U.S. patent application number 15/780500 was filed with the patent office on 2018-12-20 for woven fabric.
This patent application is currently assigned to Toray Industries ,Inc.. The applicant listed for this patent is Toray Industries, Inc.. Invention is credited to Satoshi NARUKO, Hiroshi TSUCHIKURA, Ryosuke YAMAO.
Application Number | 20180363171 15/780500 |
Document ID | / |
Family ID | 58797435 |
Filed Date | 2018-12-20 |
United States Patent
Application |
20180363171 |
Kind Code |
A1 |
NARUKO; Satoshi ; et
al. |
December 20, 2018 |
WOVEN FABRIC
Abstract
A woven fabric hardly causes yarn slippage due to friction, is
excellent in abrasion resistance, has a smooth surface, and is
excellent in touch feeling. The woven fabric includes a warp and a
weft, at least one of the warp and the weft being at least
partially a fiber (M) that is a monofilament 1, a fiber (N)
crossing the fiber (M) being at least partially a multifilament
2.
Inventors: |
NARUKO; Satoshi; (Otsu,
JP) ; TSUCHIKURA; Hiroshi; (Otsu, JP) ; YAMAO;
Ryosuke; (Osaka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Toray Industries, Inc. |
Tokyo |
|
JP |
|
|
Assignee: |
Toray Industries ,Inc.
Tokyo
JP
|
Family ID: |
58797435 |
Appl. No.: |
15/780500 |
Filed: |
December 2, 2016 |
PCT Filed: |
December 2, 2016 |
PCT NO: |
PCT/JP2016/085908 |
371 Date: |
May 31, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 15/0027 20130101;
D10B 2331/04 20130101; D03D 1/04 20130101; D03D 1/0041 20130101;
D03D 13/008 20130101; D03D 15/00 20130101 |
International
Class: |
D03D 15/00 20060101
D03D015/00; D03D 13/00 20060101 D03D013/00; D03D 1/00 20060101
D03D001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 3, 2015 |
JP |
2015-236198 |
Claims
1.-7. (canceled)
8. A woven fabric comprising a warp and a weft, at least one of the
warp and the weft being at least partially a fiber (M) that is a
monofilament 1, a fiber (N) crossing the fiber (M) being at least
partially a multifilament 2, the woven fabric satisfying either one
of conditions (1) and (2): (1) the monofilament 1 is fused to the
multifilament 2, and a multifilament coverage ratio a/L and a
monofilament concealment ratio h/b satisfy both formulae (A) and
(B): 1.0.ltoreq.a/L.ltoreq.1.5 (A) 0.5.ltoreq.h/b.ltoreq.1.0 (B);
and (2) the monofilament 1 is not fused to the multifilament 2, and
the multifilament coverage ratio a/L and the monofilament
concealment ratio h/b satisfy both formulae (C) and (D):
1.0.ltoreq.a/L.ltoreq.1.5 (C) 0.7.ltoreq.h/b.ltoreq.1.0 (D) wherein
a, b, L, and h each have meanings: a: length of the multifilament 2
in a cross section thereof in a direction of woven fabric surface;
b: length of the multifilament 2 in a cross section thereof in a
direction of woven fabric thickness; L: center-to-center distance
between filaments of the multifilament 2 adjacent across the fiber
(M); and h: crimp height of the monofilament 1.
9. The woven fabric according to claim 8, wherein the multifilament
2 has a cover factor of 800 or more and 1200 or less.
10. The woven fabric according to claim 8, wherein the
multifilament 2 has a twist coefficient of 0 or more and 10000 or
less.
11. The woven fabric according to claim 8, wherein the monofilament
1 has a flexural rigidity of 1 cN or more and 6 cN or less.
12. The woven fabric according to claim 8, wherein the monofilament
1 is a core-sheath composite yarn in which a sheath component has a
melting point at least 10.degree. C. lower than that of a core
component.
13. The woven fabric according to claim 8, having, in an abrasion
test according to JIS L1096 (2010) 8.19.3, method C, a weight
reduction after 4000 times less than 0.5 g, and no hole.
14. The woven fabric according to claim 8, having a mean friction
coefficient MIU as a KES surface friction property value of 0.10 to
0.42, and a deviation of mean friction coefficient MMD of 0.01 to
0.07.
Description
TECHNICAL FIELD
[0001] This disclosure relates to a woven fabric. More
particularly, the disclosure relates to a woven fabric that can be
preferably used in shoes, work clothes, bags and the like, and is
excellent in abrasion resistance and touch feeling.
BACKGROUND
[0002] Various kinds of fabrics have been proposed in which either
one of a warp and a weft is at least partially a monofilament, and
a fiber crossing a fiber including the monofilament is at least
partially a multifilament. For example, Japanese Patent Laid-open
Publication No. 11-200178 discloses a mesh body including a
polypropylene multifilament as, for example, a warp, and a
core-sheath composite polypropylene monofilament as a weft. The
mesh body is obtained by melting the core-sheath composite
polypropylene monofilament with the sheath melting temperature set
at a temperature higher than the core melting temperature, weaving
the warp and weft, and heating the resultant to melt the
polypropylene in the sheath section to fix the warp and the weft
together.
[0003] Moreover, Japanese Patent Laid-open Publication No.
2002-201548 discloses an abrasion-resistant woven fabric for a skin
material having a soft texture, including a polytrimethylene
terephthalate multifilament as a weft and a polytrimethylene
terephthalate monofilament as a warp (Example 6 of Japanese Patent
Laid-open Publication No. 2010-236116).
[0004] In addition to the above, Japanese Patent Laid-open
Publication No. 2010-236116 proposes, as a fabric improved in
abrasion resistance, a fabric including a core-sheath composite
fiber. The core-sheath composite fiber contains a polymer forming a
core section and a polymer in a sheath section, having a melting
point lower than that of the polymer in the core section, and the
sheath section is thermally fused to fix the fiber filaments
together so that the fabric is suppressed in the occurrence of yarn
slippage.
[0005] Conventionally, in fabric products such as shoes, work
clothes, and bags, fabrics are layered, or processed fabrics having
a coating of a synthetic rubber or the like, or artificial leather
coated with urethane or the like is used in cuffs, protrusions, and
corners that are frequently rubbed to resist repeated friction.
Either of the methods has problems that the resultant fabric
product is thick and heavy, low in air permeability, and poor in
touch feeling, and the cost increases due to such processing.
Therefore, a fabric excellent in abrasion resistance and touch
feeling, and also has lightweight properties and air permeability
has been desired.
[0006] Since the woven fabric disclosed in Japanese Patent
Laid-open Publication No. 11-200178 is intended for construction
work, Japanese Patent Laid-open Publication No. 11-200178 does not
consider the touch feeling of the woven fabric, and does not
disclose any specific structure of a woven fabric good in touch
feeling.
[0007] Moreover, although Japanese Patent Laid-open Publication No.
2002-201548 describes a woven fabric for a skin material disclosed
therein, physical properties of the polytrimethylene terephthalate
fiber and the elastic recovery of the woven fabric, it is silent on
any simple evaluation index in the actual weaving. It is impossible
to obtain a woven fabric excellent in abrasion resistance and soft
texture by carrying out the disclosure of Japanese Patent Laid-open
Publication No. 2002-201548 as it is.
