EP2500455A1 - Florgewebe und herstellungsverfahren dafür - Google Patents

Florgewebe und herstellungsverfahren dafür Download PDF

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Publication number
EP2500455A1
EP2500455A1 EP09851107A EP09851107A EP2500455A1 EP 2500455 A1 EP2500455 A1 EP 2500455A1 EP 09851107 A EP09851107 A EP 09851107A EP 09851107 A EP09851107 A EP 09851107A EP 2500455 A1 EP2500455 A1 EP 2500455A1
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EP
European Patent Office
Prior art keywords
pile
fibers
ground structure
ground
softening point
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09851107A
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English (en)
French (fr)
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EP2500455B1 (de
EP2500455A4 (de
Inventor
Sohei Nishida
Masaaki Miyoshi
Kazuya Kusunoki
Hiroyuki Tokumoto
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Kaneka Corp
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Kaneka Corp
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Publication of EP2500455A1 publication Critical patent/EP2500455A1/de
Publication of EP2500455A4 publication Critical patent/EP2500455A4/de
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Publication of EP2500455B1 publication Critical patent/EP2500455B1/de
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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D27/00—Woven pile fabrics
    • D03D27/12—Woven pile fabrics wherein pile tufts are inserted during weaving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/02—Pile fabrics or articles having similar surface features
    • D04B1/025—Pile fabrics or articles having similar surface features incorporating loose fibres, e.g. high-pile fabrics or artificial fur
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/587—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads adhesive; fusible
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D27/00—Woven pile fabrics
    • D03D27/02—Woven pile fabrics wherein the pile is formed by warp or weft
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/02—Pile fabrics or articles having similar surface features
    • D04B1/04—Pile fabrics or articles having similar surface features characterised by thread material
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/02—Pile fabrics or articles having similar surface features
    • D04B21/04—Pile fabrics or articles having similar surface features characterised by thread material
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D10B2403/0111—One hairy surface, e.g. napped or raised
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/2395—Nap type surface

Definitions

  • the present invention relates to a pile fabric whose pile fibers are inhibited from falling off, and a method of producing the same.
  • pile fabrics have been known under the names of imitation furs or fake furs, boas, etc., as fabrics designed to resemble appearances of furs. These are produced from pile knits and pile weaves.
  • a seal-fraise knitting machine or a sliver knitting machine (circular knitting machine) is used mainly for knitting, and piles are cut in both cases.
  • a double Russell machine warp knitting machine
  • piles are knitted by forming a double ground structure while intertwining the double ground structure with a binder yarn, and cutting the middle of the binder yarn.
  • Non-Patent Document 1 In a weaving method, a velvet loom or a moquette loom is used to intertwine an upper and a lower ground structure and the middle of the ground structures with a binder yarn, and cut the middle of an upper and a lower base fabrics using a knife, whereby two weaves are obtained simultaneously (Non-Patent Document 1).
  • these weaves and knits have the same problem, which is a large amount of pile fiber loss. As many pile fibers fall off, they attach to an inner wear or are dropped on the floor, resulting in a poor appearance and poor hygienic conditions.
  • Patent Document 1 In order to prevent such pile fiber loss, there has been a proposal of mixing low-melting fibers into pile fibers (Patent Document 1), and a proposal of mixing low-melting fibers into ground yarns constituting a ground structure (Patent Documents 2-3), etc.
  • Patent Documents 2-3 In order to prevent such pile fiber loss, there has been a proposal of mixing low-melting fibers into pile fibers (Patent Document 1), and a proposal of mixing low-melting fibers into ground yarns constituting a ground structure (Patent Documents 2-3), etc.
  • Patent Documents 2-3 In order to prevent such pile fiber loss, there has been a proposal of mixing low-melting fibers into pile fibers (Patent Document 1), and a proposal of mixing low-melting fibers into ground yarns constituting a ground structure (Patent Documents 2-3), etc.
