U.S. patent application number 11/578202 was filed with the patent office on 2007-09-20 for pile fabric and method for producing the same.
Invention is credited to Tadayuki Fukuro, Hirokazu Hayashi.
Application Number | 20070215231 11/578202 |
Document ID | / |
Family ID | 35150032 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070215231 |
Kind Code |
A1 |
Hayashi; Hirokazu ; et
al. |
September 20, 2007 |
Pile Fabric And Method For Producing The Same
Abstract
A pile fabric having a ground structure portion having a knitted
or woven structure comprising organic fiber yarns and a cut pile
portion comprising cut piles knitted or woven in said ground
structure and having a single fiber fineness of 0.1 to 2.0 dtex is
woven or knitted, ant then subjected to a thermal treatment to
thermally shrink the above-mentioned cut piles to obtain the pile
fabric in which the cut pile density of the cut pile portion is in
a range of 40,000 to 300,000 dtex/cm.sup.2 and the cut pile length
of the cut piles is in a range of 0.20 to 2.00 mm. If necessary,
said pile fabric is used to obtain a vehicle interior material.
Inventors: |
Hayashi; Hirokazu; (Osaka,
JP) ; Fukuro; Tadayuki; (Osaka, JP) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
SUITE 800
WASHINGTON
DC
20037
US
|
Family ID: |
35150032 |
Appl. No.: |
11/578202 |
Filed: |
April 12, 2005 |
PCT Filed: |
April 12, 2005 |
PCT NO: |
PCT/JP05/07374 |
371 Date: |
October 11, 2006 |
Current U.S.
Class: |
139/391 |
Current CPC
Class: |
D06C 7/00 20130101; D03D
27/00 20130101; D04B 21/04 20130101 |
Class at
Publication: |
139/391 |
International
Class: |
D03D 27/00 20060101
D03D027/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 13, 2004 |
JP |
2004-117639 |
Claims
1. A pile fabric having a ground structure portion having a knitted
or woven structure comprising organic fiber yarns and a cut pile
portion comprising cut piles knitted or woven in said ground
structure portion, characterized in that the cut pile density of
the above-mentioned cut pile portion is 40,000 to 300,000
dtex/cm.sup.2, and the single fiber fineness and cut pile length of
the cut piles are in the ranges of 0.1 to 2.0 dtex and 0.20 to 2.00
mm, respectively. Therein, the above-mentioned cut pile density is
calculated according to the following expression. Cut pile
density[dtex/cm.sup.2]=(single fiber fineness of cut
piles)[dtex].times.(number of cut piles per cm.sup.2)[cut
piles/cm.sup.2]
2. The pile fabric according to claim 1, wherein the single fiber
fineness of the cut piles is in a range of 0.1 to 1.2 dtex.
3. The pile fabric according to claim 1, wherein the cut pile
length is in a range of 0.20 to 0.80 mm.
4. The pile fabric according to claim 1, wherein the inclination
angle of the cut piles is in a range of 70 to 90 degree.
5. The pile fabric according to claim 1, wherein the cut piles are
polyester-based fiber yarns.
6. The pile fabric according to claim 1, wherein the organic fiber
yarns for forming the ground structure portion are polyester-based
fiber yarns.
7. A method for producing a pile fabric, characterized by weaving
or knitting a pile fabric having a ground structure portion having
a knitted or woven structure comprising organic fiber yarns and a
cut pile portion comprising cut piles knitted or woven in said
ground structure portion and having a single fiber fineness of 0.1
to 2.0 dtex and a boiling water shrinkage of not less than 20%, and
then applying a thermal treatment to said pile fabric to thermally
shrink the above-mentioned cut piles to obtain the pile fabric in
which the cut pile density of the cut pile portion is in a range of
40,000 to 300,000 dtex/cm.sup.2 and the cut pile length of the cut
piles is in a range of 0.20 to 2.00 mm.
8. The method for producing the pile fabric according to claim 7,
wherein yarns having a boiling water shrinkage of not less than 20%
are used as the organic fiber yarns for forming the ground
structure.
9. The method for producing the pile fabric according to claim 7,
wherein false-twisted yarns having a crimp percent of not less than
30% are used as the organic fiber yarns for forming the ground
structure.
10. A vehicle interior material using the pile fabric according to
claim 1.
11. A vehicle interior material using the pile fabric according to
claim 2.
12. A vehicle interior material using the pile fabric according to
claim 3.
13. A vehicle interior material using the pile fabric according to
claim 4.
14. A vehicle interior material using the pile fabric according to
claim 5.
15. A vehicle interior material using the pile fabric according to
claim 6.
