U.S. patent application number 15/533225 was filed with the patent office on 2017-11-30 for fabric having uneven-surface design, and method for producing same.
The applicant listed for this patent is SEIREN CO., LTD.. Invention is credited to Kazunori KAWAMURA.
Application Number | 20170342658 15/533225 |
Document ID | / |
Family ID | 56126232 |
Filed Date | 2017-11-30 |
United States Patent
Application |
20170342658 |
Kind Code |
A1 |
KAWAMURA; Kazunori |
November 30, 2017 |
FABRIC HAVING UNEVEN-SURFACE DESIGN, AND METHOD FOR PRODUCING
SAME
Abstract
Provided is a fabric to which an uneven-surface design which is
fine and has flexibility and wear resistance is imparted. The
fabric has a polyurethane resin applied portion on at least a
portion of a surface side of the fabric, and an uneven-surface
design shaped on the polyurethane resin applied portion. The
polyurethane resin applied portion is a region in which a
polyurethane resin which is applied is present, and the
polyurethane resin permeates between the fibers at least in a
surface portion of the fabric such that a surface of the fabric is
formed by the polyurethane resin and the fibers. In the
polyurethane resin applied portion, an application depth of the
polyurethane resin is 50 to 200 .mu.m, a filling ratio of the
polyurethane resin is 15% to 45%, and a filling ratio of the fibers
of the fabric is 50% to 80%.
Inventors: |
KAWAMURA; Kazunori;
(Fukui-shi, Fukui, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SEIREN CO., LTD. |
Fukui-shi, Fukui |
|
JP |
|
|
Family ID: |
56126232 |
Appl. No.: |
15/533225 |
Filed: |
December 10, 2015 |
PCT Filed: |
December 10, 2015 |
PCT NO: |
PCT/JP2015/006171 |
371 Date: |
June 5, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 23/16 20130101;
D06Q 1/08 20130101; D06M 15/564 20130101; D06P 1/5285 20130101;
D06C 2700/31 20130101; D06P 3/54 20130101; D06C 23/04 20130101;
D06M 15/705 20130101; D06P 5/2061 20130101; D06M 2101/32
20130101 |
International
Class: |
D06Q 1/08 20060101
D06Q001/08; D06C 23/04 20060101 D06C023/04 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 15, 2014 |
JP |
2014-253379 |
Claims
1. A fabric comprising: a polyurethane resin applied portion on at
least a portion of a surface side of the fabric constituted by
fibers; and an uneven-surface design shaped on the polyurethane
resin applied portion, wherein the polyurethane resin applied
portion is a region in which a polyurethane resin which is applied
is present, and the polyurethane resin permeates between the fibers
at least in a surface portion of the fabric such that a surface of
the fabric is formed by the polyurethane resin and the fibers, and
in the polyurethane resin applied portion, an application depth of
the polyurethane resin is 50 to 200 .mu.m, a filling ratio of the
polyurethane resin is 15% to 45%, and a filling ratio of the fibers
is 50% to 80%.
2. The fabric according to claim 1, wherein a void ratio in the
polyurethane resin applied portion is 13% or less.
3. The fabric according to claim 1, wherein the sum of outer
circumferential lengths of fiber cross-sections in the polyurethane
resin applied portion is 1500 .mu.m or more per unit area 10,000
.mu.m.sup.2.
4. The fabric according to claim 1, wherein the number of fibers
per 100 .mu.m.sup.2 of the cross-sectional area of the polyurethane
resin in the polyurethane resin applied portion is 1.5 or more.
5. The fabric according to claim 1, wherein, in the polyurethane
resin applied portion, the application depth of the polyurethane
resin is 50 to 100 .mu.m, the filling ratio of the polyurethane
resin is 20% to 35%, and the filling ratio of the fibers is 55% to
75%.
6. The fabric according to claim 1, wherein a ratio of the
application depth of the polyurethane resin to a thickness of the
fabric having the uneven-surface design is 3% to 30%.
7. The fabric according to claim 1, wherein a width of a recess
forming the uneven-surface design is 200 to 1500 .mu.m and a
maximum depth of the recess is 20 to 450 .mu.m.
8. A method for producing a fabric, the method being a method for
producing the fabric according to claim 1, the method comprising:
applying a polyurethane resin to at least a portion of a surface
side of the fabric and thereafter shaping the uneven-surface design
on a polyurethane resin applied portion by embossing.
9. The method for producing a fabric according to claim 8, wherein
the fabric as an object to which the polyurethane resin is applied
is a woven fabric, and in the woven fabric, in a region to which
the uneven-surface design is imparted, a total fineness per unit
volume 1 mm.sup.3 is 2500 to 5800 dtex.
10. The method for producing a fabric according to claim 8, wherein
the fabric as an object to which the polyurethane resin is applied
is a knitted fabric, and in the knitted fabric, in a region to
which the uneven-surface design is imparted, a total fineness per
unit volume 1 mm.sup.3 is 1000 to 5800 dtex.
Description
TECHNICAL FIELD
[0001] The present invention relates to a fabric having an
uneven-surface design, and a method for producing the same.
BACKGROUND ART
[0002] Nowadays, in the field of clothing, interior materials,
vehicle interior materials, and the like, there is a demand for
products with high design properties, and products with uneven
patterns on the surface have been developed. For example, in order
to impart an uneven-surface design to a fabric, the surface of the
fabric is subjected to embossing. However, fibers constituting the
fabric have elasticity. Therefore, there is a problem that a
sufficient shaping effect cannot be obtained due to the compression
resilience caused by the elasticity of the fibers in a case where
the design is a fine uneven-surface shape even when heat pressing
is performed through the embossing.
[0003] As a method for solving the problem described above, it is
conceivable to use fibers having a small fineness as the fibers
constituting the fabric in order to reduce the compression
resilience caused by the elasticity of the fabric. However, in this
case, although a fine uneven-surface shape can be imparted by
embossing, there is a problem that the uneven-surface shape has no
durability and the uneven-surface shape disappears due to wear.
[0004] In addition, when a resin film (resin layer) is formed on
the surface of a fabric as in PTL 1 or PTL 2, the resin has better
shaping properties than fiber and thus a fine uneven-surface shape
can be imparted. However, this causes a state in which the film is
spread on the surface like a synthetic leather or plastic film.
Therefore, there are problems that the soft feel or appearance of
the fibers is impaired and cracking may occur during bending.
CITATION LIST
Patent Literature
[0005] [PTL 1] JP-A-55-132784
[0006] [PTL 2] JP-A-2002-242085
SUMMARY OF INVENTION
Technical Problem
[0007] An object of the present invention is to provide a fabric to
which an uneven-surface design which is fine and has flexibility
and wear resistance is imparted.
Solution to Problem
[0008] First, the present invention relates to a fabric including:
a polyurethane resin applied portion on at least a portion of a
surface side of the fabric constituted by fibers; and an
uneven-surface design shaped on the polyurethane resin applied
portion. The polyurethane resin applied portion is a region in
which a polyurethane resin which is applied is present, and the
polyurethane resin permeates between the fibers at least in a
surface portion of the fabric such that a surface of the fabric is
formed by the polyurethane resin and the fibers. The polyurethane
resin applied portion satisfies the following requirements.
[0009] An application depth of the polyurethane resin is 50 to 200
.mu.m.
[0010] A filling ratio of the polyurethane resin is 15% to 45%.
[0011] A filling ratio of the fibers of the fabric is 50% to
80%.
[0012] Second, the present invention relates to a method for
producing the fabric having an uneven-surface design, including:
applying a polyurethane resin to at least a portion of a surface
side of the fabric and thereafter shaping the uneven-surface design
on a polyurethane resin applied portion by embossing.
Advantageous Effects of Invention
[0013] According to the present invention, a fabric to which an
uneven-surface design that is fine and has flexibility and wear
resistance is imparted can be provided by a polyurethane resin
which suppresses compression resilience caused by the elasticity of
fibers.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a photograph of the surface of a fabric according
to an example.
[0015] FIG. 2 is a photograph of the cross-section of the fabric
according to the example.
[0016] FIG. 3 is an enlarged photograph of the cross-section of a
polyurethane resin applied portion of the fabric according to the
example.
[0017] FIG. 4 is a weave diagram of a fabric used in Example 5.
DESCRIPTION OF EMBODIMENTS
[0018] A fabric having an uneven-surface design according to this
embodiment has a polyurethane resin applied portion on at least a
portion of the surface side of the fabric, and has an
uneven-surface design shaped on the polyurethane resin applied
portion. The polyurethane resin applied portion is a region in
which a polyurethane resin which is applied is present, the
polyurethane resin permeates between fibers at least in the surface
portion of the fabric such that the surface of the fabric is formed
by the polyurethane resin and the fibers, and the following
requirements (1) to (3) are satisfied.