[0008] In the fabric disclosed in Japanese Patent Laid-open
Publication No. 2010-236116, although the yarn slippage is
suppressed due to the fused and fixed fiber filaments crossing each
other and the fabric is improved in abrasion resistance, the fabric
is poor in touch feeling since the fused and solidified fiber
filament contacts another fiber filament that is rubbed
thereon.
[0009] It could therefore be helpful to provide a woven fabric
excellent in abrasion resistance against repeated sliding, good in
touch feeling, and suitable for a fabric product.
SUMMARY
[0010] We thus provide:
[0011] A woven fabric including a warp and a weft,
[0012] at least one of the warp and the weft being at least
partially a fiber (M) that is a monofilament 1,
[0013] a fiber (N) crossing the fiber (M) being at least partially
a multifilament 2,
[0014] the woven fabric satisfying either one of the following
conditions (1) and (2):
[0015] (1) the monofilament 1 is fused to the multifilament 2, and
a multifilament coverage ratio a/L and a monofilament concealment
ratio h/b satisfy both the formulae (A) and (B):
1.0.ltoreq.a/L.ltoreq.1.5 (A)
0.5.ltoreq.h/b.ltoreq.1.0 (B); and
[0016] (2) the monofilament 1 is not fused to the multifilament 2,
and the multifilament coverage ratio a/L and the monofilament
concealment ratio h/b satisfy both the formulae (C) and (D):
1.0.ltoreq.a/L.ltoreq.1.5 (C)
0.7.ltoreq.h/b.ltoreq.1.0 (D)
[0017] wherein a, b, L, and h each have the following meanings:
[0018] a: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric surface;
[0019] b: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric thickness;
[0020] L: center-to-center distance between filaments of the
multifilament 2 adjacent across the fiber (M); and
[0021] h: crimp height of the monofilament 1.
[0022] Preferably, in the above woven fabric, the multifilament 2
has a cover factor of 800 or more and 1200 or less.
[0023] Further preferably, the multifilament 2 has a twist
coefficient of 0 or more and 10000 or less.
[0024] Also preferably, the monofilament 1 has a flexural rigidity
of 1 cN or more and 6 cN or less.
[0025] Still further preferably, the monofilament 1 is a
core-sheath composite yarn in which a sheath component has a
melting point that is at least 10.degree. C. lower than that of a
core component.
[0026] The woven fabric may show, in the abrasion test according to
JIS L1096 (2010) 8.19.3, method C, a weight reduction after 4000
times less than 0.5 g, and no hole.
[0027] The woven fabric may have a mean friction coefficient MIU as
a KES surface friction property value of 0.10 to 0.42, and a
deviation of mean friction coefficient MMD of 0.01 to 0.07.
[0028] It is possible to achieve a state in which the monofilament
having an advantage of ensuring the abrasion resistance and the
multifilament having an advantage of ensuring the touch feeling are
suitably arranged, and a woven fabric excellent in abrasion
resistance and touch feeling is provided. Further, the monofilament
and the multifilament are fused together to satisfy the
above-mentioned condition (1), or are not fused together to satisfy
the above-mentioned condition (2) so that the yarn slippage of the
woven fabric is effectively suppressed, and the woven fabric is
further improved in abrasion resistance. It is also possible to
provide a woven fabric in which proper arrangement of the warp and
weft is hardly disturbed, and maintains a good touch feeling.
[0029] A cover factor of the multifilament within the specific
range gives an appropriate binding force between the warp and the
weft, and maintains the crimp shape of the multifilament well. As a
result, a woven fabric excellent in lightweight properties and
durability, and also good in touch feeling and air permeability is
provided.
[0030] A twist coefficient of the multifilament within the specific
range easily gives a flat sectional shape of the multifilament, and
ensures a large contact area with the monofilament. As a result, a
large number of single yarns are in contact with the monofilament.
Since the force applied to one single yarn is distributed, the
single yarn breakage hardly occurs, and a woven fabric more
excellent in abrasion resistance and good in touch feeling is
provided.
[0031] A flexural rigidity of the monofilament within the specific
range can suppress the occurrence of yarn slippage due to a low
flexural rigidity of the monofilament. At the same time, it is
possible to prevent yarn slippage due to insufficient yarn binding
force, which is caused by the deterioration of crimp shape
maintaining performance due to an excessively high flexural
rigidity, and to prevent the deterioration of abrasion resistance
due to a low monofilament concealment ratio h/b.
[0032] It is possible to easily provide a woven fabric excellent in
abrasion resistance and touch feeling without the use of a fusing
agent for fusing the warp and the weft together.
[0033] It is possible to provide a woven fabric excellent in
durability against friction in fabric products such as shoes, work
clothes, and bags.
[0034] It is possible to provide a woven fabric having a smooth
surface and good in touch feeling in fabric products such as shoes,
work clothes, and bags.
[0035] As described above, since the woven fabric is excellent in
abrasion resistance and good in touch feeling, the woven fabric can
be suitably used alone in fabric products to be worn such as shoes,
work clothes, and bags, and personal fabric products. Moreover,
application of the woven fabric is not limited to the above, and
the woven fabric can be used in various fabric products for which
abrasion resistance and soft tactile sensation are required such as
a skin material for a vehicle seat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a schematic cross-sectional view of a woven fabric
that gives an outline of measurement sites for obtaining a
multifilament coverage ratio and a monofilament concealment
ratio.
[0037] FIG. 2 is a schematic cross-sectional view illustrating the
definitions of the length a of the multifilament in a cross section
thereof in a direction of woven fabric surface, and the length b of
the multifilament in a cross section thereof in a direction of
woven fabric thickness when the woven fabric has a plain weave
structure.
[0038] FIG. 3 is a schematic cross-sectional view illustrating the
definitions of the length a of the multifilament in a cross section
thereof in a direction of woven fabric surface, and the length b of
the multifilament in a cross section thereof in a direction of
woven fabric thickness when the woven fabric has a 2/2 twill woven
fabric structure.
[0039] FIG. 4 is a schematic cross-sectional view illustrating the
definitions of the center-to-center distance L between adjacent
filaments of the multifilament, and the crimp height h of the
monofilament when the woven fabric has a plain weave structure.
[0040] FIG. 5 is a schematic cross-sectional view illustrating the
definitions of the center-to-center distance L between adjacent
filaments of the multifilament, and the crimp height h of the
monofilament when the woven fabric has a 2/2 twill woven fabric
structure.
DESCRIPTION OF REFERENCE SIGNS
[0041] 1: Monofilament [0042] 2: Multifilament [0043] a: Length of
multifilament 2 in cross section thereof in direction of woven
fabric surface [0044] b: Length of multifilament 2 in cross section
thereof in direction of woven fabric thickness [0045] L:
Center-to-center distance between filaments of multifilament 2
adjacent across fiber (M) [0046] h: Crimp height of monofilament 1
[0047] B: Bottom of multifilament [0048] C1: Crimp apex [0049] C2:
Crimp apex
DETAILED DESCRIPTION
[0050] Hereinafter, woven fabrics will be described in detail.
