CA1305602C - Fabric having a scary surface structure - Google Patents
Fabric having a scary surface structureInfo
- Publication number
- CA1305602C CA1305602C CA000575800A CA575800A CA1305602C CA 1305602 C CA1305602 C CA 1305602C CA 000575800 A CA000575800 A CA 000575800A CA 575800 A CA575800 A CA 575800A CA 1305602 C CA1305602 C CA 1305602C
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- piled
- fibers
- scaly
- dimensional fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
Abstract
ABSTRACT OF THE DISCLOSURE
Disclosed are a new fabric and a method of its preparation. The fabric is rich in a new raw material feeling which has been unparalleled before, a fashionable feeling and an unexpected feeling. The fabric is a three dimensional fabric having a unique structure in which a mass of a number of apexes of piled fibers is made in a body to form a scaly structure and a number of the scaly structures cover the surface layer of the fabric. The method for preparing the three dimensional fabric comprises subjecting the piled layer of a piled fabric having a number of piles made of fibers to a pressing treatment under heating and compression to adhere the piled surface layer formed with the apexes of piles over a wide area and to make thereby it into a film-shaped body and thereafter forming a lot of scaly structures by crumpling the fabric and by splitting the above described film-shaped monolithic structure into units of small area. The three dimensional fabric can be widely used in such various applications as outer wears and so on.
Disclosed are a new fabric and a method of its preparation. The fabric is rich in a new raw material feeling which has been unparalleled before, a fashionable feeling and an unexpected feeling. The fabric is a three dimensional fabric having a unique structure in which a mass of a number of apexes of piled fibers is made in a body to form a scaly structure and a number of the scaly structures cover the surface layer of the fabric. The method for preparing the three dimensional fabric comprises subjecting the piled layer of a piled fabric having a number of piles made of fibers to a pressing treatment under heating and compression to adhere the piled surface layer formed with the apexes of piles over a wide area and to make thereby it into a film-shaped body and thereafter forming a lot of scaly structures by crumpling the fabric and by splitting the above described film-shaped monolithic structure into units of small area. The three dimensional fabric can be widely used in such various applications as outer wears and so on.
Description
:~3@~;$~3~
DESCRIPTION
. . .
Technical Field The present invention relates to a new fabric which is rich in a new, unparalleled raw material feeling, a fashionable feeling and an unexpected feeling.
In more detail, the present invention relates to a three dimensional fibrous fabric having a new structure having many scaly structures covering the surace layer of the fabric and to its method of preparation.
Fabrics similar to the present invention have never been seen before. The closest would be a fabric prepared by embossing a scaly structure such as an embossing treatment of an artific~ial leather and followed - : :
by an enamel treatment on the~surface.
However, in the conventional fabric ~like this, the surface and cros~s-sectional structures have poor cubic effects. It looks~ artificial;~and a natural feeling is scarce because the surface~shape is in a regular manner.
The feeling is very rough ~and hard and it looks paper-llke.
.
Disclosure of Invention Technological problems to be solved by the present invention are the need for a new fabric which is rich in a new raw material feeling which has been unparalleled and has an unexpected feeling and at the same time a fashionable feeling, ancl the need for a method for preparing said fabric.
The present invention provides a three dimensional fabric having, a face surface, an opposite base fabric, ~~
a body of pile fibers therebètween piled from the base fabric, wherein the said pile fiber~, at the apex end at the face surfaae of the fabric, are abutted and joined to form contlguous substantially flat scale-like areas each bounded by a boundary;
and the said scale-like areas cover the face surface of the fabric.
Another aspect of the present invention provides a method for preparing the three dimensional fabric. One embodiment of the process comprises: :
pressing a piled layer of a piled fabric having a number of piles made of a fiber under heat and compression to adhere apexes of the piles over a wide area and thereby to make it into a film-like monolithic structure, and crumpling the said fabric and splitting the thus-formed film-like monolithic structure into units of small area, thereby to form a number of the scale-like areas.
Compared to the conventional products which are easily distinyuished as being artificial products, the present invention offers a three dimensional Eabric having a new, unique structure and a method Eor preparing it wherein the fabric has not been seen before as a fiber product, the surace appearance exhibits a scaly structure which has an outer appearance and luster rich in a feeling of a natural product and a new raw material such as mineral-like, namely mica-like and coal-like, bagworm-like or an outer appearance of the surEace skin of a pine tree and at the same time has a feeling being three dimensional and is excellent in flexibility.