[0019] (1) The application depth of the polyurethane resin is 50 to
200 .mu.m.
[0020] (2) The filling ratio of the polyurethane resin is 15% to
45%.
[0021] (3) The filling ratio of the fibers of the fabric is 50% to
80%.
[0022] By satisfying the requirements (1) to (3) and by causing the
polyurethane resin to be present between the fibers in the vicinity
of the surface of the fabric, a fine uneven-surface design having
flexibility and wear resistance can be obtained while suppressing
the compression resilience caused by the elasticity of the
fibers.
[0023] FIG. 1 is a photograph (magnification of .times.25) of the
surface of a fabric having an uneven-surface design according to an
example, and FIG. 2 is a photograph (magnification of .times.100)
of the cross-section of the fabric. On the surface of the fabric, a
fine uneven-surface design formed by embossing, that is, an
embossed pattern is formed.
[0024] The photograph of the cross-section of the fabric of FIG. 3
is a photograph of the cross-section in a vertical direction of a
polyurethane resin applied portion of the fabric having an
uneven-surface design according to the example, and shows an
example of a state in which a polyurethane resin is applied in the
polyurethane resin applied portion. The polyurethane resin is not
in the form of a film covering the surface of the fabric, but
permeates between the fibers at least in the surface portion of the
fabric to form a lump state with the fibers, and is present between
the fibers in the vicinity of the surface of the fabric to fix the
fibers to each other. Therefore, a fine uneven-surface design
having flexibility and wear resistance can be obtained while
suppressing the compression resilience caused by the elasticity of
the fibers. In this embodiment, the polyurethane resin applied
portion is a part to which the polyurethane resin is applied, and
refers to a region in which the applied polyurethane resin is
present.
[0025] A fabric as a processing object used in this embodiment,
that is, a fabric as an object to which the polyurethane resin is
applied is also called a base fabric or raw fabric. The fabric is
not particularly limited, and for example, well-known fabrics such
as a woven fabric, knitted fabric, and nonwoven fabric may be
employed. The weave of the woven fabric is not particularly
limited, and examples thereof include three foundation weaves:
plain weave, twill weave, and satin weave, derivative weaves of the
three foundation weaves, special weaves such as a crape weave, and
furthermore, a mixed weave having two or more times thereof in
combination. The knitted fabric is not particularly limited, and
examples thereof include tricot, double raschel and circular
knit.
[0026] The material of the fibers constituting the fabric in this
embodiment is not particularly limited, and natural fibers,
regenerated fibers, semi-synthetic fibers, synthetic fibers, and
the like which are well known in the related art may be used. These
can be used singly or in combination of two or more kinds. Among
these, from the viewpoints of durability, particularly mechanical
strength, heat resistance, and light fastness, the material of the
fiber is preferably a synthetic fiber, more preferably polyester,
and particularly preferably polyethylene terephthalate.
Furthermore, from the viewpoint of flame retardancy, it is
preferable to use flame retardant fibers.
[0027] On the surface of the fabric as the base fabric, a nap may
also be formed by a well-known method such as a woven or knitted
weave or a raising process. The nap length in a case where the
fabric has the nap is not particularly limited. However, from the
viewpoint of wear resistance, for example, in a case of a pile
product such as a full-cut pile product or a double raschel opened
product, the nap length is preferably 1600 .mu.m or less. By
causing the nap length to be 1600 .mu.m or less, the polyurethane
resin can be prevented from being fixed in the form of a layer on
the surface of the nap. Therefore, application of a load only to
the polyurethane resin applied portion during wear and the
deterioration in the wear resistance can be prevented.
[0028] The fabric having an uneven-surface design according to this
embodiment (hereinafter, also referred to as designed fabric) has
the polyurethane resin applied portion on at least a portion of the
surface side of the fabric. It is preferable that the single fiber
fineness (hereinafter, also referred to as single fineness) of the
fibers constituting the fabric of the polyurethane resin applied
portion is mainly a fiber of 1.5 dtex or less. By causing the
single fiber fineness to be 1.5 dtex or less, voids between the
fibers can be prevented from becoming large, and the shaping
properties of a fine uneven-surface shape formed by embossing can
be improved. The lower limit of the single fiber fineness is not
particularly limited, and may be 0.1 dtex or more, for example.
[0029] In the case of the woven fabric, in the region to which the
uneven-surface design is imparted in the fabric as the base fabric,
the total fineness per unit volume 1 mm.sup.3 is preferably 2500 to
5800 dtex, more preferably 3000 to 5800 dtex, and even more
preferably 3500 to 5800 dtex. By causing the total fineness to be
2500 dtex or more, the voids between the fibers can be reduced, and
the shaping properties of the fine uneven-surface shape formed by
embossing can be improved. Furthermore, by causing the total
fineness to be 5800 dtex or less, good weaving properties can be
secured.
[0030] The total fineness per unit volume 1 mm.sup.3 is calculated
as follows. That is, by the product of a warp density (pieces/25.4
mm) and a warp fineness (warp yarn fineness) (dtex) and 25.4 mm,
the total warp fineness in a volume of 25.4 mm in a width direction
with respect to a gray fabric longitudinal direction.times.25.4 mm
in a longitudinal direction.times.a fabric thickness (mm) is
calculated. In this calculation, the length of the warp in 25.4 mm
in the warp direction is 25.4 mm. Strictly speaking, although the
warp does not go straight and is bent at a part entangled with the
weft, the warp is assumed to go straight in the calculation. The
total weft fineness is calculated in the same manner as the warp,
and the sum of the total warp fineness and the total weft fineness
is calculated. The quotient of the calculated value divided by the
volume (width direction.times.longitudinal direction.times.fabric
thickness) is calculated to be used as the total fineness per 1
mm.sup.3.
[0031] Specifically, this is calculated by the following
expression.
Total fineness per unit volume 1 mm.sup.3=(warp density.times.warp
fineness.times.25.4++weft density.times.weft
fineness.times.25.4)/(25.4.times.25.4.times.fabric thickness
(mm))
[0032] In a case where the yarn density is different from the
actual density, such as in a case where yarn drawing is present,
the calculation is performed using the actual density. For example,
when the warp drawing is 1 in 3 out (that is, a structure of one
yarn in and three yarns out), the warp density is multiplied by 1/4
in the calculation.
[0033] In the case of the knitted fabric, in the region to which
the uneven-surface design is imparted in the fabric as the base
fabric, the total fineness per unit volume 1 mm.sup.3 is preferably
1000 to 5800 dtex, more preferably 1200 to 5800 dtex, and even more
preferably 1500 to 5800 dtex. By causing the total fineness to be
1000 dtex or more, the voids between the fibers can be reduced, and
the shaping properties of the fine uneven-surface shape formed by
embossing can be improved. Furthermore, by causing the total
fineness to be 5800 dtex or less, good knitting properties can be
secured.
[0034] The total fineness per unit volume 1 mm.sup.3 in the case of
the knitted fabric is calculated as follows. By the product of
twice a course density, the yarn fineness, and 25.4 mm, the total
fineness in a volume of the width direction (25.4 mm) with respect
to the gray fabric longitudinal direction.times.the longitudinal
direction (25.4 mm).times.the fabric thickness (mm) is calculated.
Since two cross-sections are shown in one loop in a cross-section
in a direction perpendicular to the gray fabric longitudinal
direction, the warp density is doubled in the calculation. In
addition, in this calculation, the length in 25.4 mm in the width
direction in which the cross-sections of the loop are connected is
25.4 mm. Furthermore, strictly speaking, since the knitted yarn
does not go straight and forms loops, although the knitted yarn is
bent, the knitted yarn is assumed to go straight in the
calculation. The quotient of the calculated value divided by the
volume (width direction.times.longitudinal direction.times.fabric
thickness) is calculated to be used as the total fineness per 1
mm.sup.3. In a case of multiple weaves, for each of yarns
constituting each weave, the yarn fineness in a volume of a gray
fabric width direction (25.4 mm).times.the gray fabric longitudinal
direction (25.4 mm).times.the fabric thickness (mm) is calculated,
and thereafter the calculated values are added. The quotient of the
added value divided by the volume is calculated, thereby obtaining
the total fineness per unit volume 1 mm.sup.3.
[0035] Specifically, this is calculated by the following
expression.
Total fineness per unit volume 1 mm.sup.3 (in a case of tricot
knitting and circular knitting)=(total yarn fineness*.sup.1 for
each yarn.times.course
density.times.2.times.25.4)/(25.4.times.25.4.times.fabric thickness
(mm))
[0036] *1: The total yarn fineness of a front yarn, a middle yarn,
and a back yarn in the tricot knitting, and the total yarn fineness
of a face yarn, a bonding yarn, and a rear yarn in the circular
knitting.