[0051] The woven fabric is a woven fabric including a warp and a
weft, at least one of the warp and the weft being at least
partially a fiber (M) that is a monofilament 1, a fiber (N)
crossing the fiber (M) being at least partially a multifilament 2,
the woven fabric satisfying either one of conditions (1) and
(2):
[0052] (1) the monofilament 1 is fused to the multifilament 2, and
a multifilament coverage ratio a/L and a monofilament concealment
ratio h/b satisfy both the formulae (A) and (B):
1.0.ltoreq.a/L.ltoreq.1.5 (A)
0.5.ltoreq.h/b.ltoreq.1.0 (B); and
[0053] (2) the monofilament 1 is not fused to the multifilament 2,
and the multifilament coverage ratio a/L and the monofilament
concealment ratio h/b satisfy both the formulae (C) and (D):
1.0.ltoreq.a/L.ltoreq.1.5 (C)
0.7.ltoreq.h/b.ltoreq.1.0 (D)
[0054] wherein a, b, L, and h each have the following meanings:
[0055] a: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric surface;
[0056] b: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric thickness;
[0057] L: center-to-center distance between filaments of the
multifilament adjacent across the fiber (M); and
[0058] h: crimp height of the monofilament.
[0059] Detailed definitions of a, b, L, and h are as follows. In
the following, the description will be made with reference to FIGS.
1 to 5. FIG. 1 is a schematic cross-sectional view of a woven
fabric that gives an outline of measurement sites for obtaining a
multifilament coverage ratio and a monofilament concealment ratio.
FIG. 1 shows a cut surface of the woven fabric obtained by cutting
a multifilament 2, which crosses a fiber including a monofilament 1
included in a warp or a weft of the woven fabric, in a direction
parallel to the longitudinal direction of the fiber including the
monofilament 1.
[0060] FIG. 2 is a schematic cross-sectional view illustrating the
definitions of the length a of the multifilament 2 in a cross
section thereof in a direction of woven fabric surface, and the
length b of the multifilament 2 in a cross section thereof in a
direction of woven fabric thickness when the woven fabric has a
plain weave structure. The woven fabric is cut in the same
direction as in FIG. 1.
[0061] FIG. 3 is a schematic cross-sectional view illustrating the
definitions of the length a of the multifilament 2 in a cross
section thereof in a direction of woven fabric surface, and the
length b of the multifilament 2 in a cross section thereof in a
direction of woven fabric thickness when the woven fabric has a 2/2
twill woven fabric structure. The woven fabric is cut in the same
direction as in FIG. 1 although the weave structure is
different.
[0062] FIG. 4 is a schematic cross-sectional view illustrating the
definitions of the center-to-center distance L between adjacent
filaments of the multifilament, and the crimp height h of the
monofilament 1 when the woven fabric has a plain weave structure.
The woven fabric is cut in the same direction as in FIG. 1.
[0063] FIG. 5 is a schematic cross-sectional view illustrating the
definitions of the center-to-center distance L between adjacent
filaments of the multifilament, and the crimp height h of the
monofilament when the woven fabric has a 2/2 twill woven fabric
structure. The woven fabric is cut in the same direction as in FIG.
3.
[0064] First, the lengths a and b will be described.
[0065] See FIGS. 2 and 3. A rectangle is simulated, which surrounds
a cross section of one filament of the multifilament 2, two
parallel sides of which are in contact with the cross section of
the filament of the multifilament 2, and the other two parallel
sides of which lie in the thickness direction of the multifilament
2 and a direction perpendicular thereto (that is, the direction of
the woven fabric surface). The length of the side along the
direction of the woven fabric surface is defined as the length a of
the multifilament 2 in a cross section thereof in the direction of
the woven fabric surface, and the length of the side along the
direction perpendicular to the direction of the woven fabric
surface is defined as the length b of the multifilament 2 in a
cross section thereof in the direction of woven fabric
thickness.
[0066] Then, L will be described.
[0067] See FIGS. 4 and 5. In one filament of the monofilament 1 in
contact with the multifilament in the thickness direction, a
distance between two adjacent crimp apexes C1 and C2 is defined as
2*L, and a length of half of 2*L is defined as the center-to-center
distance L between adjacent filaments of the multifilament.
[0068] Finally, h will be described.
[0069] See FIGS. 4 and 5. A rectangle is formed with an upper side
that is the line of the distance 2 L between the adjacent crimp
apexes C1 and C2 of one filament of the monofilament, and a line
that is parallel to the upper side and is in contact with the
bottom B of a multifilament (a point at which the multifilament is
in contact with the monofilament in the direction of the woven
fabric thickness). The height of the rectangle (the length of the
side of the rectangle close to the thickness direction) is defined
as the crimp height h of the monofilament.
[0070] As described above, the woven fabric includes a warp and a
weft, at least one of the warp and the weft is at least partially a
fiber (M) including a monofilament 1, and a fiber (N) crossing the
fiber (M) at least partially includes a multifilament 2. In
particular, it is preferable that a fiber of either one of the warp
and the weft be substantially a monofilament, and a fiber crossing
the above-mentioned fiber be substantially a multifilament. The
wording "substantially" means that a small amount of other fibers
may be used in combination for design and other reasons. For
example, up to 20% by mass, or up to 10% by mass of other fibers
may be used in combination. That is, it is preferable that the
fiber (M) include 80% by mass or more, more preferably 90% by mass
or more of the monofilament 1. Further, it is preferable that the
fiber (N) include 80% by mass or more, more preferably 90% by mass
or more of the multifilament 2.
[0071] A multifilament is a bundle made of a plurality of fiber
filaments. Since a multifilament has a single yarn diameter smaller
than the total fineness, a multifilament exposed to the woven
fabric surface can give a soft tactile sensation when being brought
into contact with the skin. The single yarn of the multifilament,
however, is easily broken due to abrasion. On the other hand, a
monofilament is made of a single fiber filament, has a large single
yarn diameter, and is hardly deformed in the fiber diameter even
when crushed. Therefore, a monofilament exposed to the woven fabric
surface tends to give a hard and rough texture of the surface when
touched, but is hardly broken due to abrasion. We provide a woven
fabric having both abrasion resistance against repeated friction
and a soft touch feeling by the use of fibers having these
contradictory properties, adoption of the parameters of the
monofilament concealment ratio and the multifilament coverage
ratio, and control of both the parameters.
[0072] In the woven fabric, when the multifilament coverage ratio
a/L is 1.0 or more and 1.5 or less and the monofilament is fused to
the multifilament, the monofilament concealment ratio h/b is 0.5 or
more and 1.0 or less.
[0073] The multifilament coverage ratio a/L represents the ratio of
exposure between the multifilament and the monofilament on the
woven fabric surface. Since a monofilament has a large single yarn
diameter, and is hardly deformed in the fiber diameter when being
brought into contact with the skin, a monofilament tends to give a
hard and rough texture of the surface when touched. When a/L is
within the above-mentioned range, the surface of the woven fabric
is covered with the multifilament 2 having a small single yarn
diameter and a soft tactile sensation, the area of the exposed
monofilament 1 is reduced, and a soft touch feeling can be
obtained. If a/L is less than 1.0, the monofilament 1 contacts the
skin too strongly so that the woven fabric tends to be poor in
touch feeling. On the other hand, if a/L is more than 1.5, the
abraded surface cannot be supported by the crimp-shaped apex
portions of the monofilament 1, and many single yarns of the
multifilament 2 are abraded so that the woven fabric tends to be
poor in abrasion resistance. a/L is preferably 1.2 to 1.4.