Description
TECHNICAL FIELD
[0001] The present invention relates to a pile fabric having a
ground structure portion and a cut pile portion. In more detail,
the present invention relates to a pile fabric having a ground
structure portion, and a cut pile portion comprising cut piles
knitted or woven in said ground structure portion, and exhibiting
the same high grade appearance and smooth touch as those of a
flocked pile fabric having a large cut pile density and a small cut
pile length, and to a method for producing the same.
BACKGROUND ART
[0002] Hitherto, pile fabrics composed of cut pile portions and
ground structure portions have been used in wide fields, because of
having excellent appearances and surface touches. Especially,
flocked pile fabrics obtained by electric flocking called flocking
processing exhibit high grade appearances and smooth touches
originated from the compacted touches and ultra small cut pile
lengths of cut piles, because of having large cut pile densities
and small cut pile lengths. Therefore, materials such as polyester
fibers and nylon fibers have widely been used in the fields of
interiors such as upholsteries, vehicle interior materials,
clothes, and the like, as high grade articles (for example, see the
patent document 1).
[0003] However, when such the flocked pile fabrics have been used
as car sheet members, there has been a problem that the adhesive
forces of the roots of the cut piles have been deteriorated to
cause the coming-off of the cut piles from the ground structure
portions during the repeated getting-on and off movements of
passengers, because the roots of the cut piles have chemically been
adhered to the ground structure portions.
[0004] As a method for preventing such the cut pile coming-off, the
patent document 1 has proposed to knot the root portions of the cut
piles, but has sufficiently not solved the problem of the cut pile
coming-off due to the deterioration of the adhesive forces, because
a chemical adhesion treatment has basically been applied.
[0005] [Patent document 1] JP-A 10-168693 (JP-A means "Japanese
Unexamined Patent Publication")
DISCLOSURE OF INVENTION
[0006] The object of the present invention is to provide a pile
fabric having a ground structure portion, and a cut pile portion
comprising cut piles knitted or woven in said ground structure
portion, and exhibiting the same high grade appearance and smooth
touch as those of a flocked pile fabric having a large cut pile
density and a small cut pile length, wherein the cut piles little
come off the ground structure, and a method for producing the same.
The above-mentioned object can be achieved by the pile fabric of
the present invention and the method for producing the same.
[0007] The pile fabric of the present invention is a pile fabric
having a ground structure portion having a knitted or woven
structure comprising organic fiber yarns and a cut pile portion
formed of cut piles knitted or woven in said ground structure
portion, characterized in that the cut pile density of the
above-mentioned cut pile portion is 40,000 to 300,000
dtex/cm.sup.2, and the single fiber fineness and cut pile length of
the cut piles are in the ranges of 0.1 to 2.0 dtex and 0.20 to 2.00
mm, respectively.
[0008] Therein, the above-mentioned cut pile density is calculated
according to the following expression. Cut pile
density[dtex/cm.sup.2]=(single fiber fineness of cut
piles)[dtex].times.(number of cut piles per cm.sup.2)[cut
piles/cm.sup.2].
[0009] Herein, it is preferable that the single fiber fineness of
the cut piles is in a range of 0.1 to 1.2 dtex. Also, it is
preferable that the cut pile length is in a range of 0.20 to 0.80
mm. It is preferable that the inclination angle of the cut piles is
in a range of 70 to 90 degree. Also, it is preferable that the cut
piles are polyester-based fiber yarns at the point of
recyclability. Meanwhile, it is preferable that the organic fiber
yarns for forming the ground structure portion also are
polyester-based fiber yarns at the point of recyclability.
[0010] Subsequently, the method for producing the pile fabric of
the present invention is a method for producing a pile fabric in
which the cut pile density of the cut pile portion is in a range of
40,000 to 300,000 dtex/cm.sup.2 and the cut pile length of the cut
piles is in a range of 0.20 to 2.00 mm, characterized by weaving or
knitting a pile fabric having a ground structure portion having a
knitted or woven structure comprising organic fiber yarns and a cut
pile portion formed of cut piles knitted or woven in said ground
structure and having a single fiber fineness of 0.1 to 2.0 dtex and
a boiling water shrinkage of not less than 20%, and then applying a
thermal treatment to said pile fabric to thermally shrink the
above-mentioned cut piles.
[0011] Therein, the employment of yarns having a boiling water
shrinkage of not less than 20% and/or false-twisted yarns having a
crimp percent of not less than 30% as the organic fiber yarns for
forming the ground structure portion is preferable, because the
above-mentioned cut pile density is obtained in the cut pile
portion.
[0012] Subsequently, the vehicle interior material of the present
invention is a vehicle interior material using the above-mentioned
pile fabric.