Total fineness per unit volume 1 mm.sup.3 (in a case of a double
raschel opened product)={(total yarn fineness for each ground
yarn+total yarn fineness for each pile yarn).times.course
density.times.2.times.25.4}/(25.4.times.25.4.times.fabric thickness
(mm))
Total fineness per unit volume 1 mm.sup.3 (in a case of a double
raschel unopened product)={(total yarn fineness for each ground
yarn+total yarn fineness for each connecting
yarn.times.2).times.course
density.times.2.times.25.4}/(25.4.times.25.4.times.fabric thickness
(mm))
[0037] In a case where the yarn density is different from the
actual density, such as in a case where yarn drawing is present,
the calculation is performed using the actual density. An example
is described below. Regarding the connecting yarn of the double
raschel unopened product, for example, in a case where the yarn
drawing is 1 in 1 out, the following expression is obtained.
Total fineness per unit volume 1 mm.sup.3={(total yarn fineness for
each ground yarn+total yarn fineness for connecting
yarn.times.2.times.1/2).times.course
density.times.2.times.25.4}/(25.4.times.25.4.times.fabric thickness
(mm))
[0038] The polyurethane resin used in this embodiment is not
particularly limited, and examples thereof include polyurethane
resins based on polyether, polyester, polycarbonate, and the like.
Among these, from the viewpoint of texture, a polyester-based
polyurethane resin is preferably used, and from the viewpoint of
durability, particularly wear resistance, a polycarbonate-based
polyurethane resin is preferably used.
[0039] The softening temperature of the polyurethane resin is
preferably 100.degree. C. to 200.degree. C. By causing the
softening temperature to be 100.degree. C. or higher, even in a
case of being used under conditions in which the fabric is left for
a long period of time at a high temperature such as in a vehicle
interior material, the resin can be less likely to melt. By causing
the softening temperature to be 200.degree. C. or lower, the
heating temperature of an embossing roll when the uneven-surface
design is shaped can be set to be low and the basic fabric in a
part to which the polyurethane resin is not applied can be
prevented from becoming coarse and hard. The softening temperature
is measured by differential scanning calorimetry using a DSC
thermal analyzer.
[0040] The application of the polyurethane resin may be performed
on the entire fabric, or may be performed only on the periphery of
a part to which the fine uneven-surface design is imparted. The
application amount of the polyurethane resin in the polyurethane
resin applied portion varies depending on the configuration of the
fabric as the processing object, for example, density, fineness,
and the like, but is preferably about 1 to 200 g/m.sup.2 with
respect to the fabric. By causing the application amount thereof to
be 1 g/m.sup.2 or more, the fibers are sufficiently fixed to each
other. Therefore, the wear resistance is improved or the shaping
properties of the fine uneven-surface shape formed by embossing are
improved. By causing the application amount thereof to be 200
g/m.sup.2 or less, the texture can be prevented from becoming hard.
Here, the polyurethane resin permeates between the fibers at least
in the surface portion (surface layer portion) of the fabric to
form the surface portion of the fabric together with the fibers,
and unlike a grain face synthetic leather, the skin layer of the
polyurethane resin alone is not formed over the entire surface of
the fabric. The application amount of the polyurethane resin is
obtained by converting the application amount in the part to which
the polyurethane resin is applied into the application amount per
square meter and is a value in terms of the mass of a solid content
after being dried.
[0041] The application depth of the polyurethane resin in the
polyurethane resin applied portion of this embodiment is in a range
of 50 to 200 .mu.m. By causing the application depth thereof to be
50 .mu.m or more, the fibers are sufficiently fixed to each other.
Therefore, the wear resistance is improved or the shaping
properties of the fine uneven-surface shape formed by embossing are
improved. By causing the application depth thereof to be 200 .mu.m
or less, the texture can be prevented from becoming hard. The
application depth is preferably 50 to 130 .mu.m, and more
preferably 50 to 100 .mu.m.
[0042] The application depth of the polyurethane resin is referred
to as the depth of the region in which the polyurethane resin is
present between the fibers of the fabric from the surface of the
fabric, and hereinafter, this region is also referred to as the
application depth region of the polyurethane resin. Here, the
application depth of the polyurethane resin is synonymous with the
thickness of the polyurethane resin applied portion. The
application depth of the polyurethane resin is indicated by a white
arrow in FIG. 3. The application depth of the polyurethane resin is
determined as follows. A vertical section of the polyurethane resin
applied portion is photographed with a microscope, for arbitrary
ten points, the length in the vertical direction from the surface
of the fabric to the lower end of the permeating polyurethane resin
in a part in a state in which the polyurethane resin causes the
fibers to be fixed together and form a lump state is measured, and
the average thereof is obtained.
[0043] As described above, the polyurethane resin permeates between
the fibers at least in the surface portion of the fabric and may
permeate throughout the fabric thickness. However, from the
viewpoint of texture, it is preferable that the polyurethane resin
does not permeate through the entire thickness of the fabric, that
is, permeates into a portion in the thickness direction including
the surface portion of the fabric. Specifically, a ratio of the
application depth of the polyurethane resin to the thickness of the
designed fabric may be 3% to 30%, or may be 3% to 10%. Here, the
thickness of the designed fabric is not particularly limited, and
may be, for example, 0.2 to 3.0 mm (that is, 200 to 3000 .mu.m), or
0.3 to 2.8 mm.
[0044] The filling ratio of the polyurethane resin in the
polyurethane resin applied portion of this embodiment is in a range
of 15% to 45%. By causing the filling ratio thereof to be 15% or
more, the shaping properties of the uneven-surface shape are
improved. By causing the filling ratio thereof to be 45% or less,
the flexibility is improved. The filling ratio is preferably 15% to
35%, and more preferably 20% to 35%.
[0045] The filling ratio of the polyurethane resin in the
polyurethane resin applied portion is the proportion occupied by
the polyurethane resin in the application depth region of the
polyurethane resin (the part in which the polyurethane resin causes
the fibers to be fixed together and form a lump state), and is
obtained as follows. That is, this is obtained by the following
expression from the filling ratio of the fibers and the void ratio,
which will be described later.
Filling ratio (%) of polyurethane resin=100-(filling ratio of
fibers+void ratio)
[0046] The filling ratio of the fibers of the fabric in the
polyurethane resin applied portion is in a range of 50% to 80%. By
causing the filling ratio thereof to be 50% or more, the voids
between the fibers can be reduced and thus the adhesion between the
fibers can be improved, thereby improving the wear resistance. By
causing the filling ratio thereof to be 80% or less, the
flexibility can be improved. The filling ratio is preferably 55% to
80%, more preferably 55% to 75%.
[0047] The filling ratio of the fibers in the polyurethane resin
applied portion is the proportion occupied by the fibers in the
application depth region of the polyurethane resin (the part in
which the polyurethane resin causes the fibers to be fixed together
and form a lump state), and is obtained as follows. That is, a
photograph of the vertical section of the polyurethane resin
applied portion taken with the microscope is read by a scanner, and
the number (n) of yarn sections in a measurement area having a
width of 100 .mu.m as the lateral direction and having the
application depth region of the polyurethane resin in the vertical
direction is measured, and the filling ratio of the fibers is
obtained by the following expression. The diameter R (.mu.m) of the
yarn is obtained by measuring the diameter in the vertical and
lateral directions of the cross-section of the yarn at arbitrary
five points and averaging the measured values.
Filling ratio (%) of
fibers=(78.5.times.R.sup.2.times.n)/(100.times.application depth
(.mu.m) of polyurethane resin)
[0048] The filling ratio of the fibers in the polyurethane resin
applied portion is the average value of the filling ratios of the
fibers obtained at arbitrary five points.
[0049] The sum of the outer circumferential lengths of the fiber
cross-sections in the polyurethane resin applied portion of this
embodiment is preferably 1500 .mu.m or more per unit area 10,000
.mu.m.sup.2, more preferably 1800 .mu.m or more, and even more
preferably 2700 .mu.m or more. When the sum thereof is 1500 .mu.m
or more, the adhesion between the polyurethane resin and the fibers
is improved, the compression resilience of the fibers is
suppressed, and thus the shaping properties of the fine
uneven-surface shape formed by embossing can be improved. It is
thought that this is because as the sum of the outer
circumferential lengths increases, a large number of fibers
(filaments) having a small single fineness are present, the voids
between the fibers are small, and the polyurethane resin and the
fibers are easily fixed together. Furthermore, it is thought that a
large number of fibers having a small single fineness results in an
increase in the surface area with respect to the total fineness,
and thus the area covered with the polyurethane resin is increased
and is easily fixed. The upper limit of the sum of the outer
circumferential lengths of the fiber cross-sections is not
particularly limited, and may be, for example, 9000 .mu.m or less,
or 6000 .mu.m or less.