[0074] The monofilament concealment ratio h/b represents the ratio
of exposure height between the multifilament 2 and the monofilament
1 in the direction of woven fabric thickness. Since the
multifilament 2 has a small single yarn diameter and is easily
broken due to abrasion, if b is too much larger than h, the woven
fabric tends to be poor in abrasion resistance. When h/b is within
the above-mentioned range, the abraded surface is supported by the
crimp-shaped apex portions of the tough monofilament 1, the
multifilament 2 is concealed in the valleys of the monofilament 1,
and the multifilament 2 is protected from the abrasion. As a
result, the woven fabric is excellent in abrasion resistance. When
a surface of a woven fabric is rubbed, the diameter of the fiber
bundle shape of the multifilament 2 is crushed to a certain extent
by the load of rubbing. Therefore, when h/b is within the
above-mentioned range, even if b is larger than h, it is possible
to impart sufficient abrasion resistance and a soft touch feeling
to the woven fabric. When the monofilament 1 is fused to the
multifilament 2, if h/b is less than 0.5, the abraded surface
cannot be supported by the crimp-shaped apex portions of the
monofilament, and many single yarns of the multifilament 2 are
abraded so that the woven fabric tends to be poor in abrasion
resistance. On the other hand, if h/b exceeds 1.0, the monofilament
1 contacts the skin too strongly so that the woven fabric is poor
in touch feeling. Therefore, when the monofilament 1 is fused to
the multifilament 2, h/b is 0.5 to 1.0. h/b is preferably 0.7 to
0.9.
[0075] The multifilament coverage ratio a/L and the monofilament
concealment ratio h/b can be adjusted within the specific ranges by
adjusting the degree of crimping through the adjustment and weaving
of the filaments and thermal processing conditions after the
weaving. As for the filaments, the material, intrinsic viscosity,
fineness, stretch ratio, stretching temperature, relaxation ratio,
relaxation temperature, cross-sectional shape, weaving density, and
flexural rigidity of the monofilament, and the material, twist
coefficient, fineness, weaving density, and flexural rigidity of
the multifilament are adjusted. In the weaving, the warp tension
and weft tension are adjusted. In the heat setting, the
longitudinal shrinkage ratio and the transverse shrinkage ratio are
adjusted. In addition, when the monofilament 1 is not fused to the
multifilament 2, the force of binding the multifilament 2 is weaker
than when the monofilament 1 is fused to the multifilament 2, and
many single yarns of the multifilament 2 are abraded during the
rubbing. Thus, this is disadvantageous in terms of abrasion
resistance. Therefore, in addition to the multifilament coverage
ratio a/L of 1.0 or more and 1.5 or less, the monofilament
concealment ratio h/b is adjusted to 0.7 or more and 1.0 or less to
avoid too small a concealment ratio. The monofilament concealment
ratio is preferably from 0.8 to 0.9.
[0076] The warp or the weft including the multifilament preferably
has a cover factor of 800 or more and 1200 or less, more preferably
1000 or more and 1200 or less. Herein, the cover factor is a value
calculated as follows:
(Cover factor)=(density: number of yarns/2.54 cm).times. (fineness:
dtex).
[0077] If the cover factor of the multifilament is small, the
binding force between the warp and the weft is insufficient, yarn
slippage occurs during the abrasion, and desired durability is
hardly obtained. On the other hand, if the cover factor of the
multifilament is too large, the crimp shape of the monofilament
tends to be flat, and as a result, desired durability is hardly
obtained.
[0078] The material of the multifilament is not particularly
limited, and polyethylene terephthalate, polybutylene
terephthalate, polypropylene terephthalate, polyamides,
polypropylene, polyethylene, polyphenylene sulfide, acrylic and the
like can be suitably used as a base polymer. In particular,
polyethylene terephthalate (PET) can be suitably used as a base
polymer from the viewpoint of strength. If necessary, the base
polymer can be used after being modified, for example, in the form
of a copolymer with other components, or a composition containing
other components. For example, a cation-dyeable polyester capable
of being dyed with a cationic dye, which is obtained by introducing
a sulfonic acid group into PET or the like, is suitable since it
gives a multifilament excellent in strength and coloring
properties. A suitable commercial product of such a cation-dyeable
polyester yarn is, for example, LOCII manufactured by TORAY
INDUSTRIES, INC.
[0079] The multifilament may include a twisted yarn, a false
twisted yarn, a Taslan textured yarn, or an air textured yarn as
long as the desired object is not impaired. However, when a bulky
multifilament including a Taslan textured yarn or an air textured
yarn is used, care must be taken because the multifilament may be
poor in abrasion resistance due to too large a length b of the
multifilament in a cross section thereof in the direction of woven
fabric thickness. Further, apart from the textured yarns, additives
such as a flame retardant, an antistatic agent, a weathering agent,
a pigment, and a matting agent may be mixed as other materials. A
pre-dyed yarn that has been dyed in advance may also be used as the
multifilament.
[0080] The single yarn fineness of the multifilament is desirably 1
dtex or more and 10 dtex or less, more desirably 2 dtex or more and
6 dtex or less. When the single yarn fineness of the multifilament
is 1 dtex or more, the required flexural rigidity is easily
ensured, and the crimp shape of one of the yarns is easily formed.
When the single yarn fineness of the multifilament is 10 dtex or
less, the multifilament hardly has a stiff touch feeling, and a
soft texture is easily obtained.
[0081] The total fineness of the multifilament is desirably 100
dtex or more and 2000 dtex or less, more desirably 150 dtex or more
and 1700 dtex or less, still more desirably 300 dtex or more and
1000 dtex or less. When the total fineness of the multifilament is
100 dtex or more, the required flexural rigidity is easily ensured.
When the total fineness of the multifilament is 2000 dtex or less,
handling in woven fabric production is easy.
[0082] A fiber yarn having a multifilament strength of 3.0 cN/dtex
or more is preferably used from the viewpoint of the strength of
the woven fabric. The condition of strength is preferably a high
strength, and a fiber yarn having a strength of 5.0 cN/dtex or more
and 15.0 cN/dtex or less is practically more preferable.
[0083] The multifilament preferably has a twist coefficient of 0 or
more and 10000 or less and is in a weakly twisted state, more
preferably has a twist coefficient of 0 or more and 8500 or less.
Herein, the twist coefficient is obtained by the following
formula:
(Twist coefficient)=(number of twists: T/m).times.(fineness:
dtex).
[0084] A twist coefficient of the multifilament within the
above-mentioned range gives a multifilament having a flat
cross-sectional shape. The multifilament has a large contact area
with the monofilament crossing the multifilament, and a large
number of single yarns are in contact with the monofilament. As a
result, the force applied to the single yarns of the multifilament
is distributed so that single yarn breakage hardly occurs and the
multifilament tends to be improved in abrasion resistance. In
addition, the multifilament coverage ratio a/L is large, and the
woven fabric is good in touch feeling. Conversely, if the twist
coefficient of the multifilament is more than 10000, the range of
yarns that can come into contact with the monofilament is narrow,
and the number of single yarns that do not contact the monofilament
is large so that yarn slippage easily occurs and the multifilament
tends to be poor in abrasion resistance.