BRIEF DESCRIPTION OF DRAWING
[0013] FIG. 1 is an explanatory drawing for explaining the
inclination angle .theta. and cut pile length of the cut piles in
the pile fabric of the present invention. 1 indicates a ground
structure. 2 indicates cut piles. 3 indicates a cut pile
portion.
BEST MODE FOR CARRYING OUT THE INVENTION
[0014] The pile fabric of the present invention has a ground
structure portion (A) having a knitted or woven structure
comprising organic fiber yarns and a cut pile portion (B)
comprising cut piles knitted or woven in the above-mentioned ground
structure portion and extended from at least one side of the
above-mentioned ground structure portion. The pile fabric of the
present invention has a characteristic that the cut piles less come
off the ground structure portion than cut piles in conventional
flocked pile fabrics, because the cut piles are knitted or woven in
the ground structure portion.
[0015] It is necessary that the single fiber fineness of the
above-mentioned cut piles is in a range of 0.1 to 2.0 dtex
(preferably 0.1 to 1.2 dtex, especially preferably 0.2 to 0.6
dtex). It is not preferable that the single fiber fineness of the
cut piles is smaller than 0.1 dtex, because there is a fear of
problems such as the breakage of the cut piles and the
deterioration of color fastness due to friction, as well as because
the maintenance of the pile state becomes difficult. Conversely, it
is not preferable that said single fiber fineness is larger than
2.0 dtex, because it becomes difficult to exhibit a smooth
touch.
[0016] Also, it is necessary that the cut pile length of the
above-mentioned cut piles is in a range of 0.20 to 2.00 mm
(preferably 0.20 to 0.80 mm, especially preferably 0.30 to 0.70
mm). It is not preferable that said cut pile length is smaller than
0.20 mm, because the transparent appearance of the ground structure
portion is increased to give an irregular appearance and
deteriorate a high grade appearance. Conversely, it is not
preferable that said cut pile length is larger than 2.00 mm,
because the retention in the standing state of the cut piles
becomes difficult to again deteriorate the high grade appearance.
In the present invention, the cut pile length is a value L/sin
.theta. obtained by dividing a cut pile height L by sin .theta., as
shown in FIG. 1.
[0017] It is necessary that the cut pile density of the cut pile
portion formed of such the cut piles is in a range of 40,000 to
300,000 dtex/cm.sup.2 (preferably 50,000 to 150,000 dtex/cm.sup.2,
especially preferably 100,000 to 140,000 dtex/cm.sup.2). It is not
preferable that said cut pile density is smaller than 40,000
dtex/cm.sup.2, because the cut piles are liable to fall, thereby
not giving the same high grade appearance and smooth touch, the
main purposes of the present invention, as those of flocked pile
fabrics. Such the pile-falling phenomenon is remarkable, when the
pile fabric of the present invention is used as a vehicle interior
material such as a car seat member in severe using conditions. To
the contrary, it is not preferable that said cut pile density is
larger than 300,000 dtex/cm.sup.2, because the increase in the
production cost as well as the hardening of the hand are
caused.
[0018] Therein, the above-described cut pile density is calculated
according to the following expression. Cut pile
density[dtex/cm.sup.2]=(single fiber fineness of cut
piles)[dtex].times.(number of cut piles per cm.sup.2)[cut
piles/cm.sup.2].
[0019] The number of the cut piles per cm.sup.2 may be obtained by
measuring the number of the cut piles per cm.sup.2 (square whose
one side is 1 cm)[cut piles/cm.sup.2], but may be calculated
according to the following expression. Number of cut piles per
cm.sup.2[cut piles/cm.sup.2]=(number of loop piles per
cm.sup.2)[loop piles/cm.sup.2].times.(number of filaments of pile
yarn)[filaments].times.2
[0020] The cut pile portion having such the cut pile density can
easily be obtained by using highly thermally shrinkable yarns or
false-twisted crimped yarns as the yarns for the ground structure
portion as described later.
[0021] It is preferable for obtaining the same high grade
appearance and smooth touch as those of flocked pile fabrics that
the inclination angle of the above-mentioned cut piles is in a
range of 70 to 90 degree. When said inclination angle is smaller
than 70 degree, a directional property is formed in the cut pile
portion, whereby it is feared that the objective high grade
appearance and smooth touch are not obtained. Such the inclination
angle is easily obtained by forming a pile knitted or woven fabric
having such the cut pile density as in the above-mentioned range
and then, if necessary, uprightly standing the cut piles with an
ordinary rotary heat brush having a straight card cloth on the
surface. Therein, the inclination angle is an angle .theta. between
the cut piles and the ground structure portion as shown in FIG. 1.