In more detail, the three dimensional fabric having a unique structure of~ered by the present inven-tion has practical eEfects as described in the following (1~
to (9~ which have not been seen in si~ilar, conventional fabrics~
tl) A fabric whose outer appearance exhibits an aspect being very rich in a natural feeling such as scale-like, mineral-likei surface skin-like of a pine tree, bagworm-like and so on and haviny never been seen in the conventional product and being rich in a new raw material feeling and an unexpected feeling, is ofEered by the scaly struc-ture covering.the surface layer of the ~.
" l~ .
fabric.
DESCRIPTION
. . .
Technical Field The present invention relates to a new fabric which is rich in a new, unparalleled raw material feeling, a fashionable feeling and an unexpected feeling.
In more detail, the present invention relates to a three dimensional fibrous fabric having a new structure having many scaly structures covering the surace layer of the fabric and to its method of preparation.
Fabrics similar to the present invention have never been seen before. The closest would be a fabric prepared by embossing a scaly structure such as an embossing treatment of an artific~ial leather and followed - : :
by an enamel treatment on the~surface.
However, in the conventional fabric ~like this, the surface and cros~s-sectional structures have poor cubic effects. It looks~ artificial;~and a natural feeling is scarce because the surface~shape is in a regular manner.
The feeling is very rough ~and hard and it looks paper-llke.
.
Disclosure of Invention Technological problems to be solved by the present invention are the need for a new fabric which is rich in a new raw material feeling which has been unparalleled and has an unexpected feeling and at the same time a fashionable feeling, ancl the need for a method for preparing said fabric.
The present invention provides a three dimensional fabric having, a face surface, an opposite base fabric, ~~
a body of pile fibers therebètween piled from the base fabric, wherein the said pile fiber~, at the apex end at the face surfaae of the fabric, are abutted and joined to form contlguous substantially flat scale-like areas each bounded by a boundary;
and the said scale-like areas cover the face surface of the fabric.
Another aspect of the present invention provides a method for preparing the three dimensional fabric. One embodiment of the process comprises: :
pressing a piled layer of a piled fabric having a number of piles made of a fiber under heat and compression to adhere apexes of the piles over a wide area and thereby to make it into a film-like monolithic structure, and crumpling the said fabric and splitting the thus-formed film-like monolithic structure into units of small area, thereby to form a number of the scale-like areas.
Compared to the conventional products which are easily distinyuished as being artificial products, the present invention offers a three dimensional Eabric having a new, unique structure and a method Eor preparing it wherein the fabric has not been seen before as a fiber product, the surace appearance exhibits a scaly structure which has an outer appearance and luster rich in a feeling of a natural product and a new raw material such as mineral-like, namely mica-like and coal-like, bagworm-like or an outer appearance of the surEace skin of a pine tree and at the same time has a feeling being three dimensional and is excellent in flexibility.
In more detail, the three dimensional fabric having a unique structure of~ered by the present inven-tion has practical eEfects as described in the following (1~
to (9~ which have not been seen in si~ilar, conventional fabrics~
tl) A fabric whose outer appearance exhibits an aspect being very rich in a natural feeling such as scale-like, mineral-likei surface skin-like of a pine tree, bagworm-like and so on and haviny never been seen in the conventional product and being rich in a new raw material feeling and an unexpected feeling, is ofEered by the scaly struc-ture covering.the surface layer of the ~.
" l~ .
fabric.
(2) The scaly structure covering the surface layer of the fabric gives a characteristic luster feeling by the phenomenon of reflection of light due to its flat-shape and thereby a fabric having esthetic and fashionable feelings is offered. Such a unique luster feeling is especially remarkable in a deep color such as black and so on.
(3) Contrary to the outer appearance of the surface which is apparently rough and hard, a fabric which is rich in flexibility is offered.
(4) A fihrous fabric whose whole outer appearance is rich in a cubic effect is offered because it is consti-tuted by a three dimensional fabric and forms scaly struct~res of various areas.
Because each scaly structure is constituted by an independent apex part of piles, independent movement is possible to some extent and it is therefore possible to obtain changing effects of outer appearance and luster in accordance with the movement of the fabric while in use.
Because each scaly structure is constituted by an independent apex part of piles, independent movement is possible to some extent and it is therefore possible to obtain changing effects of outer appearance and luster in accordance with the movement of the fabric while in use.