  • Patent Documents 2-3 because the whole fabric is heated at a temperature equal to or higher than a melting point of the low-melting fibers, the entire ground structure or the pile
  • Non-Patent Document 1 " Fiber Handbook third edition", page 341-342, edited by The Society of Fiber Science and Technology, Japan, published by Maruzen, issued on December 15, 2004
  • the present invention provides a pile fabric whose pile fibers are inhibited from falling off without impairing the texture by fusing only a specific area of the pile fabric, and a method of producing the same.
  • a pile fabric of the present invention is a pile fabric that includes: a ground structure; and pile fibers that are intertwined with ground yarns constituting the ground structure and napped on a front surface of the ground structure, wherein the pile fibers include at least one selected from the group consisting of acrylic fibers and acrylic-based fibers and have a softening point lower than a softening point of fibers constituting the ground structure, and wherein among the pile fibers intertwined with the ground yarns constituting the ground structure, at least part of the pile fibers located outside of the ground yarns constituting the ground structure are fused but the pile fibers napped on the front surface of the ground structure are not fused.
  • a method of producing a pile fabric of the present invention is a method of producing a pile fabric, the pile fabric including: a ground structure; and pile fibers that are intertwined with ground yarns constituting the ground structure and napped on a front surface of the ground structure, wherein the pile fibers include at least one selected from the group consisting of acrylic fibers and acrylic-based fibers and have a softening point lower than a softening point of fibers constituting the ground structure, and a contact heating/pressurization is performed at a temperature equal to or higher than the softening point of the pile fibers and lower than the softening point of the fibers constituting the ground structure from a back surface side of the ground structure, whereby among the pile fibers intertwined with the ground yarns constituting the ground structure, at least part of the pile fibers located outside of the ground yarns constituting the ground structure are fused but the pile fibers napped on the front surface of the ground structure are not fused.
  • the pile fibers include at least one selected from the group consisting of acrylic fibers and acrylic-based fibers, and at least part of the pile fibers located outside of the ground yarns constituting the ground structure are fused but the pile fibers napped on the front surface of the ground structure are not fused. Thereby, the pile fibers can be prevented from falling off without impairing the texture.
  • a contact heating/pressurization is performed at a temperature equal to or higher than the softening point of the pile fibers but lower than the softening point of the fibers constituting the ground structure from a back surface side of the ground structure, whereby only a limited area of the pile fibers located outside of the ground yarns constituting the ground structure is fused but the pile fibers napped on the front surface of the ground structure are not fused. Thereby, the pile fibers can be prevented from falling off without impairing the texture.
  • Apile fabric of the present invention is a pile fabric that includes: a ground structure; and pile fibers that are intertwined with ground yarns constituting the ground structure (hereinafter, also referred to as "ground yarn” simply) and napped on a front surface of the ground structure.
  • the pile fabric can be manufactured using a seal-fraise knitting machine, a sliver knitting machine (circular knitting machine), a boa machine (circular knitting machine), a double Russell machine, a velvet loom, a moquette loom, etc.
  • the pile fabric of the present invention is not limited particularly, it may be a high pile fabric, a boa pile fabric, a tufted carpet, etc.
  • the pile fabric is preferably a high pile fabric or a boa pile fabric, and more preferably a high pile fabric.
  • the pile fibers have a softening point lower than a softening point of fibers constituting the ground structure (hereinafter, also referred to as "ground structure constituent fibers", simply).
  • ground structure constituent fibers a softening point of fibers constituting the ground structure
  • the means for the fusion is not limited as long as at least part of the pile fibers located outside of the ground yarns can be fused, it is preferable to perform a contact heating/pressurization at a temperature equal to or higher than the softening point of the pile fibers and lower than the softening point of the ground structure constituent fibers from a back surface side of the ground structure, i.e., a back surface side of the pile fabric.
  • outside of the ground yarns constituting the ground structure refers to the back surface side of the pile fabric when a surface thereof with napped pile fibers is defined as a front surface, and an outer side of the ground yarns. Further, there is a case where part of the pile fibers intertwined with the ground yarns are stitched into ground yarns. If the remaining parts of such fibers are present outside of ground yarns, they are considered as being located outside of the ground yarns.