90 degree is right angle.
[0022] The kind of the fibers for forming the above-mentioned cut
piles is especially not limited, but may be conventional fibers
such as cotton, wool, linen, viscose rayon fibers, polyester
fibers, polyetherester fibers, acrylic fibers, nylon fibers,
polyolefin fibers, cellulose acetate fibers, or aramid fibers.
Among them, the polyester-based fibers are especially preferable at
the point of recyclability. The polyester-based fibers are produced
from a dicarboxylic acid component and a diglycol component. It is
preferable that terephthalic acid is mainly used as the
dicarboxylic acid component, and it is preferable that one or more
alkylene glycols selected from ethylene glycol, trimethylene glycol
and tetramethylene glycol are mainly used as the diglycol
component. The polyester resin may contain the third component in
addition to the above-mentioned dicarboxylic acid component and
glycol component. One or more of cationic dye-dyeable anionic
components, such as sodium sulfoisophthalic acid; dicarboxylic
acids except the terephthalic acid, such as isophthalic acid,
naphthalene dicarboxylic acid, adipic acid, and sebacic acid;
glycol compounds except the alkylene glycol, such as diethylene
glycol, polyethylene glycol, bisphenol A, and biphenol sulfone may
be used as said third component. Furthermore, biodegradable
polyester fibers such as polylactate fibers may be contained.
[0023] The resin for forming the fibers may, if necessary, contain
one or more of a matting agent (titanium dioxide), a micro
pore-forming agent (a metal organic sulfonate), a
coloration-preventing agent, a thermal stabilizer, a flame
retardant (antimony trioxide), a fluorescent brighter, a coloring
pigment, an antistatic agent (a metal sulfonate), a moisture
absorbent (a polyoxyalkylene glycol), an anti-microbial agent, and
other inorganic particles.
[0024] The form of the cut piles may be the form of non-crimped
piles or the form of crimped piles obtained by a false-twisting
crimping method, a mechanically crimping method, or a method for
thermally treating side-by-side type latent crimping conjugated
fibers especially without being limited, but the form of the
non-crimped piles is preferable for obtaining a high grade
appearance.
[0025] The single fiber cross-sectional shape of the cut piles is
especially not limited, but may be an ordinary circular
cross-sectional shape or a triangular, flat, constricted flat,
cruciate, six-lobar or hollow cross-sectional shape.
[0026] In the pile fabric of the present invention, the ground
structure portion has the knitted or woven structure comprising the
organic fiber yarns. Fibers constituting such the organic fiber
yarns may be the same fibers as the above-mentioned fibers
exemplified for the cut piles. Especially for the use of vehicle
interior materials, the polyester-based fibers are preferable at
the point of recyclability.
[0027] The form of the organic fiber yarns constituting the ground
structure portion is especially not limited, but is preferably the
form of filaments (multi-filament yarns). The single fiber fineness
and total fineness of said organic fiber yarns are preferably 0.5
to 5.0 dtex and 30 to 300 dtex, respectively, for preventing the
deterioration in the hand of the fabric. The cross-sectional shape
of the single fiber is not limited, but may be an ordinary circular
cross-sectional shape or a triangular, flat, constricted flat,
cruciate, six-lobar or hollow cross-sectional shape. Additionally,
such the organic fiber yarns may be false-twisted crimped yarns,
composite yarns obtained by subjecting two or more kinds of
constituting yarns to an air-blending treatment or a composite
false-twisting treatment, or covered yarns comprising elastic
fibers placed in the core portions and non-elastic fibers placed in
the sheath portions.
[0028] The pile fabric of the present invention can easily be
obtained, for example, by the following production method. First,
yarns comprising the above-mentioned fibers having a single fiber
fineness of 0.1 to 2.0 dtex (preferably 0.1 to 1.2 dtex, especially
preferably 0.2 to 0.6 dtex) as the yarns for the cut piles, and
yarns comprising the above-mentioned fibers as the organic fiber
yarns for the ground structure portion are knitted or woven to
produce the pile fabric.
[0029] Therein, it is important that the yarns for the cut piles
have a boiling water shrinkage (BWS) of not less than 20%
(preferably 22 to 40%). By using the yarns having such the large
boiling water shrinkage as the yarns for the piles, the piles can
thermally be shrunk by the later-described thermal treatment to
obtain the extremely short pile length of 0.20 to 2.00 mm. As the
yarns having such the high boiling water shrinkage, for example,
the following polyester filament yarns are suitably exemplified.
