched fibers (A) to thermal relaxing treatment in an atmosphere of air at a temperature of from 110 to 140° C. until the entire length of the fibers becomes from 60 to 95% of the length before the treatment, and
- (e) gear-crimping the fibers (A) treated for thermal relaxing, at a gear surface temperature of from 30 to 100° C. at a crimping rate of from 0.5 to 10 m/min, wherein (a) to (e) occur sequentially.
12. The fiber bundle for artificial hair according to claim 5, wherein the thermal stabilizer is at least one member selected from the group consisting of a Ca—Zn thermal stabilizer, a hydrotalcite thermal stabilizer, a tin thermal stabilizer and a zeolite thermal stabilizer.
13. The fiber bundle for artificial hair as defined in claim 9, in the form of a braid.
Type: Application
Filed: Nov 28, 2007
Publication Date: Feb 18, 2010
Applicant: Denki Kagaku Kogyo Kabushiki Kaisha (Chuo-ku, Tokyo)
Inventor: Atsushi Horihata (Kanagawa)
Application Number: 12/519,186
International Classification: A41G 5/00 (20060101); A63H 3/44 (20060101); A41G 3/00 (20060101); D01D 5/22 (20060101); D01D 5/08 (20060101);