[0050] The sum of the outer circumferential lengths of the fiber
cross-sections in the polyurethane resin applied portion is
obtained as follows. That is, the photograph of the vertical
section of the polyurethane resin applied portion taken with the
microscope is read by the scanner, and the number (n) of yarn
sections in the measurement area having a width of 100 .mu.m as the
lateral direction and having the application depth region of the
polyurethane resin in the vertical direction is measured, and the
sum of the outer circumferential lengths of the fiber
cross-sections is obtained by the following expression. The
diameter R (.mu.m) of the yarn is obtained by measuring the
diameter in the vertical and lateral directions of the
cross-section of the yarn at arbitrary five points and averaging
the measured values.
Sum (.mu.m) of outer circumferential lengths of fiber
cross-sections=(31,400.times.R.times.n)/(100.times.application
depth of polyurethane resin (.mu.m))
[0051] The sum of the outer circumferential lengths of the fiber
cross-sections in the polyurethane resin applied portion is the
average value of the sums of the outer circumferential lengths of
the fiber cross-sections obtained at arbitrary five points.
[0052] The void ratio in the polyurethane resin applied portion is
preferably 13% or less, and more preferably 9% or less. By causing
the void ratio to be 13% or less, the uneven-surface shape can be
easily shaped by embossing. The lower limit of the void ratio is
not particularly limited, and for example, may be 0.1% or more, or,
2% or more.
[0053] The void ratio in the polyurethane resin applied portion is
the ratio of the void portions in the application depth region of
the polyurethane resin (the part in which the polyurethane resin
causes the fibers to be fixed together and form a lump state), and
is obtained as follows. That is, the photograph of the vertical
section of the polyurethane resin applied portion taken with the
microscope is read by the scanner, and the voids and the other
parts in the measurement area having a width of 100 .mu.m as the
lateral direction and having the application depth region of the
polyurethane resin in the vertical direction are binarized, and the
proportion of the voids in the application depth region of the
polyurethane resin of the fabric is calculated. The void ratio in
the polyurethane resin applied portion is the average value of the
void ratios obtained at arbitrary five points.
[0054] The number of fibers per 100 .mu.m.sup.2 of the
cross-sectional area of the polyurethane resin in the polyurethane
resin applied portion is preferably 1.5 or more, and more
preferably 2.0 or more. By causing the number to be 1.5 or more,
the number of fibers per polyurethane resin is increased, and thus
a binder effect of the polyurethane resin can be enhanced.
Therefore, the shaping properties of the fine uneven-surface shape
formed by embossing can be improved, and the wear resistance can be
improved. The upper limit of the number of the fibers is not
particularly limited, and for example, may be 100 or less, 50 or
less, or 20 or less.
[0055] The number of fibers per 100 .mu.m.sup.2 of the polyurethane
resin in the polyurethane resin applied portion is obtained by
using the photograph of the vertical section of the polyurethane
resin applied portion taken with the microscope, similar to the
filling ratio of the polyurethane resin. The number of fiber
cross-sections in the measurement region is counted. The area of
the polyurethane resin is calculated by multiplying the filling
ratio of the polyurethane resin by the area of the measurement
region. From these values, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin is calculated.
[0056] The uneven-surface design in this embodiment is preferably a
fine uneven-surface design having a recess shape with a width of
200 to 1500 .mu.m and a maximum depth of 20 to 450 .mu.m. The
uneven-surface design preferably has a maximum pattern spacing of
10,000 .mu.m or less. As a preferable embodiment, in the
uneven-surface design, the width of the recess may be 200 to 1200
.mu.m, the maximum depth of the recess may be 20 to 250 .mu.m, and
the maximum pattern spacing may be 5000 .mu.m or less. As a more
preferable embodiment, the width of the recess may be 200 to 800
.mu.m, the maximum depth of the recess may be 20 to 150 .mu.m, and
the maximum pattern spacing may be 2000 .mu.m or less. By
satisfying these ranges, a fine uneven-surface design that could
not be hitherto obtained by embossing, for example, an
uneven-surface design which is as fine as the grain of natural
leather can be expressed.
[0057] The width and the depth of the recess in the uneven-surface
design can be obtained by measuring the width and the depth of the
recess from the photograph of the vertical section of the
polyurethane resin applied portion taken with the microscope.
Specifically, as shown in FIG. 2, the width (W) of the recess of
the uneven-surface design is obtained by measuring the distance
from one end to the other end of arbitrary three recesses and
calculating the average value thereof. The depth (D) of the recess
of the uneven-surface design is obtained by measuring the distance
of a perpendicular drawn to the deepest part of the recess from the
straight line connecting one end to the other end of the recess
when the width of the recess is measured as described above, and
the maximum value for three arbitrary recesses is obtained. The
pattern spacing of the uneven-surface design is obtained by
measuring the distance between the apexes of adjacent protrusions
from a photograph of the surface of the polyurethane resin applied
portion taken with the microscope, and the maximum value for
arbitrary three sets of protrusions is obtained.
[0058] The cross-sectional shape of the uneven-surface design in
the vertical direction is not particularly limited, but is
preferably a corrugated shape that can express a finer pattern. In
a case of the corrugated shape, it is preferable that the
inclination angle of the straight line connecting the highest
position of the projection and the lowest position of the recess in
the projection and the recess adjacent to each other is 5 to 40
degrees. The inclination angle is more preferably 5 to 30 degrees,
and even more preferably 5 to 20 degrees.
[0059] The inclination angle of a corrugated design is measured as
follows. The inclination angle is obtained by measuring the angle
between the straight line connecting the highest position of the
projection to the lowest position of the recess and a tangent to
the highest position of the projection from the photograph of the
vertical section of the polyurethane resin applied portion taken
with the microscope.
[0060] The fabric having an uneven-surface design according to this
embodiment can be obtained by applying the polyurethane resin to at
least a portion of the surface side of the fabric as the base
fabric and thereafter shaping the uneven-surface design on the
polyurethane resin applied portion by embossing.
[0061] In a manufacturing method of this embodiment, first, a
treatment liquid containing the polyurethane resin is applied to at
least a portion of the surface side of the fabric. For example, the
treatment liquid may be applied to the entire surface on the
surface side of the fabric. Alternatively, the treatment liquid may
be applied to a portion of the surface side of the fabric, and in
this case, may be applied into a pattern. The treatment liquid
contains at least the polyurethane resin and a medium (for example,
water) for dispersing the polyurethane resin, and if necessary, may
contain additives such as a coloring material (dye, pigment, or
metal powder), or a thickener.
[0062] A method for applying the treatment liquid is not
particularly limited, and examples thereof include screen printing,
rotary printing, ink jet printing, and the like. In a case where
the fabric has an uneven surface, a gravure coater, a comma coater,
a reverse coater, or the like may also be used.
[0063] Next, the polyurethane resin is dried and solidified. The
drying may be performed to the extent that the medium does not
remain, and the conditions thereof are not particularly limited,
and may be appropriately set in consideration of the boiling point
of the medium and production efficiency.
[0064] As described above, after the polyurethane resin is applied
to the surface portion of the fabric and dried, the entire surface
is subjected to embossing. Specifically, for example, the surface
is caused to pass through an embossing roll having a temperature of
100.degree. C. to 160.degree. C. and a pressure (linear pressure)
of 490 to 1960 N/cm to soften and shape the polyurethane resin on
the surface of the fabric. On the surface of the embossing roll, an
uneven-surface pattern having an uneven surface reverse to a
desired fine uneven-surface pattern is carved. The temperature of
the embossing roll is set in consideration of the softening
temperature of the polyurethane resin, the material of the fibers
constituting the fabric, required durability, and the like.
[0065] A heat treatment may be performed on the fabric after the
shaping process in order to soften the texture. The heat treatment
is preferably performed at 100.degree. C. to 150.degree. C. for 30
seconds to 3 minutes.
[0066] As described above, the fabric having an uneven-surface
design of this embodiment can be obtained. The polyurethane resin
permeates between the fibers at least in the surface portion in the
thickness direction to form the surface portion of the fabric
together with the fibers.
[0067] The application of the fabric having an uneven-surface
design according to this embodiment is not particularly limited,
and can be used in various fields such as vehicle interior
materials, interior materials, clothing, bags, and the like.
EXAMPLES
[0068] Hereinafter, the present invention will be described in more
detail using examples, but the present invention is not limited to
these examples. In addition, the evaluation of the fabric was
performed according to the following methods.
[0069] (1) Shaping Properties
[0070] Products subjected to embossing using embossing rolls A, B
and C having the following uneven-surface shapes were visually
checked and evaluated according to the following evaluation
criteria.