Namely, the polyester filament yarn is obtained by supplying a
copolyester resin obtained by copolymerizing a conventional
dicarboxylic acid component, a conventional alkylene glycol
component, and one or more compounds selected from the group
consisting of dicarboxylic acids such as isophthalic acid,
naphthalene dicarboxylic acid, adipic acid, and sebacic acid,
glycols such as diethylene glycol and polyethylene glycol,
bisphenol A, bisphenol sulfone, and the like, as the third
component, to a conventional spinning process, and then drawing the
obtained undrawn filament yarn by a conventional method. In a case
for obtaining a polyester filament yarn having a higher boiling
water shrinkage, the obtained undrawn filament yarn is directly
wound up at a winding rate of about 3,500 m/min without applying a
drawing treatment to the undrawn filament yarn, and then slightly
drawing the undrawn filament yarn at a draw ratio of 1.3 to 1.5 at
temperature of 60 to 80.degree. C. to obtain the polyester filament
yarn having the higher boiling water shrinkage.
[0030] Also, it is preferable that yarns having a boiling water
shrinkage of not less than 20% (preferably not less than 40%,
especially preferably 50 to 90%) or conventional false-twisted
crimped yarns having a crimp percent of not less than 30%
(preferably 35 to 50%) are used as the organic fiber yarns for the
ground structure portion, because the fabric is shrunk by thermal
shrinkage due to a thermal treatment or by the
elasticity-recovering force of the false-twisted crimped yarns to
easily give a cut pile density in the above-mentioned range.
[0031] Herein, when a pile fabric whose ground structure portion
has a knitted structure is obtained, a method for knitting a ground
structure to form a loop pile structure, such as a sinker pile
structure, a pole tricot pile structure, or a double raschel pile
structure, extended on the ground structure, and then cutting the
loop piles, or the like, is adopted. The pole tricot pile structure
is obtained by treating the pile knitted portion of the tricot
knitted structure with a raising machine to form the loop
piles.
[0032] Meanwhile, when a pile fabric whose ground structure portion
has a woven structure is obtained, a method for forming a warp pile
woven fabric or a weft pile woven fabric, and then cutting the loop
piles, or a method for forming a moquette woven fabric, and then
center-cutting the loop piles is adopted.
[0033] Subsequently, a conventional dyeing-finishing treatment is
applied to such the pile fabric. Thereby, the cut piles are
thermally shrunk with heat generated in the treatment to obtain the
pile fabric of the present invention, wherein the cut pile density
of the cut pile portion of the pile fabric is controlled to a range
of 40,000 to 300,000 dtex/cm.sup.2 (preferably 50,000 to 150,000
dtex/cm.sup.2, especially preferably 100,000 to 140,000
dtex/cm.sup.2), and the cut pile length of the cut piles is
controlled to a range of 0.20 to 2.00 mm (preferably 0.20 to 0.80
mm, especially preferably 0.30 to 0.70 mm).
[0034] Therein, when the dyeing-finishing treatment is not applied,
it is preferable that the cut piles are thermally shrunk by a wet
heat treatment method at 80 to 130.degree. C. (more preferably 100
to 110.degree. C.) or a dry heat treatment method at 150 to
200.degree. C. (more preferably 160 to 180.degree. C.).
[0035] In the pile fabric thus obtained, the cut piles having a
small single fiber fineness of 0.1 to 2.0 dtex form the cut pile
portion having the high cut pile density and the extremely small
cut pile length. Consequently, such the pile fabric exhibits the
same high grade appearance and smooth touch as those of flocked
pile fabrics produced by a flocking method. Furthermore, the pile
fabric has a characteristic that the cut piles less come off than
those of conventional flocked pile fabrics, because the cut piles
are knitted or woven in the ground structure portion.
[0036] In addition, in the ground structure portion of the short
cut pile fabric of the present invention, another layer such as a
known back coating layer or a pile portion may be formed on the
surface of the side opposite to the cut pile portion. Furthermore,
various function-imparting treatments such as a conventional
dyeing-finishing treatment, a color-printing treatment, a
water-repelling treatment, an ultraviolet ray-shading agent, a
microbicide, a deodorant, an insecticide, a luminous agent, a
retro-reflecting agent, or a minus ion generator are added and
applied.
[0037] Subsequently, the vehicle interior material of the prevent
invention is a vehicle interior material using the above-mentioned
pile fabric. A concrete vehicle interior material includes a car
seat member and a ceiling material. The vehicle interior material
of the present invention exhibits the same high grade appearance
and smooth touch as those of flocked pile fabrics, because of using
the above-mentioned pile fabric.
EXAMPLES
[0038] Examples and Comparative Examples of the present invention
will be explained in more detail hereafter, but the present
invention is not limited to Examples and Comparative Examples.