[0085] When a woven fabric shows a weight reduction less than 0.5 g
and no hole in the abrasion test, it is preferable because the
woven fabric has desired durability, and a woven fabric with long
life can be provided to users. The weight reduction is more
preferably less than 0.4 g. If the weight reduction exceeds 0.5 g
or a hole is generated in the abrasion test, the targeted
durability cannot be obtained. The abrasion test herein is carried
out according to JIS L1096 (2010) 8.19.3, method C (JIS Handbook
2013) by 4000 times of abrasion with a Taber abrasion tester under
conditions of a load of 250 g, an abrasive wheel H-18, and a disc
diameter of 100 mm.
[0086] The mean friction coefficient MIU as a KES surface friction
property value represents the slipperiness of the sample surface.
The larger the value is, the less slippery the surface is. The
deviation of friction coefficient (MMD) represents the roughness
and irregular texture of the sample surface. The larger the value
is, the rougher the surface is. It is preferable that the woven
fabric have a mean friction coefficient MIU as a KES surface
friction property value of 0.10 to 0.42, and a deviation of mean
friction coefficient MMD of 0.01 to 0.07. More preferably, the
woven fabric has a mean friction coefficient MIU of 0.20 to 0.40,
and a deviation of mean friction coefficient MMD of 0.02 to 0.065.
Still more preferably, the woven fabric has a mean friction
coefficient MIU of 0.25 to 0.38, and a deviation of mean friction
coefficient MMD of 0.025 to 0.060.
[0087] The monofilament 1 preferably has a flexural rigidity of 1
cN or more and 6 cN or less. When the flexural rigidity of the
monofilament 1 is 1 cN or more, the monofilament plays a role of a
framework to prevent the occurrence of yarn slippage during the
rubbing, and the monofilament is good in abrasion resistance. When
the flexural rigidity is 6 cN or less, the monofilament is not too
rigid and easily forms a crimp shape so that a sufficient binding
force of the yarn is obtained to prevent the occurrence of yarn
slippage during the rubbing, or a high monofilament concealment
ratio b/h gives good abrasion resistance.
[0088] The material of the monofilament is not particularly
limited, and polyesters such as polyethylene terephthalate,
polybutylene terephthalate, and polypropylene terephthalate,
polyolefins such as polyamides, polypropylene, and polyethylene,
polyphenylene sulfide, polyester elastomers, polysulfide
elastomers, and polyurethane elastomers can be suitably used as a
base polymer. However, when a material having a low flexural
rigidity is used as a base polymer to form a monofilament, it is
easy to form a desired crimp shape even when a thinner
multifilament is used and, thus, a thinner and lighter woven fabric
can be obtained. From such a viewpoint, an elastic yarn made from
an elastomer such as a polyester elastomer, a polysulfide
elastomer, or a polyurethane elastomer as a base polymer can be
more suitably used, and an elastic yarn made from a polyester
elastomer as a base polymer can be still more suitably used.
[0089] As the polyester elastomer, one having a hard segment and a
soft segment in the molecular structure is preferable. The hard
segment preferably includes, as a main constituent unit, an
aromatic polyester unit mainly formed from an aromatic dicarboxylic
acid or an ester-forming derivative thereof and a diol or an
ester-forming derivative thereof. Meanwhile, the soft segment
preferably includes, as a main constituent unit, an aliphatic
polyether unit and/or an aliphatic polyester unit and a diol.
[0090] In general, of filaments made from the same polymer, a
filament having a lower fineness tends to have a lower flexural
rigidity, and a multifilament tends to have a lower flexural
rigidity than a monofilament does if they have the same total
fineness. A filament having a lower flexural rigidity tends to
easily form crimps. From the viewpoint of maintaining an
appropriate balance of crimps between the monofilament and the
multifilament in a woven fabric to increase the binding force of
the yarn, and controlling the balance of exposure between the
multifilament and the monofilament, the range of fineness of the
monofilament is preferably 0.2 times or more and 1.5 times or less,
more preferably 0.3 times or more and 1.0 time or less, still more
preferably 0.4 times or more and 0.8 times or less the total
fineness of the multifilament. When the fineness of the
monofilament is 0.2 times or more the total fineness of the
multifilament, the multifilament is easily bent due to the rigidity
and tension of the monofilament. When the fineness of the
monofilament is 1.5 times or less the total fineness of the
multifilament, the monofilament is easily bent due to the rigidity
and tension of the multifilament. As a result, crimps of both the
yarns are easily formed in an appropriate balance.
[0091] When the woven fabric is required to have air permeability,
the warp and the weft that constitute the woven fabric are
preferably fused together to the extent that the air permeability
is not impaired. When the warp and the weft are fused together,
yarn slippage hardly occurs, and the woven fabric is improved in
abrasion resistance. However, fusing the surface layer of the
multifilament is not preferable because the soft touch feeling
tends to be impaired.
[0092] The monofilament 1 may be a composite yarn such as a
core-sheath composite yarn, or a non-composite yarn entirely made
from a single material. In fusing either one of a warp and a weft
that is a monofilament with a multifilament used in at least a part
of a warp or a weft other than the monofilament, it is preferable
that the monofilament be a core-sheath composite yarn. In this
case, it is desirable that the material that constitutes the sheath
component of the monofilament have a melting point that is at least
10.degree. C. lower than that of the material that constitutes the
core component of the monofilament. Usually, it is desirable that
the entire sheath section of the monofilament be fused to the other
yarn. However, if the sheath component of the monofilament has a
melting point that is lower than the melting point of the core
component of the monofilament +10.degree. C., when the heat setting
temperature exceeds the melting point of the core component, the
core component also melts during the heat setting, and the strength
or the fused portion may decrease. The monofilament that is the
above-mentioned core-sheath composite yarn or a non-composite yarn
can also be used when the yarns are not fused together.
[0093] When the monofilament has a core-sheath structure, the
materials of the core component and the sheath component may be of
the same kind or different from each other. However, it is
preferable that the core component and the sheath component contain
the same component, and it is more preferable that the core
component and the sheath component are made from the same
component, from the viewpoint of enhancing the adhesion between the
core component and the sheath component. In particular, it is more
preferable that each of the core component and the sheath component
be a copolymer composed of a plurality of constituent components
including common constituent components, and that the core
component and the sheath component be different in the melting
point due to different composition ratios or the like of the
plurality of constituent components.
[0094] In particular, it is most preferable from the viewpoint of
adhesion in the heat setting and yarn strength to employ a
core-sheath composite fiber having a core component made from a
polyester elastomer having a melting point of 190 to 250.degree. C.
and a sheath component made from a polyester elastomer having a
melting point of 140 to 190.degree. C.
[0095] The basis weight of the woven fabric is desirably 100 to 500
g/m.sup.2, more desirably 100 to 300 g/m.sup.2, still more
desirably 100 to 200 g/m.sup.2. When the basis weight is 100
g/m.sup.2 or more, the required durability is easily obtained. On
the other hand, when the basis weight is 500 g/m.sup.2 or less, the
advantages of light weight are easily obtained.
[0096] The woven fabric can be basically produced by an ordinary
method including, for example, 1) twisting of a multifilament, 2)
weaving, and 3) heat treatment.