[0071] Embossing roll A: recess width 800 .mu.m, maximum recess
depth 150 .mu.m, pattern spacing 2000 .mu.m, uneven-surface
cross-sectional shape in vertical direction; corrugated,
inclination angle 5 to 20 degrees, leather grain pattern
[0072] Embossing roll B: recess width 1200 .mu.m, maximum recess
depth 250 .mu.m, pattern spacing 5000 .mu.m, uneven-surface
cross-sectional shape in vertical direction; corrugated,
inclination angle 10 to 30 degrees, leather grain pattern
[0073] Embossing roll C: recess width 1500 .mu.m, maximum recess
depth 450 .mu.m, pattern spacing 10,000 .mu.m, uneven-surface
cross-sectional shape in vertical direction; trapezoidal, line
pattern
[0074] (Evaluation Criteria)
[0075] 1: All the uneven-surface shapes of A, B, C are clearly
shaped.
[0076] 2: The uneven-surface shape of A is unclear, but the
uneven-surface shapes of B and C are clearly shaped.
[0077] 3: The uneven-surface shapes of A and B are unclear, but the
uneven-surface shape of C is clearly shaped.
[0078] 4: All the uneven-surface shapes of A, B, C are unclear.
[0079] (2) Flexibility
[0080] The specimen after the evaluation of the shaping properties
was cut into a width of 25 mm and a length of 150 mm, and then
fixed to De Mattia flexing tester (manufactured by Tester Sangyo
Co., Ltd.). With a bending stroke of 57 mm, the specimen was bent
300 times per minute, a total of 3000 times. The specimen after
being bent was observed and evaluated according to the following
criteria.
[0081] (Evaluation Criteria)
[0082] 1: Cracking had not occurred.
[0083] 2: Cracking had occurred.
[0084] (3) Wear Resistance
[0085] After cutting the specimen after the evaluation of the
shaping properties into a width of 70 mm and a length of 300 mm, a
urethane foam having a size of 70 mm in width, 300 mm in length,
and 10 mm in thickness was attached to the rear surface thereof,
and the resultant was fixed to Plane Abrasion Tester T-TYPE
(manufactured by DAIEI KAGAKU SEIKI MFG. co., ltd.). The specimen
was worn by applying a load of 9.8 N to a rubbing finger covered
with a cotton cloth (cotton canvas). The rubbing finger had worn
back and forth 10,000 times at a rate of 60 reciprocations/min
between 140 mm on the surface of the specimen. The cotton canvas
was replaced every 2500 times of wear reciprocation, and was
reciprocated a total of 10,000 times to be worn. The specimen after
being worn was observed and evaluated according to the following
criteria.
[0086] (Evaluation Criteria)
[0087] 1: The uneven-surface shape had not disappeared.
[0088] 2: The uneven-surface shape had slightly disappeared.
[0089] 3: The uneven-surface shape had clearly disappeared.
Example 1
[0090] A polyethylene terephthalate false twisted yarn of 167
dtex/288 f was used as a warp, a polyethylene terephthalate false
twisted yarn of 167 dtex/48 f was used as a weft, and these were
woven into a warp-faced 5-harness satin weave, thereby obtaining a
gray fabric. Next, a heat treatment was performed at 190.degree. C.
for 1 minute by a heat setter. The density of the warps of the
obtained fabric was 178 pieces/25.4 mm, the density of wefts was 61
pieces/25.4 mm, and the fineness per 1 mm.sup.3 volume was 3928
dtex.
[0091] Next, a polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation, softening temperature=120.degree.
C.) solution (solid content 28 mass %) was applied to the entire
surface by a screen printing machine. The number of applications
was set so that the application amount of the polyurethane resin
was 30 g/m.sup.2 in terms of mass after drying. After applying the
polyurethane resin solution, the resultant was dried for 10 minutes
in a 90.degree. C. dryer. Next, embossing was performed thereon
with an embossing machine at a roll temperature of 150.degree. C.,
a roll pressure of 588 N/cm, and a fabric speed of 3 m/min. As the
embossing roll, three types of rollers A to C described in Shaping
Properties in the above-mentioned evaluation item were used.
[0092] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and fine uneven-surface design (fine embossed pattern)
formed by the embossing was imparted to the entire surface of the
fabric. In the polyurethane resin applied portion of this designed
fabric, the application depth of the polyurethane resin was 98
.mu.m, the filling ratio of the fibers was 69.1%, the filling ratio
of the polyurethane resin was 26.4%, the void ratio was 4.5%, the
number of fibers per 100 .mu.m.sup.2 of the polyurethane resin was
6.5, the circumferential length of filament cross-sections was 3863
.mu.m, and the thickness of the fabric was 400 .mu.m. Evaluation
results are shown in Table 1.
Example 2
[0093] Using a three-reed tricot knitting machine, a polyethylene
terephthalate false twisted yarn of 84 dtex/96 f was used for L1
(front yarn) for a 3-needle swing cord stitch (1-0/3-4), a
polyethylene terephthalate flame retardant yarn of 84 dtex/36 f was
used for L2 (middle yarn) for a denbigh stitch (1-0/1-2), a
polyethylene terephthalate flame retardant yarn of 84 dtex/36 f was
used for L3 (back yarn) for a 3-needle swing cord stitch (2-1/1-0),
these were each knitted by full set threading, thereby obtaining a
gray fabric. Next, this was subjected to dyeing by a dyeing machine
with a gray disperse dye at 130.degree. C. for 60 minutes. Next, by
a card cloth raising machine provided with a card cloth roll having
12 pile rollers and 12 counter pile rollers, full cut raising was
performed by performing raising thereon 13 times alternately in a
knitting end direction and in a knitting start direction at a card
cloth roller torque of 2.5 MPa and a fabric speed of 12 m/min.
Next, the resultant was subjected to a heat treatment by the heat
setter at 190.degree. C. for 1 minute and was finished. The
obtained fabric had a density of 71 loops/25.4 mm in the course, a
density of 38 loops/25.4 mm in the wale, and a fineness of 2310
dtex per 1 mm.sup.3 volume.
[0094] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 120.degree. C., a roll pressure of 1470 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0095] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and a fine uneven-surface design formed by the embossing
was imparted to the entire surface of the fabric. In the
polyurethane resin applied portion of this designed fabric, the
application depth of the polyurethane resin was 92 .mu.m, the
filling ratio of the fibers was 66.2%, the filling ratio of the
polyurethane resin was 25.4%, the void ratio was 8.4%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 4.0,
the circumferential length of filament cross-sections was 2934
.mu.m, and the thickness of the fabric was 610 .mu.m. Evaluation
results are shown in Table 1.
Example 3
[0096] A polyethylene terephthalate false twisted yarn of 178
dtex/24 f was used as a warp, a polyethylene terephthalate false
twisted yarn of 167 dtex/144 f was used as a weft, and these were
woven into a warp-faced 8-harness satin weave and a weft-faced
8-harness satin weave to form a border pattern with an interval of
10 mm, thereby obtaining a gray fabric. Next, by the card cloth
raising machine provided with the card cloth roll having 12 pile
rollers and 12 counter pile rollers, semi-cut raising was performed
by performing raising thereon 13 times alternately in a weaving end
direction and in a weaving start direction at a card cloth roller
torque of 2.5 MPa and a fabric speed of 12 m/min. Next, the
resultant was subjected to a heat treatment by the heat setter at
150.degree. C. for 1 minute and was finished. The density of the
warps of the obtained fabric was 184 pieces/25.4 mm, the density of
wefts was 88 pieces/25.4 mm, and the fineness per 1 mm.sup.3 volume
was 3113 dtex.
[0097] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied only to the weft portion by a reverse coater at a
fabric speed of 5 m/min and a roll rotation speed of 12 m/min. The
roll rotation speed conditions were set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 150.degree. C., a roll pressure of 588 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0098] In the obtained fabric, a fine uneven-surface design formed
by the embossing was imparted to the weft portion which was exposed
to the surface of the fabric and was provided with the resin
applied thereto. The application depth of the polyurethane resin in
the polyurethane resin applied portion thereof was 66 .mu.m, the
filling ratio of the fibers was 59.6%, the filling ratio of the
polyurethane resin was 30.9%, the void ratio was 9.5%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 2.4,
and the circumferential length of filament cross-sections was 2353
.mu.m. The thickness of the designed fabric was 600 .mu.m.
Evaluation results are shown in Table 1.
Example 4
[0099] Using a 3-reed tricot knitting machine, a polyethylene
terephthalate false twisted yarn of 84 dtex/72 f was used for L1
(front yarn) for a 4-needle swing cord stitch (1-0/4-5), a
polyethylene terephthalate regular yarn of 84 dtex/36 f was used
for L2 (middle yarn) for a denbigh stitch (1-0/1-2), a polyethylene
terephthalate regular yarn of 84 dtex/36 f was used for L3 (back
yarn) for a 4-needle swing cord stitch (2-1/1-0), these were each
knitted by full set threading, thereby obtaining a gray fabric.