  • the pile fibers are at least one selected from the group consisting of acrylic fibers and acrylic-based fibers. Thereby, it is possible to obtain a pile fabric with an excellent texture. If thermoplastic fibers are used as the pile fibers and a polishing process is performed at a temperature equal to or higher than a melting point of the thermoplastic fibers, generally the pile fibers on the front surface of the pile fabric melt, such that a pile fabric with a favorable appearance and texture is not obtained. Further, when the polishing process is performed at a temperature equal to or lower than the melting point of the thermoplastic fibers, crimps of the pile fibers on the front surface of the pile fabric are not straightened, such that a pile fabric with a favorable appearance and texture is not obtained.
  • crimps of acrylic fibers and acrylic-based fibers can be straightened at temperatures equal to or lower than their softening points. Because of this, when at least one fiber selected from the group consisting of acrylic fibers and acrylic-based fibers is used as the pile fibers, the polishing process can be performed at a temperature equal to or lower than its softening point, (i.e., 150-160°C). Therefore, when at least one fiber selected from the group consisting of acrylic fibers and acrylic-based fibers is used as the pile fibers, the pile fibers on the front surface of the pile fabric are not fused in the polishing process, such that a pile fabric with a favorable appearance and texture is obtained.
  • the pile fibers contain fibers other than acrylic fibers and acrylic-based fibers, such as thermoplastic fibers having a softening point of 160°C or lower (i.e., low-melting polyester fibers having a softening point of 160°C or lower, etc.), these low-melting polyester fibers on the front surface of the pile fabric melt in the polishing process at 150-160°C, which makes it difficult to obtain a pile fabric with a favorable appearance and texture.
  • thermoplastic fibers having a softening point of 160°C or lower i.e., low-melting polyester fibers having a softening point of 160°C or lower, etc.
  • the pile fibers are not limited particularly as long as the softening point is lower than the softening point of the fibers constituting the ground structure.
  • a difference between the softening point of the ground structure constituent fibers and the softening point of the pile fibers is preferably 10°C or more, more preferably 20°C or more, and particularly preferably 30°C or more. The difference of 10°C or more makes it easier to cause only at least part of the fibers located outside of the ground yarns constituting the ground structure to be fused and not to cause the pile fibers napped on the front surface of the ground structure to be fused.
  • the pile fibers may be fibers that are softened altogether at a predetermined temperature, or mixed fibers composed of fibers that are softened in different temperatures.
  • the pile fibers are mixed fibers composed of fibers softened at different temperatures, it is preferable that fibers to be softened at a relatively lower temperature are mixed at a ratio of 20% by weight (wt%) or more so that the fibers to be softened at a relatively lower temperature are fused.
  • a softening point is a softening temperature before fusion or decomposition.
  • a softening point of acrylic fibers is 190-232°C
  • a softening point of acrylic-based fibers is 150-220°C
  • An acrylic fiber refers to a fiber containing 85 wt% or more of acrylonitrile.
  • an acrylic-based fiber refers to a fiber composed of a polymer containing 35 wt% or more and less than 85 wt% of acrylonitrile and 15 wt% or more and 65 wt% or less of other copolymerizable monomers.
  • examples of other copolymerizable monomers include: vinyl halides and vinylidene halides represented by vinyl chloride, vinylidene chloride, vinyl bromide, and vinylidene bromide; sulfonic acid-containing monomers represented by allylsulfonic acid, methallylsulfonic acid, styrenesulfonic acid, isoprenesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, and their metal salts and amine salts; acrylic acid and methacrylic acid, and their lower alkyl esters, N- or N,N-alkyl substituted aminoalkyl esters and glycidyl esters; acrylamide and methacrylamide, and their N- or N,N-alkyl substituted products; anionic vinyl monomers such as carboxyl group-containing vinyl monomers represented by acrylic acid, methacrylic acid and itaconic acid and their sodium, potassium or ammonium salts; cationic vinyl monomers represented by
  • These monomers may be used alone or as a mixture of two or more kinds.