[0097] Although an effect is produced even without the heat
treatment, it is more desirable to perform the heat treatment to
fuse one of the yarns to the multifilament. When the woven fabric
is produced using a monofilament having a core-sheath structure in
which the sheath section has a melting point at least 10.degree. C.
lower than that of the core section, it is preferable that the heat
treatment temperature be higher than the melting point of the
sheath section and lower than the melting point of the core
section. The heat treatment can be performed at a temperature of
150 to 220.degree. C. for 30 to 120 seconds, for example.
[0098] The woven fabric structure may be appropriately selected
according to the application from the structures such as a plain
weave structure, a twill weave structure, a satin weave structure,
and a double weave structure combining these structures. The plain
weave structure is preferable since the warp and the weft bind each
other at many points, and the woven fabric hardly causes yarn
slippage. The plain weave structure is also good in handling
properties such as prevention of frays. Further, the weaving method
and the loom to be used are not particularly limited as long as the
woven fabric can be obtained, and may be appropriately
selected.
[0099] The weaving conditions for obtaining the woven fabric depend
on the properties of the fibers used. For example, when focusing on
the warp tension and the weft tension, it is difficult to limit the
tensions within specific ranges since they vary depending on the
properties of the fibers used and the combination thereof. However,
these tensions act on the fibers mutually, have an effect on the
crimp shapes of the warp and the weft, and thereby change the
multifilament coverage ratio a/L and the monofilament concealment
ratio h/b. When the warp tension is low or the weft tension is
high, the warp crimp tends to be small and the weft crimp tends to
be large. When the warp tension is high or the weft tension is low,
the warp crimp tends to be large and the weft crimp tends to be
small.
[0100] Since the longitudinal shrinkage ratio and the transverse
shrinkage ratio in the heat setting also vary depending on the
properties of the fibers used and the combination thereof, it is
difficult to limit the shrinkage ratios within specific ranges to
produce the woven fabric. These shrinkage ratios act mutually, have
an effect on the crimp shapes of the warp and the weft, and thereby
change the multifilament coverage ratio a/L and the monofilament
concealment ratio h/b. When the longitudinal shrinkage ratio is
high or the transverse shrinkage ratio is low, the warp crimp tends
to be small and the weft crimp tends to be large. Alternatively,
when the longitudinal shrinkage ratio is low or the transverse
shrinkage ratio is high, the warp crimp tends to be large and the
weft crimp tends to be small.
[0101] Therefore, in selecting weaving conditions, the weaving
conditions should be appropriately adjusted so that the crimp
shapes of the weaving yarns fall within our defined ranges in view
of the properties of the fibers used and the combination
thereof.
[0102] The woven fabric can be used in applications such as skin
materials for shoes, work clothes, fabrics for bags, members such
as vehicle seat members and skin materials for shoes, members for
sports balls such as balls of soccer and volleyball, adhesive
tapes, base fabrics for nonwoven fabrics, interior members, members
for inner layers of vehicles and housing, and materials for civil
engineering.
EXAMPLES
[0103] In the following, our woven fabrics will be described with
reference to the examples. Methods of measuring properties
described in the examples are as follows.
1. Multifilament Coverage Ratio (Hereinafter Sometimes Abbreviated
as "Coverage Ratio")
[0104] From a woven fabric, a fiber (N) including a multifilament 2
crossing a fiber (M) including a monofilament 1 was cut off in a
direction parallel to the direction of the fiber (M), and used as
an observation sample. The sample was attached to a sample stand in
a non-tensioned state, and an enlarged photograph was taken with a
scanning electron microscope (SEM) at a magnification of 40. The
length a (mm) of the multifilament 2 that crosses the monofilament
1 in a cross section thereof in a direction of woven fabric
surface, and the center-to-center distance L (mm) between adjacent
filaments of the multifilament were measured each at five
positions. The multifilament coverage ratios (a/L) were determined
according to the following formula, and the average thereof was
calculated (see FIG. 1):
Multifilament coverage ratio (a/L)=a/L
[0105] a: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric surface
[0106] L: center-to-center distance between filaments of the
multifilament 2 adjacent across the fiber (M).
2. Monofilament Concealment Ratio (Hereinafter Sometimes
Abbreviated as "Concealment Ratio")
[0107] A cut sample was prepared in the same manner as in the case
of measurement of the multifilament coverage ratio. Then, the
sample was attached to a sample stand in a non-tensioned state, and
an enlarged photograph was taken with a scanning electron
microscope (SEM) at a magnification of 40. The length b (mm) of the
multifilament 2 in a cross section thereof in a direction of woven
fabric thickness, and the crimp height h (mm) of the monofilament
were measured each at five positions. The multifilament coverage
ratios (h/b) were determined according to the following formula,
and the average thereof was calculated (see FIG. 1):
Multifilament coverage ratio (h/b)=h/b
[0108] b: length of the multifilament 2 in a cross section thereof
in a direction of woven fabric thickness
[0109] h: crimp height of the monofilament 1.
3. Weaving Density
[0110] According to JIS L1096: 2010 8.6.1, method A, five different
positions on the woven fabric surface were observed with a
magnifying glass, the numbers of warps and wefts in the section of
25.4 mm were counted, and the averages thereof were calculated.
4. Fineness
[0111] According to JIS L1013: 2010 8.3.1, method B, the fineness
based on corrected mass was measured as the fineness.
5. Cover Factor
[0112] The cover factor was calculated according to the following
formula:
cover factor=(weaving density: number of yarns/2.54 cm).times.
(fineness: dtex).
6. Twist Coefficient
[0113] According to JIS L1013: 2010 8.13.1, a sample was attached
to a twist counter manufactured by Asano machine MFG. Co. with a
length between grips of 50 cm under an initial load of 2.94
mN.times.display decitex, the number of twists was measured, and
the obtained number was doubled to give the number of twists per
meter. The twist coefficient was calculated according to the
following formula:
Twist coefficient=(number of twists: T/m).times. (fineness:
dtex).
7. Flexural Rigidity of Monofilament
[0114] Under two stainless steel rods each having a diameter of 2
mm horizontally placed at an interval of 10 mm, a monofilament cut
into about 4 cm in length was set, and a J-shaped stainless steel
hook having a diameter of 1 mm suspended on the monofilament at the
center of the two stainless steel rods. The stainless steel hook
was pulled up at a speed of 50 mm/min with a TCM-200 type universal
tensile and compression testing machine manufactured by
MinebeaMitsumi Inc., and the flexural rigidity was evaluated based
on the maximum stress generated during the pulling.
8. Whether the Fiber was Fused or Not
[0115] A sample of 10 mm.times.10 mm was collected, and the front
and back surfaces of the woven fabric surface were observed with a
scanning electron microscope (SEM) at a magnification of 100 to
determine whether the fiber was fused or not.
9. Taber Abrasion Test
[0116] According to JIS L1096: 2010 8.19.3, method C, a sample was
abraded 4000 times with a Taber abrasion tester under conditions of
a load of 250 g, an abrasive wheel H-18, and a disc diameter of 100
mm, and then the sample was weighed. The weight difference (g) from
the weight before the test was taken as the "weight reduction after
4000 times". For the judgment of rupture of the sample piece, a
sample without hole was judged as A, and a sample with hole was
judged as B. As a comprehensive judgment of abrasion resistance, a
sample that showed a weight reduction after 4000 times less than
0.5 g and no hole was judged as acceptable, and others were judged
as rejectable.