Additionally, measurement items in Examples and Comparative
Examples were measured by the following methods, respectively.
[0039] (1) Pile Coming-Off Quantity (PCO)
[0040] A 70 mm-wide, 300 mm-long test fabric was prepared in the
warp direction of the pile fabric. A 70 mm-wide, 300 mm-long test
fabric was also prepared in the weft direction of the pile fabric.
A slab urethane foam having the same size as that of said test
fabric was attached to the back side of the prepared test fabric.
Then, both the ends of said test fabric were fixed to the slab
urethane foam in a non-loose state. The 140 mm-long area of the
test fabric was reciprocatedly rubbed with a 9.8.+-.0.098 N-loaded
rubbing member having a contact area of 20 mm.times.20 mm 10,000
times at a rate of 60.+-.10 times/min. The test was carried out in
each direction. Pile coming-off quantities (PCO) were calculated
according to the following expression, and their average value was
calculated. PCO (%)=(W1-W2)/(W1.times.0.152).times.100
[0041] Therein, W1 is the mass of the un-rubbed test fabric, and W2
is the mass of the rubbed test fabric.
[0042] (2) Inclination Angle of Cut Piles
[0043] The cross section of the pile fabric was photographed (50
magnifications) with a microscope (model: VH-6300) manufactured by
Keyence (Ltd.), and the angle .theta. between the cup piles and the
ground structure portion shown in FIG. 1 was measured. Therein, the
number of n was 5, and the average value was determined.
[0044] (3) Cut Pile Length of Cut Piles
[0045] The cross section of the pile fabric was photographed (50
magnifications) with a microscope (model: VH-6300) manufactured by
Keyence (Ltd.), and the whole thickness of the pile fabric and the
thickness of the ground structure portion were measured. The cut
pile length L/sin 0 of the cut piles was calculated according to
the following expression. Therein, the whole thickness was obtained
by measuring the distance from the lowest portion of the ground
structure portion to the highest portion of the cup piles. The
number of n was 5, and the average value was determined. L=(whole
thickness)[mm]-(thickness of ground structure portion)[mm]Cut pile
length(mm)=L/sin .theta.
[0046] (4) Cut Pile Density
[0047] First, the number of cut piles per cm.sup.2 (1 cm.times.1
cm) [cut piles/cm.sup.2] was calculated according to the following
expression. Number of cut piles per cm.sup.2[cut
piles/cm.sup.2]=(number of loop piles per cm.sup.2)(loop
piles/cm.sup.2).times.(number of filaments of cut pile)
(filaments).times.2
[0048] Subsequently, the cut pile density was calculated according
to the following expression. Therein, the number of n is 5, and the
average value was determined. Cut pile
density[dtex/cm.sup.2]=(single fiber fineness)[dtex].times.(number
of cut piles)[cut piles/cm.sup.2]
[0049] (5) Boiling Water Shrinkage (BWS)
[0050] A sample filament yarn was wound on a counter wheel having a
circumferential length of 1.125 m at ten revolutions to make the
skein, and the skein was hung from a hanging nail of a scale plate.
A load of 1/30 based on the total weight of the skein was hung from
the lower end of the hung skein, and the length L1 of the untreated
skein was measured.
[0051] The load was removed from the skein, and the skein was put
in a cotton bag. The cotton bag receiving the skein was taken out
from boiling water, and the skein was taken out from the cotton
bag. The water contained in the skein was absorbed in filter paper.
The dehydrated skein was dried in air at room temperature for 24
hours, and then hung from the hanging nail of the above-mentioned
scale plate. A load of 1/3 based on the total mass of the skein was
hung from the lower portion of the hung skein similarly as above
mentioned, and the length L2 of the shrunk skein was measured.
[0052] The boiling water shrinkage (BWS) of the sample filament
yarn was calculated according to the following expression. BWS
(%)=((L1-L2)/L1).times.100
[0053] (6) Crimp Percent CP
[0054] A sample filament yarn was wound on a counter wheel having a
circumferential length of 1.125 m to prepare a skein having a dry
fineness of 3,333 dtex.
[0055] The above-mentioned skein was hung from a hanging nail of a
scale plate. An initial load of 6 g and additionally a load of 600
g were hung from the lower portion of the skein, and the length L0
of the skein was measured. Then, the loads were immediately
removed, and the skein was separated from the scale plate and
immersed in boiling water for 30 minutes to develop the crimps.
Subsequently, the skein treated in the boiling water was taken out
from the boiling water, and the water contained in the skein was
absorbed off in filter paper. The skein was dried in air at room
temperature for 24 hours, and then hung from the hanging nail of
the scale plate. A load of 600 g was hung from the lower portion,
and the length Lla of the treated skein was measured one minute
later. Then, the load was detached, and the length L2a of the skein
was measured one minute later. The crimp percent (CP) of the sample
filament yarn was calculated according to the following expression.