Next, this was subjected to dyeing by the dyeing machine with a
gray disperse dye at 130.degree. C. for 60 minutes. Next, by the
card cloth raising machine provided with the card cloth roll having
12 pile rollers and 12 counter pile rollers, full cut raising was
performed by performing raising thereon 13 times alternately in a
knitting end direction and in a knitting start direction at a card
cloth roller torque of 2.5 MPa and a fabric speed of 12 m/min.
Next, the resultant was subjected to a heat treatment by the heat
setter at 190.degree. C. for 1 minute and was finished. The
obtained fabric had a density of 67 loops/25.4 mm in the course, a
density of 28 loops/25.4 mm in the wale, and a fineness of 2179
dtex per 1 mm.sup.3 volume.
[0100] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface at a fabric speed of 10 m/min
by a knife coater. The shape and the position of the knife were set
so that the application amount of the polyurethane resin was 30
g/m.sup.2 in terms of mass after drying. After applying the
polyurethane resin solution, the resultant was dried for 1 minutes
in a 130.degree. C. dryer. Next, embossing was performed thereon
with the embossing machine at a roll temperature of 120.degree. C.,
a roll pressure of 1470 N/cm, and a fabric speed of 3 m/min. As the
roll, three types of rollers A to C described above were used.
[0101] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and a fine uneven-surface design formed by the embossing
was imparted to the entire surface of the fabric. In the
polyurethane resin applied portion of this designed fabric, the
application depth of the polyurethane resin was 53 .mu.m, the
filling ratio of the fibers was 50.5%, the filling ratio of the
polyurethane resin was 42.1%, the void ratio was 7.4%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 1.5,
the circumferential length of filament cross-sections was 1996
.mu.m, and the thickness of the fabric was 610 .mu.m. Evaluation
results are shown in Table 1.
Example 5
[0102] Using a 26-gauge double knit circular knitting machine, a
polyethylene terephthalate flame retardant yarn of 110 dtex/48 f
was used as a rear yarn (3F, 6F), a polyethylene terephthalate
flame retardant yarn of 110 dtex/36 f was used as a bonding yarn
(2F, 5F), a polyethylene terephthalate false twisted yarn of 84
dtex/94 f was used as a face yarn (1F, 3F), and a double knit gray
fabric was knitted according to a weave diagram of FIG. 4. Next,
this was subjected to dyeing by the dyeing machine with a gray
disperse dye at 130.degree. C. for 60 minutes. Next, by the card
cloth raising machine provided with the card cloth roll having 12
pile rollers and 12 counter pile rollers, semi-cut raising was
performed by performing raising thereon 13 times alternately in a
knitting end direction and in a knitting start direction at a card
cloth roller torque of 2.5 MPa and a fabric speed of 12 m/min.
Next, the resultant was subjected to a heat treatment by the heat
setter at 190.degree. C. for 1 minute and was finished. The
obtained fabric had a density of 73 loops/25.4 mm in the course, a
density of 34 loops/25.4 mm in the wale, and a fineness of 2912
dtex per 1 mm.sup.3 volume.
[0103] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 130.degree. C., a roll pressure of 1470 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0104] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and a fine uneven-surface design formed by the embossing
was imparted to the entire surface of the fabric. In the
polyurethane resin applied portion of this designed fabric, the
application depth of the polyurethane resin was 84 .mu.m, the
filling ratio of the fibers was 66.2%, the filling ratio of the
polyurethane resin was 24.8%, the void ratio was 9.0%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 4.1,
the circumferential length of filament cross-sections was 2924
.mu.m, and the thickness of the fabric was 600 .mu.m. Evaluation
results are shown in Table 1.
Example 6
[0105] Using a 22-gauge double raschel knitting machine with 6
reeds, a polyethylene terephthalate false twisted yarn of 84
dtex/36 f as a ground yarn was fed through reeds L1 and L6 in a
full set, a polyethylene terephthalate false twisted yarn of 110
dtex/94 f as a ground yarn was fed through reeds L2 and L5 in a
full set, a polyethylene terephthalate false twisted yarn of 84
dtex/216 f as a pile yarn was fed through reeds L3 and L4 in a full
set, and a double raschel knitted gray fabric was knitted according
to the following weaves. [0106] Reed L1: 1-2/1-1/1-0/1-1 [0107]
Reed L2: 1-0/1-1/1-2/1-1 [0108] Reed L3: 1-0/0-1 [0109] Reed L4:
1-0/0-1 [0110] Reed L5: 1-0/1-1/1-2/1-1 [0111] Reed L6:
1-2/1-1/1-0/1-1
[0112] The gray fabric was center-cut and trimmed. Next, this was
subjected to dyeing by the dyeing machine with a gray disperse dye
at 130.degree. C. for 60 minutes. Next, the resultant was subjected
to a heat treatment by the heat setter at 190.degree. C. for 1
minute and was finished. The obtained fabric had a density of 53
loops/25.4 mm in the course, a density of 38 loops/25.4 mm in the
wale, and a fineness of 1259 dtex per 1 mm.sup.3 volume.
[0113] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 110.degree. C., a roll pressure of 1960 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0114] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and a fine uneven-surface design formed by the embossing
was imparted to the entire surface of the fabric. In the
polyurethane resin applied portion of this designed fabric, the
application depth of the polyurethane resin was 96 .mu.m, the
filling ratio of the fibers was 63.1%, the filling ratio of the
polyurethane resin was 27.9%, the void ratio was 9.0%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 9.6,
the circumferential length of filament cross-sections was 4609
.mu.m, and the thickness of the fabric was 1200 .mu.m. Evaluation
results are shown in Table 1.
Example 7
[0115] Using a 22-gauge double raschel knitting machine with 6
reeds, a polyethylene terephthalate false twisted yarn of 167
dtex/30 f as a rear ground weave ground yarn was fed through reeds
L1 and L2 in a full set, a polyethylene terephthalate false twisted
yarn of 33 dtex/1 f as a connecting yarn was fed through a reed L3
in a full set, a polyethylene terephthalate false twisted yarn of
330 dtex/144 f as a connecting yarn was fed through a reed L4 in a
full set, a polyethylene terephthalate false twisted yarn of 220
dtex/288 f as a face ground weave ground yarn was fed through a
reed L5 in a full set, a polyethylene terephthalate false twisted
yarn of 110 dtex/144 f as a face ground weave ground yarn was fed
through a reed L6 in 1 in 3 out, and a double raschel knitted gray
fabric was knitted according to the following weaves. [0116] Reed
L1: 1-0/0-0/2-3/3-3 [0117] Reed L2: 0-1/1-1/2-1/1-1 [0118] Reed L3:
0-1/0-1/1-0/1-0 [0119] Reed L4:
0-0/0-1/0-0/0-1/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-0/0-
-0/0-0 [0120] Reed L5: 0-0/0-1/1-1/1-0 [0121] Reed L6:
0-0/4-4/4-4/0-0/0-0/4-4/4-4/0-0/0-0/8-8/8-8/0-0/0-0/8-8/8-8
[0122] Next, this was subjected to dyeing by the dyeing machine
with a gray disperse dye at 130.degree. C. for 60 minutes. Next,
the resultant was subjected to a heat treatment by the heat setter
at 190.degree. C. for 1 minute and was finished. The obtained
fabric had a density of 43 loops/25.4 mm in the course, a density
of 25 loops/25.4 mm in the wale, and a fineness of 1771 dtex per 1
mm.sup.3 volume.
[0123] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 100.degree. C., a roll pressure of 1764 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0124] In the obtained fabric, the polyurethane resin had permeated
between the fibers in the surface portion of the fabric, the
surface of the fabric was formed by the polyurethane resin and the
fibers, and a fine uneven-surface design formed by the embossing
was imparted to the entire surface of the fabric. In the
polyurethane resin applied portion of this designed fabric, the
application depth of the polyurethane resin was 95 .mu.m, the
filling ratio of the fibers was 70.1%, the filling ratio of the
polyurethane resin was 21.9%, the void ratio was 8.0%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 5.8,
the circumferential length of filament cross-sections was 3329
.mu.m, and the thickness of the fabric was 2500 .mu.m. Evaluation
results are shown in Table 1.
Comparative Example 1
[0125] A polyethylene terephthalate false twisted yarn of 333
dtex/96 f was used as a warp, a polyethylene terephthalate false
twisted yarn of 600 dtex/192 f was used as a weft, and these were
woven into a weft-faced 8-harness satin weave, thereby obtaining a
gray fabric. Next, a heat treatment was performed at 190.degree. C.
for 1 minute by the heat setter. The density of the warps of the
obtained fabric was 78 pieces/25.4 mm, the density of wefts was 36
pieces/25.4 mm, and the fineness per 1 mm.sup.3 volume was 2341
dtex.