  • it is preferable to use one or more kinds of monomers selected from the group consisting of vinyl halides, vinylidene halides, and metal salts of sulfonic acid-containing monomers and more preferable to use one or more kinds of monomers selected from the group consisting of vinyl chloride, vinylidene chloride, and sodium styrenesulfonate.
  • modacrylic fibers are used as the acrylic-based fibers.
  • a modacrylic fiber refers to a fiber composed of a polymer containing 35 wt% or more and less than 85 wt% of acrylonitrile, and 15 wt% or more and 65 wt% or less, in total, of one or more kinds of monomers selected from the group consisting of vinyl chloride and vinylidene chloride as well as other copolymerizable monomers.
  • pile fibers located outside of the ground yarns are fused and pressure-bonded.
  • pressure-bonded refers to, for example, a state in which respective pile fibers are fused and bonded, or a state in which respective pile fibers are gathered into a mass and flattened, as shown in SEM photographs ( FIG. 5 ) of pile fabrics of Production Examples 5,11 and 17 after a contact heating/pressurization treatment.
  • it is preferable that all the pile fibers located outside of the ground yarns are fused and pressure-bonded, because a more superior effect of preventing pile fiber loss can be obtained.
  • the thickness of the fused and pressure-bonded pile fibers located outside of the ground yarns is preferably 300 pm or less, more preferably 250 ⁇ m or less, and particularly preferably 200 ⁇ m or less. If the thickness of the pile fibers located outside of the ground yarns is 300 ⁇ m or less, the pile fibers are fused and fixed to each other with sufficient strength. In the present invention, the thickness of the pile fibers located outside of the ground yarns is measured in the following manner, for example. First, in order to maintain the shape of piles at the time of cutting a pile fabric, only front portions of the piles are fixed using an adhesive, and then the pile fabric is cut vertically to a knitting direction of the ground yarns.
  • the cutting line is set so as to traverse loops of the ground yarns, and indicated by a line I-I in FIG. 3 , for example.
  • a back surface of the ground structure is made to face upward (turned upside down from a state of FIG. 1 ) for observing the cross section at 50x magnification using a scanning electron microscope (SEM).
  • SEM scanning electron microscope
  • a thickness indicated by a shortest distance between parallel lines 19a and 19b in FIG. 5 is measured.
  • An average value of ten measured points is defined as the thickness.
  • SEM scanning electron microscope
  • an optical microscope a laser microscope or the like that allows observation at 50x or more magnification may be used for distinguishing between the ground yarns and the pile fibers.
  • a back surface of the pile fabric is impregnated with a backing resin. If the back surface is impregnated with a backing resin, the napped pile fibers can be aligned before the process of performing a contact heating/pressurization from the back surface side of the ground structure, i.e., the back surface side of the pile fabric.
  • the backing resin it is possible to use a latex, an emulsion, a dispersion, etc., of acrylic ester-based resin, polyurethane-based resin, etc.
  • the amount of the impregnation backing resin generally is, for example, about 50 g/m 2 at the concentration of solid resin.
  • the amount of the impregnation backing resin may be about 1/2 to 1/3 of the above-described general amount.
  • the back surface may be impregnated with the backing resin at the concentration of solid resin of about 17-25 g/m 2 .
  • any polishing process of pile fibers is performed before fusing a specific area of the pile fibers, and the pile fibers can be fixed temporarily using a backing resin to prevent the fibers from falling off.
  • the amount of the resin impregnation need not be high.
  • the method of producing a pile fabric of the present invention includes performing a contact heating/pressurization at a temperature equal to or higher than a softening point of the pile fibers and lower than a softening point of the ground structure constituent fibers from the back surface side of the ground structure. Thereby, among the pile fibers intertwined with the ground yarns, at least part of the pile fibers located outside of the ground yarns are fused and pressure-bonded.
  • the contact heating/pressurization is performed using a heating roller or a hot plate.