CP [%]=((L1a-L2a)/L0).times.100
[0056] (7) Evaluation of High Grade Appearance
[0057] The appearance was visually judged by three testers. Grade 3
excellent at the point of the high grade appearance. Grade 2:
somewhat inferior. Grade 1: inferior.
[0058] (8) Evaluation of Surface Touch
[0059] The surface touch was sensually evaluated by three testers.
Grade 3: excellent in smoothness. Grade 2: somewhat inferior in
smoothness.
[0060] Grade 1: inferior in smoothness.
Example 1
[0061] A copolyester having a relative viscosity of 1.45 was
prepared from an acid component comprising terephthalic acid and
isophthalic acid in a molar ratio of 93/7 and a glycol component
comprising ethylene glycol. This copolyester resin was melt-spun,
and wound up at a winding rate of 3,500 m/min to produce the
partially oriented un-drawn copolyester multifilament. The undrawn
multifilament yarn was drawn between the 65.degree. C. first roller
and the 75.degree. C. second roller of a drawing machine at a draw
ratio of 1.4 without being thermally set to obtain the copolyester
filament yarn (yarn count: 100 dtex/12 filaments) which was used as
a yarn for a ground structure. The boiling water shrinkage (BWS) of
the copolyester filament yarn was 65%.
[0062] Meanwhile, the same copolyester as the above-described
copolyester was melt-spun and wound up at a winding rate of 3,500
m/min to produce the partially oriented un-drawn copolyester
multifilament. The partially oriented un-drawn copolyester
multifilament was drawn by a conventional drawing method to obtain
the copolyester filament yarn (yarn count: 140 dtex/288 filaments),
which was used as a yarn for cut piles. The boiling water shrinkage
(BWS) of this copolyester filament yarn was 24%.
[0063] Subsequently, the above-mentioned yarns for the ground
structure and the above-mentioned yarns for the piles were fully
set and arranged to the back reed and front reed, respectively, of
a conventional pole sinker knitting machine (manufactured by Karl
Mayer Corp., 28 gauges, the height of the pole sinker: 1 mm) to
obtain the pile knitted fabric having a loop pile height of 1.0 mm
by a knitting method (front: 10/45, back: 10/12).
[0064] Then, the tip portions of the piles of the above-mentioned
pile fabric were cut in a length of 0.21 mm with a conventional
shearing machine (manufactured by Nikki (Ltd.)) to obtain the pile
fabric having the cut piles having a cut pile length of 0.79 mm.
Thereafter, said pile fabric was subjected to a dry heat treatment
using a conventional dry heat setter at 190.degree. C. for 45 sec
to thermally shrink the yarns for the ground structure and the cut
piles, thus obtaining the pile fabric in which the cut pile density
of the cut pile portion was 125,000 dtex/cm.sup.2 and the cut pile
length of the cut piles was 0.60 mm.
[0065] Said pile fabric was dyed with a conventional disperse dye
by the use of a conventional jet dyeing machine (manufactured by
(Ltd.) Hisaka Seisakusho) at a temperature of 130.degree. C. for a
time of 30 min. After dyed, the pile fabric was subjected to a
fallen pile-standing treatment using a rotary heat brush machine
(straight card cloth) manufactured by Nikki (Ltd.) at a temperature
of 170.degree. C. for a time of one min. to stand the fallen piles
developed during the dyeing treatment. Finally, the treated pile
fabric was subjected to a dry heat treatment using a conventional
dry heat setter (manufactured by (Ltd.) Hirano Tecseed) at a
temperature of 180.degree. C. for a time of one minute to obtain
the pile fabric having a cut pile portion cut pile density of
130,000 dtex/cm.sup.2, a cut pile length of 0.60 mm, an inclination
angle of 83 degree and a cut pile single fiber fineness of 0.49
dtex. The obtained pile fabric had a pile coming-out quantity (PCO)
of 0.82%, and exhibited excellent pile coming-out resistance,
excellent high grade appearance (third grade), and smooth surface
touch (third grade).
[0066] Additionally, the pile fabric was used to obtain a car seat
member, which exhibited an excellent high grade appearance (third
grade) and an excellent smooth surface touch (third grade).