[0126] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 150.degree. C., a roll pressure of 588 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0127] In the obtained product, the application depth of the
polyurethane resin was 37 .mu.m, the filling ratio of the fibers
was 64.9%, the filling ratio of the polyurethane resin was 20.1%,
the void ratio was 15.0%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 1.3, the circumferential length of
filament cross-sections was 1480 .mu.m. Evaluation results are
shown in Table 1.
Comparative Example 2
[0128] Using a 2-reed tricot knitting machine, a polyethylene
terephthalate false twisted yarn of 55 dtex/24 f was used for L1
(front yarn) for a 2-needle swing cord stitch (1-0/4-5), a
polyethylene terephthalate false twisted yarn of 33 dtex/12 f was
used for L2 (back yarn) for a denbigh stitch (1-0/1-2), these were
each knitted by full set threading, thereby obtaining a gray
fabric. Next, this was subjected to dyeing by the dyeing machine
with a gray disperse dye at 130.degree. C. for 60 minutes. Next, by
the card cloth raising machine provided with the card cloth roll
having 12 pile rollers and 12 counter pile rollers, full cut
raising was performed by performing raising thereon 13 times
alternately in a knitting end direction and in a knitting start
direction at a card cloth roller torque of 2.5 MPa and a fabric
speed of 12 m/min. Next, the resultant was subjected to a heat
treatment by the heat setter at 190.degree. C. for 1 minute and was
finished. The obtained fabric had a density of 66 loops/25.4 mm in
the course, a density of 36 loops/25.4 mm in the wale, and a
fineness of 915 dtex per 1 mm.sup.3 volume.
[0129] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. After applying the polyurethane resin, the resultant was
dried for 10 minutes in the 90.degree. C. dryer. The application
amount of the polyurethane resin was about 30 g/m.sup.2 in terms of
mass after drying. Next, embossing was performed thereon with the
embossing machine at a roll temperature of 120.degree. C., a roll
pressure of 1470 N/cm, and a fabric speed of 3 m/min. As the roll,
three types of rollers A to C described above were used.
[0130] In the obtained product, the application depth of the
polyurethane resin was 27 .mu.m, the filling ratio of the fibers
was 14.6%, the filling ratio of the polyurethane resin was 62.0%,
the void ratio was 23.4%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 0.1, the circumferential length of
filament cross-sections was 409 .mu.m. Evaluation results are shown
in Table 1.
Comparative Example 3
[0131] A polyethylene terephthalate false twisted yarn of 167
dtex/288 f was used as a warp, a polyethylene terephthalate false
twisted yarn of 167 dtex/288 f was used as a weft, and these were
woven into a warp-faced 5-harness satin weave, thereby obtaining a
gray fabric. Next, a heat treatment was performed at 190.degree. C.
for 1 minute by the heat setter. The density of the warps of the
obtained fabric was 178 pieces/25.4 mm, the density of wefts was 65
pieces/25.4 mm, and the fineness per 1 mm.sup.3 volume was 4204
dtex.
[0132] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 60 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer. In
the obtained fabric, the fibers were not exposed to the surface,
and a polyurethane resin layer was formed thereon. Next, embossing
was performed thereon with the embossing machine at a roll
temperature of 150.degree. C., a roll pressure of 588 N/cm, and a
fabric speed of 3 m/min. As the roll, three types of rollers A to C
described above were used.
[0133] In the obtained product, the application depth of the
polyurethane resin was 35 .mu.m, the filling ratio of the fibers
was 70.4%, the filling ratio of the polyurethane resin was 23.6%,
the void ratio was 6.0%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 7.4, the circumferential length of
filament cross-sections was 3931 .mu.m. The polyurethane resin was
in the form of a film. Evaluation results are shown in Table 1.
Comparative Example 4
[0134] A product was obtained in the same manner as in Comparative
Example 1 except that the number of applications was changed to
cause the application amount of the polyurethane resin to be 15
g/m.sup.2 in terms of mass after drying. In the obtained product,
the application depth of the polyurethane resin was 40 .mu.m, the
filling ratio of the fibers was 64.9%, the filling ratio of the
polyurethane resin was 9.5%, the void ratio was 25.6%, the number
of fibers per 100 .mu.m.sup.2 of the polyurethane resin was 2.8,
the circumferential length of filament cross-sections was 1480
.mu.m. Evaluation results are shown in Table 1.
Comparative Example 5
[0135] A polyethylene terephthalate split yarn of 122 dtex/444 f
was used as a warp, a polyethylene terephthalate split yarn of 244
dtex/888 f was used as a weft, and these were woven into a
warp-faced 5-harness satin weave, thereby obtaining a gray fabric.
Next, a heat treatment was performed at 190.degree. C. for 1 minute
by the heat setter. The density of the warps of the obtained fabric
was 232 pieces/25.4 mm, the density of wefts was 110 pieces/25.4
mm, and the fineness per 1 mm.sup.3 volume was 5713 dtex.
[0136] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by screen printing. The number
of applications was set so that the application amount of the
polyurethane resin was 60 g/m.sup.2 in terms of mass after drying.
After applying the polyurethane resin solution, the resultant was
dried for 10 minutes in the 90.degree. C. dryer. Next, embossing
was performed thereon with the embossing machine at a roll
temperature of 150.degree. C., a roll pressure of 588 N/cm, and a
fabric speed of 3 m/min. As the roll, three types of rollers A to C
described above were used.
[0137] In the obtained product, the application depth of the
polyurethane resin was 42 .mu.m, the filling ratio of the fibers
was 86.2%, the filling ratio of the polyurethane resin was 10.0%,
the void ratio was 3.8%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 48.2, the circumferential length of
filament cross-sections was 7215 .mu.m. The polyurethane resin was
in the form of a film. Evaluation results are shown in Table 1.
Comparative Example 6
[0138] A polyethylene terephthalate false twisted yarn of 333
dtex/96 f was used as a warp, a polyethylene terephthalate false
twisted yarn of 600 dtex/192 f was used as a weft, and these were
woven into a warp-faced 5-harness satin weave, thereby obtaining a
gray fabric. Next, a heat treatment was performed at 190.degree. C.
for 1 minute by the heat setter. The density of the warps of the
obtained fabric was 78 pieces/25.4 mm, the density of wefts was 36
pieces/25.4 mm, and the fineness per 1 mm.sup.3 volume was 2341
dtex.
[0139] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 160.degree. C., a roll pressure of 490 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0140] In the obtained product, the application depth of the
polyurethane resin was 130 .mu.m, the filling ratio of the fibers
was 72.2%, the filling ratio of the polyurethane resin was 12.4%,
the void ratio was 15.4%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 2.4, the circumferential length of
filament cross-sections was 1647 .mu.m. Evaluation results are
shown in Table 1.
Comparative Example 7
[0141] The woven fabric after the heat treatment by the heat setter
of Comparative Example 6 was used. By the card cloth raising
machine provided with the card cloth roll having 12 pile rollers
and 12 counter pile rollers, semi-cut raising was performed by
performing raising on the rear surface (weft-faced side) of the
woven fabric 13 times alternately in a knitting end direction and
in a knitting start direction at a card cloth roller torque of 2.5
MPa and a fabric speed of 12 m/min. Next, the resultant was
subjected to a heat treatment by the heat setter at 190.degree. C.
for 1 minute and was finished.
[0142] Next, the polyurethane resin "RYUDTE-W BINDER UF6025"
(manufactured by DIC Corporation) solution (solid content 28 mass
%) was applied to the entire raised surface by the screen printing
machine. The number of applications was set so that the application
amount of the polyurethane resin was 30 g/m.sup.2 in terms of mass
after drying. After applying the polyurethane resin solution, the
resultant was dried for 10 minutes in the 90.degree. C. dryer.
Next, embossing was performed thereon with the embossing machine at
a roll temperature of 160.degree. C., a roll pressure of 490 N/cm,
and a fabric speed of 3 m/min. As the roll, three types of rollers
A to C described above were used.
[0143] In the obtained product, the application depth of the
polyurethane resin was 158 .mu.m, the filling ratio of the fibers
was 40.0%, the filling ratio of the polyurethane resin was 20.7%,
the void ratio was 40.3%, the number of fibers per 100 .mu.m.sup.2
of the polyurethane resin was 0.8, the circumferential length of
filament cross-sections was 888 .mu.m. Evaluation results are shown
in Table 1.