  • the use of a heating roller or a hot plate shortens the time of the contact heating treatment, and allows only at least part of the pile fibers located outside of the ground yarns to be fused and pressure-bonded. Further, since the temperature of the heating is not so high as to melt the pile fibers on the front surface of the pile fabric, the pile fibers napped on the front surface of the ground structure are not fused.
  • the pile fibers are mixed fibers composed of fibers that are softened in different temperatures
  • pile fiber loss can be prevented and a pile fabric with an excellent texture can be easily obtained.
  • the napped pile fiber side it is preferable to cool the napped pile fiber side. Further, after performing the contact heating/pressurization step, it is preferable to perform cooling from the back surface side of the ground structure. In the above-described cooling step, it is preferable to cool the surface of the napped pile fibers using a cooling roller through which water of 30°C or lower passes. By performing such cooling, dimensional stability is maintained, and damages to the pile fibers due to heat is reduced.
  • the ground structure constituent fibers are not particularly limited as long as the softening point is higher than the softening point of the pile fibers, the fibers may be synthetic fibers composed of polyester resin such as polyethylene terephthalate, cotton, etc.
  • the ground structure constituent fibers for example, it is possible to use one or more fibers selected from the group consisting of acrylic-based fibers and acrylic fibers as the pile fibers.
  • the pile fibers are acrylic-based fibers, or mixed fibers of acrylic-based fibers and acrylic fibers. The following fibers can be used as the acrylic-based fibers.
  • cotton (no softening point) fibers as the ground structure constituent fibers, for example, acrylic fibers (e.g., trade name "Exlan K691" manufactured by Exlan Co., Ltd., softening point 190-232°C, literature value) can be used as the pile fibers.
  • acrylic fibers e.g., trade name "Exlan K691” manufactured by Exlan Co., Ltd., softening point 190-232°C, literature value
  • FIG. 1 is a schematic perspective view of a pile fabric in one example of the present invention.
  • a pile fabric 5 is composed of ground yarns 1, and pile fibers 2 that are intertwined with the ground yarns 1 and opened on a front surface of a ground structure to form napped piles 3. Additionally, in a back surface of the pile fabric 5, at least part of the pile fibers 2 are fused at the outside of the ground yarns 1 to form a fused part 4, and the fused part 4 is pressure-bonded to the ground yarns 1. Further, the back surface of the pile fabric 5 may be impregnated with a backing resin.
  • FIG. 2 is a diagram of a boa knit.
  • a pile fabric 25 is composed of ground yarns 21, and pile fibers 22 that are intertwined with the ground yarns 21 and opened on a front surface of a ground structure to form napped piles.
  • FIG. 3 is a knitting diagram of a sliver knit.
  • a pile fabric 35 is composed of ground yarns 31, and pile fibers 32 that are intertwined with the ground yarns 31 and opened on a front surface of a ground structure to form napped piles.
  • a contact heating/pressurization treatment is performed on a surface opposite to the napped pile side, i.e., a back surface of the pile fabric, whereby the pile fibers located outside of the ground yarns are fused.
  • FIG. 4 shows a production process in one example of the present invention.
  • a processing device 10 to be used in this method includes a heating roller 11 that is coated with a fluorocarbon resin such as polytetrafluoroethylene, a cooling rubber roller 12 through which cooling water of 30°C passes and that applies pressure to the heating roller 11, metal cooling rollers 13, 14 through which cooling water of 30°C passes and that apply pressure to the cooling rubber roller 12, and a guide roller 15.
  • a raw pile fabric 18 is led out from a container 16 and supplied so that a back surface 18b of the raw pile fabric 18 contacts the heating roller and a front surface (napped pile side) 18a thereof contacts the cooling rubber roller 12.
  • the pile fabric 5 after this processing is contained in a container 17.
  • the device for the contact heating/pressurization treatment is not limited to the processing device shown in FIG. 4 , but may be a device that is partially modified from the processing device shown in FIG. 4 , a hot plate, or other device.
  • the heating temperature may be equal to or higher than the softening point of the pile fibers and lower than the softening point of the ground structure constituent fibers, for example.