Example 2
[0067] A pile knitted fabric was produced similarly as in Example 1
except that false-twisted crimped yarns (yarn count: 167 dtex/48
fibers) comprising ordinary polyethylene terephthalate and having a
crimp percent of 40% were used as the yarns for the ground
structure in Example 1. Then, the tip portions of the piles of the
above-described pile knitted fabric were cut in a length of 0.15 mm
with a conventional shearing machine (manufactured by Nikki (Ltd.)
to obtain the pile fabric having cut piles having a cut pile length
of 0.85 mm. Thereafter, the treated pile knitted fabric was
subjected to the same thermal treatment, dyeing treatment, cut
pile-standing treatment, and dry heat treatment as those in Example
1 to obtain the pile fabric having a cut pile portion cut pile
density of 105,000 dtex/6 m.sup.2, a cut pile length of 0.68 mm, an
inclination angle of 78 degree and a cut pile single fiber fineness
of 0.49 dtex. The obtained pile fabric exhibited a pile coming-out
quantity (PCO) of 0.92%, excellent pile coming-out resistance,
excellent high grade appearance (third grade), and smooth surface
touch (third grade). Further, said pile fabric had excellent
handleability on a sewing treatment, because of having good
stretchability.
Comparative Example 1
[0068] A pile knitted fabric was produced similarly as in Example 1
except that drawn yarns (yarn count: 167 dtex/48 fibers) comprising
ordinary polyethylene terephthalate and having a boiling water
shrinkage of 3.2% were used as the yarns for the piles in Example
1. Then, the tip portions of the piles of the above-described pile
knitted fabric were cut in a length of 0.23 mm with a conventional
shearing machine (manufactured by Nikki (Ltd.)) to obtain the pile
fabric having the cut piles having a cut pile length of 0.77 mm.
Therein, the load of the shearing machine was increased to cause
the deterioration of the surface grade by shearing stages or the
like. Then, the treated pile knitted fabric was subjected to the
same thermal treatment, dyeing treatment, cut pile-standing
treatment, and dry heat treatment as those in Example 1 to obtain
the pile fabric having a cut pile length of 0.74 mm. In the
obtained pile fabric, the deterioration of the surface grade by the
above-mentioned shearing stages or the like was observed.
Comparative Example 2
[0069] A pile knitted fabric was produced similarly as in Example 1
except that drawn yarns (yarn count: 167 dtex/48 fibers) comprising
ordinary polyethylene terephthalate and having a boiling water
shrinkage of 3.2% were used as the yarns for the piles in Example
1. Then, the tip portions of the piles of the above-described pile
knitted fabric were cut in a length of 0.14 mm with a conventional
shearing machine (manufactured by Nikki (Ltd.)) to obtain the pile
fabric having the cut piles having a cut pile length of 0.86 mm.
Then, the treated pile knitted fabric was subjected to the same
thermal treatment, dyeing treatment, cut pile-standing treatment,
and dry heat treatment as those in Example 1 to obtain the pile
fabric having a cut pile length of 0.83 mm. The obtained pile
fabric was somewhat inferior (second grade) at the point of high
grade appearance, because the single fiber fineness of the cut
piles was large.
Comparative Example 3
[0070] Drawn yarns (yarn count: 84 dtex/36 fibers) comprising
ordinary polyethylene terephthalate were knitted to produce the
knitted fabric having a tricot knitted satin structure. Then, cut
piles were flocked in said knitted fabric by an electric flocking
method to obtain the electrically flocked pile fabric having a cut
pile portion pile density of 84,000 dtex/cm.sup.2, a cut pile
length of 0.38 mm, and a cut pile single fiber fineness of 0.1
dtex.
[0071] Said electrically flocked pile fabric had a pile coming-off
quantity (PCO) of 4.13%, and was hence insufficient at the point of
pile coming-off resistance.
Comparative Example 4
[0072] A pile fabric was produced similarly as in Example 1 except
that the cut pile density of the cut pile portion was changed into
38,000 dtex/cm.sup.2 in Example 1. In the obtained pile fabric, the
inclination angle of the cut piles was 56 degree, and it was
difficult to hold the standing state of the cut piles, thereby
causing the directional property of the cut piles. Hence, the
obtained pile fabric was inferior (first grade) at the point of
high grade appearance, and also inferior (first grade) in the
smoothness of touch.
INDUSTRIAL APPLICABILITY
[0073] The pile fabric of the present invention has a
characteristic that the pile fabric exhibits the same high grade
appearance and smooth touch as those of a flocked pile fabric
having a large cut pile density and a short cut pile length and a
characteristic that the cut piles of the pile fabric little come
off the ground structure portion, and can therefore be used in the
uses of vehicle interior materials such as car seat members,
interior members such as upholsteries and carpet members, and the
like. Especially, the pile fabric can preferably be used for the
use of the car seat members needing good getting-on or off
resistance.
* * * * *