Comparative Example 8
[0144] A product was obtained in the same manner as in Comparative
Example 7 except that the application amount of the polyurethane
resin was caused to be 50 g/m.sup.2 in terms of mass after drying
and the embossing conditions were set to a roll temperature of
130.degree. C. In the obtained product, the application depth of
the polyurethane resin was 161 .mu.m, the filling ratio of the
fibers was 42.1%, the filling ratio of the polyurethane resin was
12.0%, the void ratio was 45.9%, the number of fibers per 100
.mu.m.sup.2 of the polyurethane resin was 1.4, the circumferential
length of filament cross-sections was 959 .mu.m. Evaluation results
are shown in Table 1.
Comparative Example 9
[0145] A product was obtained in the same manner as in Comparative
Example 7 except that the application amount of the polyurethane
resin was caused to be 10 g/m.sup.2 in terms of mass after drying
and the embossing conditions were set to a roll temperature of
130.degree. C. In the obtained product, the application depth of
the polyurethane resin was 31 .mu.m, the filling ratio of the
fibers was 42.8%, the filling ratio of the polyurethane resin was
25.7%, the void ratio was 30.0%, the number of fibers per 100
.mu.m.sup.2 of the polyurethane resin was 0.7, the circumferential
length of filament cross-sections was 977 .mu.m. Evaluation results
are shown in Table 1.
[0146] The products obtained in Examples 1 to 7 were excellent in
any of the shaping properties, flexibility, and wear resistance of
the uneven-surface design. On the other hand, the products obtained
in Comparative Examples 1, 2, 4, 8, and 9 were inferior in the
evaluation of the shaping properties and wear resistance. The
products obtained in Comparative Examples 3 and 5 were inferior in
the evaluation of the flexibility. The product obtained in
Comparative Example 6 was inferior in the evaluation of the shaping
properties. The product obtained in Comparative Example 7 was
inferior in the evaluation of the wear resistance.
TABLE-US-00001 TABLE 1 Example Example Example Example Example
Example Example Comparative Comparative 1 2 3 4 5 6 7 Example 1
Example 2 Woven fabric used [Table 2] Woven Woven Woven fabric A
fabric B fabric C Knitted fabric used [Table 3] Knitted Knitted
Knitted Knitted Knitted Knitted fabric a fabric b fabric c fabric d
fabric e fabric f Polyurethane Application 98 92 66 53 84 96 95 37
27 resin applied depth of portion polyurethane resin (.mu.m)
Filling ratio of 26.4 25.4 30.9 42.1 24.8 27.9 21.9 20.1 62.0
polyurethane resin (%) Filling ratio of 69.1 66.2 59.6 50.5 66.2
63.1 70.1 64.9 14.6 fibers (%) Void ratio (%) 4.5 8.4 9.5 7.4 9.0
9.0 8.0 15.0 23.4 Number of 6.5 4.0 2.4 1.5 4.1 9.6 5.8 1.3 0.1
fibers per 100 .mu.m.sup.2 of polyurethane resin Sum of outer 3863
2934 2353 1996 2924 4609 3329 1480 409 circumferential lengths of
fiber cross-section (.mu.m) (per unit area 10,000 .mu.m.sup.2)
Evaluation Shaping 1 1 2 2 1 1 1 4 4 items properties Wear 1 1 1 1
1 1 1 2 3 resistance Flexibility 1 1 1 1 1 1 1 1 2 Comparative
Comparative Comparative Comparative Comparative Comparative
Comparative Example 3 Example 4 Example 5 Example 6 Example 7
Example 8 Example 9 Woven fabric used [Table 2] Woven Woven Woven
Woven Woven Woven Woven fabric D fabric C fabric E fabric F fabric
F fabric F fabric F Knitted fabric used [Table 3] Polyurethane
Application 35 40 42 130 158 161 31 resin applied depth of portion
polyurethane resin (.mu.m) Filling ratio of 23.6 9.5 10.0 12.4 20.7
12.0 25.7 polyurethane resin (%) Filling ratio of 70.4 64.9 86.2
72.2 40.0 42.1 42.8 fibers (%) Void ratio (%) 6.0 25.6 3.8 15.4
40.3 45.9 30.0 Number of 7.4 2.8 48.2 2.4 0.8 1.4 0.7 fibers per
100 .mu.m.sup.2 of polyurethane resin Sum of outer 3931 1480 7215
1647 888 959 977 circumferential lengths of fiber cross-section
(.mu.m) (per unit area 10,000 .mu.m.sup.2) Evaluation Shaping 1 4 1
4 2 4 4 items properties Wear 1 3 1 1 3 3 3 resistance Flexibility
2 1 2 1 1 1 1
TABLE-US-00002 TABLE 2 Woven Woven Woven Woven Woven Woven fabric A
fabric B fabric C fabric D fabric E fabric F Warp Type
Multifilament Multifilament Multifilament Multifilament
Multifilament Multifilament false false false false split yarn
false twisted yarn twisted yarn twisted yarn twisted yarn twisted
yarn Yarn fineness 167 178 333 167 122 333 (dtex) Number of 288 24
96 288 444 96 filaments (pieces) Single fiber 0.58 7.42 3.47 0.58
0.27 3.47 fineness (dtex) Weft Type Multifilament Multifilament
Multifilament Multifilament Multifilament Multifilament false false
false false split yarn false twisted yarn twisted yarn twisted yarn
twisted yarn twisted yarn Yarn fineness 167 167 600 167 244 600
(dtex) Number of 48 144 192 288 888 192 filaments (pieces) Single
fiber 3.48 1.16 3.13 0.58 0.27 3.13 fineness (dtex) Warp density
178 184 78 178 232 78 (pieces/25.4 mm) Weft density 61 88 36 65 110
36 (pieces/25.4 mm) Fabric thickness (mm) 0.40 0.60 0.80 0.38 0.38
0.80 Fineness per unit volume 1 3928 3113 2341 4204 5713 2341
mm.sup.3 (dtex) Weave formation Warp-faced Warp-faced Weft-faced
Warp-faced Warp-faced Warp-faced 5-harness satin 8-harness satin
8-harness satin 5-harness satin 5-harness satin 5-harness satin
Weft-faced 8-harness satin weave
TABLE-US-00003 TABLE 3 Knitted Knitted Knitted Knitted Knitted
Knitted fabric a fabric b fabric c fabric d fabric e fabric f
tricot tricot circular knit double raschel double raschel tricot L1
or Type Multifilament Multifilament Multifilament Multifilament
Multifilament Multifilament face yarn (false yarn (false yarn
(false yarn (false yarn (false yarn (false yarn twisted yarn)
twisted yarn) twisted yarn) twisted yarn) twisted yarn) twisted
yarn) Yarn fineness (dtex) 84 84 84 84 167 55 Number of filaments
(pieces) 96 72 94 36 30 24 Single fiber fineness (dtex) 0.88 1.17
0.89 2.33 5.57 2.29 L2 or Type Multifilament Multifilament
Multifilament Multifilament Multifilament Multifilament bonding
yarn (flame yarn (false yarn (flame yarn (false yarn (false yarn
(false yarn retardant twisted yarn) retardant twisted yarn) twisted
yarn) twisted yarn) yarn) yarn) Yarn fineness (dtex) 84 84 110 110
167 33 Number of filaments (pieces) 36 36 36 94 30 12 Single fiber
fineness (dtex) 2.33 2.33 3.06 1.17 5.57 2.75 L3 or Type
Multifilament Multifilament Multifilament Multifilament
Multifilament rear yarn (flame yarn (false yarn (flame yarn (false
yarn (false yarn retardant twisted yarn) retardant twisted yarn)
twisted yarn) yarn) yarn) Yarn fineness (dtex) 84 84 110 84 33
Number of filaments (pieces) 36 36 48 216 1 Single fiber fineness
(dtex) 2.33 2.33 2.29 0.39 33.00 L4 Type Multifilament
Multifilament yarn (false yarn (false twisted yarn) twisted yarn)
Yarn fineness (dtex) 84 330 Number of filaments (pieces) 216 144
Single fiber fineness (dtex) 0.39 2.29 L5 Type Multifilament
Multifilament yarn (false yarn (false twisted yarn) twisted yarn)
Yarn fineness (dtex) 110 220 Number of filaments (pieces) 94 288
Single fiber fineness (dtex) 1.17 0.76 L6 Type Multifilament
Multifilament yarn (false yarn (false twisted yarn) twisted yarn)
Yarn fineness (dtex) 84 110 Number of filaments (pieces) 36 144
Single fiber fineness (dtex) 2.33 0.76 Course density (loops/25.4
mm) 71 67 73 53 43 66 Wale density (loops/25.4 mm) 38 28 34 38 25
36 Fabric thickness (mm) 0.61 0.61 0.60 1.20 2.50 0.50 Nap length
(.mu.m) 1060 1514 -- 900 -- -- Fineness per unit volume 1 mm.sup.3
(dtex) 2310 2179 2912 1259 1771 915
* * * * *