  • the pressure force is 0.01-100 Kgf/cm 2 in linear pressure
  • the supply rate of the raw pile fabric is 0.1-20 m/minutes
  • the contact time with the heater is 1-60 seconds. More preferably, the pressure force is 0.05-7 Kgf/cm 2 in linear pressure
  • the contact time with the heater is 2-10 seconds, in order to reduce damage on the front surface of the pile fabric.
  • An amount of pile fiber loss of the pile fabric according to the present invention is preferably 0.6 g/m 2 or less, and more preferably 0.3 g/m 2 or less.
  • the amount of pile fiber loss is measured by: rubbing a front surface of a pile fabric ten times in a forward direction and ten times in a reverse direction of piles with a stroke width of 30 cm while applying a constant load of 600 g (14.3 kg/cm 2 ) using a rubber brush (trade name "prescale mat” 5 mm (particle diameter), length 4 cm, width 10.5 cm, manufactured by FUJIFILM Corporation); collecting fallen pile fibers by an adhesive tape; and converting the weight into per 1m 2 .
  • a rubber brush (trade name "prescale mat” 5 mm (particle diameter), length 4 cm, width 10.5 cm, manufactured by FUJIFILM Corporation) was used to rub a front surface of a pile fabric ten times in a forward direction and ten times in a reverse direction of piles with a stroke width of 30 cm while applying a constant load of 600 g (14.3 kg/cm 2 ). Thereafter, fallen pile fibers were collected using an adhesive tape, and the weight was converted into per 1m 2 , which was defined as the amount of pile fiber loss.
  • the pile fiber loss of a pile fabric was ranked on a scale ofA to D as below:
  • the texture was ranked on a scale ofA to D as below:
  • ground structure constituent fiber ground yarn
  • a multifilament with a total fineness of 334 dtex (a fiber yarn composed of two filaments, each filament having a fineness of 167 dtex and being composed of 50 polyester single fibers) was used.
  • the softening point is 258°C.
  • a cotton yarn composed of two spun yarns of cotton count 40 was used. Cotton does not have a softening point, and is decomposed at high temperature.
  • Production Examples 1-30 Production Examples 1, 7, 13, 19, 23 and 27 are comparative examples, and the other Production Examples are examples.
  • a sliver knitting machine circular knitting machine for manufacturing fake furs was used.
  • the above identified polyester fiber yarns were used as the ground yarns.
  • Pile fabrics of Production Examples 1-30 were knitted by supplying pile fiber slivers (10-14 g/m) composed of acrylic-based fibers respectively shown in Table 1 below.
  • the number of loops in the wales of the ground structure was 16-17/inch, and the number of loops in the course of the ground structure was 22-33/inch.
  • the other conditions are shown in Table 1 below.
  • back surfaces of the pile fabrics were impregnated with a backing resin.
  • the backing resin an emulsion copolymer latex composed mainly of acrylic ester was used.
  • the backing resin was an aqueous solution (emulsified solution) with a latex concentration of 40 wt%.
  • the pile fabrics of the examples and the pile fabrics of the comparative examples were impregnated and attached with the backing resin at a solid resin concentration of 25 g/m 2 and 50 g/m 2 , respectively, and then dried. Next, pile fibers on front surfaces of the pile fabrics were aligned by polishing, brushing and shearing.
  • Production Example 1 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 2-6 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 7-12.
  • Production Example 7 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 8-12 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 13-18.
  • Production Example 13 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 14-18 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 19-22.
  • Production Example 19 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 20-22 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 23-26.
  • Production Example 23 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 24-26 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 27-30.
  • Production Example 27 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 28-30 are examples in which the contact heating/pressurization treatment was performed differently from each other.