10. Evaluation of Surface Friction Feeling and Friction Coefficient
(MIU)
[0117] The measurement was performed 3 times for each of the two
directions of warp and weft directions with a KES-SE friction
tester manufactured by KATO TECH CO., LTD. under the conditions of
a test stand moving speed of 1.00 mm/sec, a friction static load of
50 g, and a 10-mm square piano wire as an abrading material, and
the average of the measured values was obtained. The formula for
obtaining the friction coefficient (MIU) is as follows:
MIU=(1/X) .intg..mu.dx (Integration range: 0 to X)
[0118] .mu.: Frictional force/force pressing the sample (50 gf)
[0119] x: Position on the sample surface
[0120] X: Movement distance (2 cm).
The friction coefficient (MIU) represents the slipperiness of the
sample surface, and the larger the value is, the less slippery the
surface is. For the judgment, a sample having a MIU of 0.40 or less
was judged as A, a sample having a MIU more than 0.40 and 0.42 or
less was judged as B, and a sample having a MIU more than 0.42 was
judged as C.
11. Evaluation of Surface Friction Feeling and Deviation of
Friction Coefficient (MMD)
[0121] The measurement was performed 3 times for each of the two
directions of warp and weft directions with a KES-SE friction
tester manufactured by KATO TECH CO., LTD. under the conditions of
a test stand moving speed of 1.00 mm/sec, a friction static load of
50 g, and a 10-mm square piano wire as an abrading material, and
the average of the measured values was obtained. The formula for
obtaining the deviation of friction coefficient (MMD) is as
follows:
MMD=(1/X) .intg.|.mu.-.mu.'|dx (integration range: 0 to X)
[0122] .mu.: Frictional force/force pressing the sample (50 gf)
[0123] x: Position on the sample surface
[0124] X: Movement distance (2 cm)
[0125] .mu.': Average of .mu..
The deviation of friction coefficient (MMD) represents the
roughness and irregular texture of the sample surface, and the
larger the value is, the more rough the surface is. For the
judgment, a sample having a MMD of 0.05 or less was judged as A, a
sample having a MMD more than 0.05 and 0.07 or less was judged as
B, and a sample having a MMD more than 0.07 was judged as C.
12. Basis Weight
[0126] According to JIS L1096: 2010 8.3.2, method A, three samples
of 200 mm.times.200 mm were collected, the absolute dry masses of
the samples were measured, the masses per 1 m.sup.2 were
calculated, and the average thereof was calculated.
EXAMPLES 1 TO 4 AND COMPARATIVE EXAMPLES 1 TO 4
[0127] "HYTREL" (registered trademark) 6347 (melting point:
215.degree. C.) manufactured by DU PONT-TORAY CO., LTD., a
thermoplastic polyester elastomer, was used as a core component,
and "HYTREL" (registered trademark) 4056 (melting point:
153.degree. C.) was used as a sheath component. The pellets were
dried, melted in separate extruders, weighed with a gear pump,
poured into a composite pack, and fed into an extrusion machine. In
this way, a 700 dtex monofilament elastic yarn having a core/sheath
mass ratio of 70:30 was obtained. The elastic yarn had a flexural
rigidity of 1.0 cN, and was used as the weft.
[0128] In addition, ten 167 dtex-48 filament cation-dyeable
polyester yarns (LOCII manufactured by TORAY INDUSTRIES, INC.) were
combined. The resultant 480 filament having a total fineness of
1670 dtex was twisted so as to have a twist coefficient of the warp
as shown in Table 1. The resultant yarn was used as a warp. The
plain weave fabric as shown in Table 1 was produced under the
adjusted weaving conditions such as the warp tension. The obtained
woven fabric was heat-treated with a pin tenter at a temperature of
180.degree. C. for 1 minute at the same inlet and outlet widths and
0% overfeed rate in the warp direction. Then, the woven fabric was
dyed according to an ordinary cationic dye-dyeing method. In all of
the finished woven fabrics, the polyester elastomer as the sheath
component adhered and solidified at the intersection of the warp
and the weft of the woven fabric. The warp density and weft density
of the finished woven fabrics are as shown in Table 1.
[0129] As shown in Tables 2 and 3, Examples 1 to 4 are different
from one another in one of the numerical values of weft density and
twist coefficient of the warp, but the coverage ratio and
concealment ratio were within the specific ranges, and the woven
fabrics were excellent in abrasion resistance and had a soft touch
feeling.
[0130] In addition, as shown in Tables 2 and 3, in Comparative
Examples 1 to 4, the coverage ratio or the concealment ratio was
not within the specific range, and the woven fabrics were
inadequate in either of the abrasion resistance and touch feeling.
Comparative Example 1 is an example of when the concealment ratio
is too small. Although the obtained woven fabric had a soft touch
feeling due to the flat shape of the warp and the high coverage
ratio, the woven fabric was low in concealment ratio and poor in
abrasion resistance. Comparative Example 2 is an example of when
the concealment ratio is too large. The monofilament exposed to the
surface, and the woven fabric had a hard touch feeling. In
Comparative Example 3, since the coverage ratio was too small, the
monofilament exposed to the surface, and the woven fabric had a
hard touch feeling. Comparative Example 4 is also an example of
when the coverage ratio is too small. The monofilament exposed to
the surface, and the woven fabric had a hard touch feeling although
it was excellent in abrasion resistance.
EXAMPLE 5
[0131] "HYTREL" (registered trademark) 6347 (melting point:
215.degree. C.) manufactured by DU PONT-TORAY CO., LTD., a
thermoplastic polyester elastomer, was prepared as a core
component. In addition, "HYTREL" (registered trademark) 4056
(melting point: 153.degree. C.) was prepared as a sheath component.
The pellets were dried, melted in separate extruders, weighed with
a gear pump, poured into a composite pack, and fed into an
extrusion machine. In this way, a 400 dtex monofilament elastic
yarn having a core/sheath mass ratio of 70:30 was obtained. The
elastic yarn had a flexural rigidity of 0.3 cN, and was used as the
weft.
[0132] Five 167 dtex-48 filament cation-dyeable polyester yarns
(LOCII manufactured by TORAY INDUSTRIES, INC.) were combined. The
resultant 240 filament having a total fineness of 835 dtex was
twisted so as to have a twist coefficient of the warp of 2890. The
resultant yarn was used as a warp. The plain weave fabric as shown
in Table 1 was produced under the adjusted weaving conditions such
as the warp tension. The obtained woven fabric was heat-treated
with a pin tenter at a temperature of 180.degree. C. for 1 minute
at the same inlet and outlet widths and 0% overfeed rate in the
warp direction. In the finished woven fabric, the polyester
elastomer as the sheath component adhered and solidified at the
intersection of the warp and the weft of the woven fabric. The warp
density and weft density of the finished woven fabric are as shown
in Table 1.
[0133] As shown in Tables 2 and 3, we confirmed that in Example 5,
the coverage ratio and concealment ratio were within the specific
ranges, and the woven fabric was excellent in abrasion resistance
and had a soft touch feeling.