  • Pile fabrics of Production Examples 31-35 were obtained in the same manner as Production Examples 1-30, except that pile fiber slivers composed of acrylic fibers shown in Table 2 below were used, and the contact heating/pressurization treatment was performed under the conditions shown in Table 2 below. Further, pile fabrics of Production Examples 36-40 were obtained in the same manner as Production Examples 1-30, except that the above cotton yarns were used as the ground yarns, pile fiber slivers composed of acrylic fibers shown in Table 2 below were used, and the contact heating/pressurization treatment was performed under the conditions shown in Table 2 below. The same pile fibers and the same ground yarns were used in Production Examples 31-35. Production Example 31 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 32-34 are comparative examples in which the contact heating/pressurization treatment was performed at a predetermined temperature lower than a softening point of the pile fibers.
  • Production Example 35 is an example in which the contact heating/pressurization treatment was performed at a predetermined temperature equal to or higher than a softening point of the pile fibers. Further, the same pile fibers and the same ground yarns were used in Production Examples 36-40.
  • Production Example 36 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 37-40 are examples in which the contact heating/pressurization treatment was performed differently from each other.
  • Pile fabrics of Production Examples 41-52 were obtained in the same manner as Production Examples 1-30, except that pile fiber slivers composed of mixed fibers of acrylic-based fibers and acrylic fibers shown in Table 3 below were used, and the contact heating/pressurization treatment was performed under the conditions shown in Table 3 below.
  • the same pile fibers and the same ground yarns were used in Production Examples 41-44.
  • Production Example 41 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 42-44 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 45-48.
  • Production Example 45 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 46-48 are examples in which the contact heating/pressurization treatment was performed differently from each other. Further, the same pile fibers and the same ground yarns were used in Production Examples 49-52.
  • Production Example 49 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Examples 50-52 are examples in which the contact heating/pressurization treatment was performed differently from each other. In all Examples, the contact heating/pressurization treatments were performed at a temperature equal to or higher than the softening point of acrylic-based fibers and lower than the softening point of acrylic fibers.
  • FIG. 5 shows photographs (50x magnification) of the pile fabrics of Production Example 1 (comparative example), Production Example 5 (example), Production Example 7 (comparative example), Production Example 11 (example), Production Example 13 (comparative example) and Production Example 17 (example), taken by a scanning electron-microscope (SEM).
  • reference numbers 19a and 19b indicate a thickness of the pile fibers located outside of the ground yarns.
  • FIG. 5 also indicates the thickness and the amount of pile fiber loss. As can be seen from FIG. 5 , by performing the contact heating/pressurization treatment, the thickness of the pile fibers located outside of the ground structure constituent fibers was reduced to a fraction of the thickness without the contact heating/pressurization treatment, and the amount of pile fiber loss was greatly reduced.
  • the pile fiber loss was low and the texture was favorable for those examples that underwent the contact heating/pressurization treatment.
  • at least part of the pile fibers located outside of the ground structure constituent fibers were fused and pressure-bonded by the contact heating/pressurization treatment at a temperature equal to or higher than the softening point of the pile fibers and lower than the softening point of the ground structure constituent fibers.
  • the thickness of the fused and pressure-bonded pile fibers located outside of the ground yarns was 300 ⁇ m or less
  • the pile fiber loss was low and the texture was favorable. Incidentally, it can be confirmed from SEM photographs (50x magnification) such as those shown in FIG. 5 that at least part of the pile fibers located outside of the ground yarns were fused and pressure-bonded.
  • a pile fabric of Production Example 53 was obtained in the same manner as Production Example 26, except that the pile fabric was not impregnated with a backing resin.
  • Results of the amount of pile fiber loss, the evaluation of pile fiber loss, the texture, the thickness, etc., of the pile fabric of Production Example 53 are shown in Table 4 below.
  • the results of Production Example 23 (comparative example) also are shown in Table 4.
  • a comparison between Production Example 23 (comparative example) and Production Example 53 (example) indicates that, even without impregnation with a backing resin, the amount of pile fiber loss was greatly reduced. In other words, only performing the contact heating/pressurization treatment on the back surface of the ground structure greatly reduced the amount of pile fiber loss.
  • Pile fabrics of Production Examples 54-55 were obtained in the same method as a general method of producing boa piles, using the above polyester fiber yarns as ground yarns and pile fibers composed of mixed fibers of acrylic-based fibers shown in Table 5 below.
  • Conditions for the contact heating/pressurization treatment on the back surface of the ground structure of boa piles as well as results of the amount of pile fiber loss, the evaluation of pile fiber loss, the texture, the thickness, etc., are shown in Table 5 below.
  • the same pile fibers and the same ground yarns were used in Production Examples 54-55.
  • Production Example 54 is a comparative example in which the contact heating/pressurization treatment was not performed.
  • Production Example 55 is an example in which the contact heating/pressurization treatment was performed.
  • Pile fabrics of Production Examples 56-59 were obtained in the same manner as Production Example 16, except that the above polyester fiber yarns were used as ground yarns, pile fibers shown in Table 6 below were used, and the contact heating/pressurization treatment was performed using the processing device shown in FIG. 4 under the conditions shown in Table 6 below. Conditions for the contact heating/pressurization treatment as well as results of the amount of pile fiber loss, the evaluation of pile fiber loss, the texture, the thickness, etc., are shown in Table 6 below. The results of Production Example 13 also are shown in Table 6.
  • Pile fabrics of Production Examples 60-95 were obtained in the same manner as Production Examples 1-30, except that polyester fiber yarns were used as ground yarns, low-melting polyester fibers or mixed fibers of low-melting polyester fibers and acrylic fibers shown in Table 7 below were used as pile fibers, and the contact heating/pressurization treatment was performed under the conditions shown in Table 7 below. Conditions for the contact heating/pressurization treatment as well as results of the amount of pile fiber loss, the evaluation of pile fiber loss, the texture, the thickness, etc., are shown in Table 7 below. All of Production Examples 60-95 are comparative examples.
  • Pile fabrics of Production Examples 96-107 were obtained in the same manner as Production Examples 1-30, except that polyester fiber yarns were used as ground yarns, low-melting polyester fibers or mixed fibers of low-melting polyester fibers and acrylic fibers shown in Table 8 below were used as pile fibers, and the contact heating/pressurization treatment was performed under the conditions shown in Table 8 below. Conditions for the contact heating/pressurization treatment as well as results of the amount of pile fiber loss, the evaluation of pile fiber loss, the texture, the thickness, etc., are shown in Table 8 below. All of Production Examples 96-107 are comparative examples.
  • the low-melting polyester fibers "UNITIKA 1680” When compared to acrylic fibers and acrylic-based fibers, the low-melting polyester fibers "UNITIKA 1680" have a strong resilience (i.e., an elasticity of staple fibers is strong), have a strong crimp and are voluminous, and they are difficult to be processed into a pile fabric when the content of the low-melting polyester fibers "UNITIKA 1680" in the pile fibers exceeds 20 wt%.
  • the present invention provides a pile fabric whose pile fibers are inhibited from falling off while having an excellent texture, and can be applied to general pile fabrics, such as fake furs, boa piles, car sheets and carpets.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Knitting Of Fabric (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Woven Fabrics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Laminated Bodies (AREA)
EP09851107.4A 2009-11-09 2009-11-09 Florgewebe und herstellungsverfahren dafür Active EP2500455B1 (de)

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EP3330434A4 (de) * 2015-07-31 2019-02-13 Kaneka Corporation Vliesstoff und verfahren zur herstellung davon
CN106167951A (zh) * 2016-08-18 2016-11-30 浙江真爱毯业科技有限公司 一种兔绒拉舍尔毛毯的生产工艺

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CN102597348A (zh) 2012-07-18
EP2500455B1 (de) 2020-05-06
EA201290302A1 (ru) 2012-10-30
EA023898B1 (ru) 2016-07-29
EP2500455A4 (de) 2014-01-01
JPWO2011055455A1 (ja) 2013-03-21
CN102597348B (zh) 2015-04-08
JP5461572B2 (ja) 2014-04-02
KR101389764B1 (ko) 2014-04-29
CN201942838U (zh) 2011-08-24
KR20120102042A (ko) 2012-09-17
WO2011055455A1 (ja) 2011-05-12
US20120219751A1 (en) 2012-08-30

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