EXAMPLES 6 TO 8 AND COMPARATIVE EXAMPLES 5 AND 6
[0134] Pellets of "HYTREL" (registered trademark) 6347 (melting
point: 215.degree. C.) manufactured by DU PONT-TORAY CO., LTD., a
thermoplastic polyester elastomer, were dried. Then, the pellets
were melted in an extruder, weighed with a gear pump, poured into a
composite pack, and fed into an extrusion machine. In this way, a
700 dtex monofilament elastic yarn was obtained. The elastic yarn
was used as a weft. In addition, ten 167 dtex-48 filament
cation-dyeable polyester yarns (LOCII manufactured by TORAY
INDUSTRIES, INC.) were combined as a warp. The resultant 480
filament having a total fineness of 1670 dtex was twisted so as to
have a twist coefficient of the warp as shown in Table 1. The plain
weave fabric as shown in Table 1 was produced under the adjusted
weaving conditions such as the warp tension. The obtained woven
fabric was heat-treated with a pin tenter at a temperature of
180.degree. C. for 1 minute at the same inlet and outlet widths and
0% overfeed rate in the warp direction. Then, the woven fabric was
dyed according to an ordinary cationic dye-dyeing method. The warp
density and weft density of the finished woven fabrics are as shown
in Table 1. No fused portion was found in each of the yarns that
constitute the finished woven fabrics.
[0135] As shown in Tables 2 and 3, we confirmed that in Examples 6
to 8, the coverage ratio and concealment ratio were within the
specific ranges, and the woven fabrics were excellent in abrasion
resistance and had a soft touch feeling.
[0136] In Comparative Examples 5 and 6, since the woven fabrics
were low in concealment ratio, they were poor in abrasion
resistance.
COMPARATIVE EXAMPLE 7
[0137] "HYTREL" (registered trademark) 6347 (melting point:
215.degree. C.) manufactured by DU PONT-TORAY CO., LTD., a
thermoplastic polyester elastomer, was used as a core component.
"HYTREL" (registered trademark) 4056 (melting point: 153.degree.
C.) was used as a sheath component. The pellets were dried, melted
in separate extruders, weighed with a gear pump, poured into a
composite pack, and fed into an extrusion machine. In this way, a
700 dtex monofilament elastic yarn having a core/sheath mass ratio
of 70:30 was obtained. The elastic yarn had a flexural rigidity of
1.0 cN, and was used as the weft.
[0138] A 288 filament high-strength polyester multifilament yarn
(manufactured by TORAY INDUSTRIES, INC.) made from polyethylene
terephthalate and having a total fineness of 1670 dtex was twisted
so as to have a twist coefficient of the warp as shown in Table 1,
and the resultant yarn was used. The plain weave fabric as shown in
Table 1 was produced under the adjusted weaving conditions such as
the warp tension, and at a weft density of 33 yarns/2.54 cm and a
warp density of 25 yarns/2.54 cm. The obtained woven fabric was
heat-treated with a pin tenter at a temperature of 180.degree. C.
for 2 minutes at the same inlet and outlet widths and 0% overfeed
rate in the warp direction with the woven fabric overfeed 20% only
in the warp direction. In the finished woven fabric, the polyester
elastomer as the sheath component adhered and solidified at the
intersection of the warp and the weft of the woven fabric. The warp
density and weft density of the finished woven fabric are as shown
in Table 1.
[0139] In Comparative Example 7, since the coverage ratio was too
small and the concealment ratio was too large, the woven fabric was
excellent in abrasion resistance but had a hard touch feeling.
TABLE-US-00001 TABLE 1 Warp Weft Warp density Weft density Twist
Flexural rigidity Basis fineness fineness (number of (number of
coefficient Cover factor of of monofilament weight (dtex) (dtex)
yarns/2.54 cm) yarns/2.54 cm) of warp warp (cN) (g/m.sup.2) Example
1 1,670 700 29 39 8,173 1,185 1.0 352 Example 2 1,670 700 29 46
8,173 1,185 1.0 377 Example 3 1,670 700 29 38 0 1,185 1.0 347
Example 4 1,670 700 29 41 0 1,185 1.0 356 Example 5 835 400 41 50
3,034 1,170 0.3 258 Example 6 1,670 700 28 46 8,173 1,144 1.0 369
Example 7 1,670 700 28 41 0 1,144 1.0 348 Example 8 1,670 700 28 42
8,173 1,144 1.0 355 Comparative Example 1 1,670 700 29 36 0 1,185
1.0 342 Comparative Example 2 1,670 700 29 42 2,861 1,185 1.0 361
Comparative Example 3 1,670 700 29 42 40,866 1,185 1.0 367
Comparative Example 4 1,670 700 29 49 40,866 1,185 1.0 388
Comparative Example 5 1,670 700 28 39 8,173 1,144 1.0 345
Comparative Example 6 1,670 700 28 38 0 1,144 1.0 339 Comparative
Example 7 1,670 700 25 47 8,173 1,038 1.0 349
TABLE-US-00002 TABLE 2 Concealment a b L h Coverage ratio ratio
Whether fiber (.mu.m) (.mu.m) (.mu.m) (.mu.m) a/L h/b was fused or
not Example 1 870 250 865 130 1.0 0.5 Fused Example 2 865 250 865
250 1.0 1.0 Fused Example 3 1,300 165 870 80 1.5 0.5 Fused Example
4 1,300 165 870 160 1.5 1.0 Fused Example 5 525 180 410 160 1.3 0.9
Fused Example 6 870 250 860 250 1.0 1.0 Not fused Example 7 1,310
165 860 160 1.5 1.0 Not fused Example 8 870 250 865 185 1.0 0.7 Not
fused Comparative Example 1 1,310 165 865 60 1.5 0.4 Fused
Comparative Example 2 1,250 170 860 185 1.5 1.1 Fused Comparative
Example 3 700 310 870 160 0.8 0.5 Fused Comparative Example 4 700
310 860 305 0.8 1.0 Fused Comparative Example 5 870 250 870 125 1.0
0.5 Not fused Comparative Example 6 1,300 170 870 85 1.5 0.5 Not
fused Comparative Example 7 900 245 1,000 300 0.9 1.2 Fused
TABLE-US-00003 TABLE 3 Abrasion resistance Weight reduction
Judgment of Surface friction feeling after 4000 times (g) rupture
MIU Judgment MMD Judgment Example 1 0.41 A 0.305 A 0.037 A Example
2 0.20 A 0.389 A 0.062 B Example 3 0.44 A 0.268 A 0.029 A Example 4
0.32 A 0.341 A 0.047 A Example 5 0.24 A 0.266 A 0.041 A Example 6
0.28 A 0.392 A 0.065 B Example 7 0.44 A 0.353 A 0.049 A Example 8
0.42 A 0.343 A 0.048 A Comparative Example 1 0.50 C 0.245 A 0.025 A
Comparative Example 2 0.30 A 0.421 C 0.051 B Comparative Example 3
0.39 A 0.424 C 0.052 B Comparative Example 4 0.19 A 0.473 C 0.070 C
Comparative Example 5 0.56 C 0.303 A 0.037 A Comparative Example 6
0.59 C 0.269 A 0.030 A Comparative Example 7 0.17 A 0.501 C 0.071
C
[0140] As shown in Tables 1 to 3, our woven fabrics are good in
abrasion resistance and touch feeling.
* * * * *