(5) Because the intermediate layers between the bottom of the piles and~the inside of the scaly structures are constituted by many piles fibers, the ratio of vacancy is high, and good heat retaining, flexibility, cushioning characteristics can be obtained by a structure wherein ~5~
sald intermediate layers exist.
sald intermediate layers exist.
(6) Because almost the whole fabric surace is covered with scaly structure of flat shapes, the fabric repels water and does not allow wind to pass through.
Namely, it has both good windbreak performance and water repellency.
Namely, it has both good windbreak performance and water repellency.
(7) The fabric has two different characteristics, namely both being rich in rural beauty and having high class, new raw material feeling.
(8) It is possible to cut the fabric by a cutter, scissors and so on in the same way as ordinary fibrous fabric. No fluff is practically generated, and it is easy to produce various final manufactured goods.
(9) In case wherein the apex parts of piled fibers with a resin are made in a body as a group with a flat-shape, said scaly structure has excellent durability and therefore can keep a new raw mat.erial feeling, an unex-pected feeling and the good, fashionable characteristics which are the expected effects of the present invention.
Brief Description of Drawin~
Figure 1 is a rough model cross-sectional picture showing an example of a cross-sectional structure of the three dimensional fabric having the unique structure of the present invention as a model.
Figure 2 is a rough model surface picture showing the scaly structure of the fabric of the present invention as a model.
Figure 3 is a microscopic picture showing an example of a cross-sectional shape of the fabric of the present invention.
Figure 4 is a m.icroscopic picture enlarging the fabric surface, which shows an example of the outer appearance of the scaly structure of the fabric of the present invention wherein the area of a constituent unit is relatively large and the size is not relatively uniform.
Figure 5 is a microscop:ic picture of the fabric surfaee showing an example of the outer appearanee of the scaly structure wherein the area of a constituent unit is relatively small in the fabrie of the present invention.
Figure 6 is a microscopic picture enlarging further a part of the sealy strueture o~ the three dimen-sional fabric of the present invention.
Figure 7 is a microseopie pieture o the fabrie surfaee enlarging further more a part of the sealy struc-ture shown in Figure 6.
Best Mode for Carrying Out the Inv ntlon A three dimensional fabric having the unique strueture of the present invention and its method of preparation will be hereinafter further explained in ~5~2 detail.
The scaly structure in the present invention means a structure wherein apexes of a number of piled fibers are made in a body as a group with a flat-shape and exist on the surface layer of the fabri.c like scales and the Eabric of the present invention is constituted by many of these scaly structures covering the surface of the abric layer.
As the three dimensional fabric having a unique structure of the present invention, the base fabric is constituted by a piled fabric, for example, a double velludo fabric, a chinchilla fabric, woven and knitted fabrics using chenille yarns, a piled tricot, other warp knitted piled products, an electric flock, a mechanical flock and so on, but it is not restricted thereto and any fabric having a lot of piles, for example, piled fabric prepared by other method of preparation, can be used.
Figure 1 is a rough model cross-sectional picture showing an example of a cross-sectional structure of the three dimensional fabric having the unique structure of the present invention as a model.
As shown ln the figure, the three dimensional fabric 1 of the present lnvention exhibits a structure of three layers, and in the upper-most layer, the ~irst layer 2, the apexes of many piled fibers 3 are made in a body with a flat-shape by self-adhering action due to heat-fusion of the polymer constituting said piled fibers or by adhering action of an adhesive when said adhesive, made of a resin and so on, is used in parallel and a face 4 having a proper area is formed. The ground texture of the piled fabric 5 is the most lower layer among three layers and the layer of piled fibers 6 is the intermediate layer among three layers. In the intermediate layer, the piled fibers 3 usually exist in an inclined state and stand close together.
A number of the above described faces 4 shown in Figure 1 are formed on the surface of the fabric in such a way that they cover whole area of said fabric. Figure 2 is a surface picture showing the state of the fabric surface as a model.
Namely, a scaly structure 7 i5 formed as a whole by locating a number of faces 4 covering densely the surface with a crack 8 between. A unit face ~a scale constituting unit3 4 o~ scaly structure adjoining each other i5 separated by a crack 8 from the surface outer appearance, but practically connected through piled fibers 3, a ground texture 5 and other piled fibers 3. Namely, a number of piled fibers 3 existing between the scaly structure 7 and the ground texture ~ are inclined in general but stand close together as piled fibers to form an intermediate layer having high ratio of vacanc~ consti~
tuted by a number of piled fibers, and the ground texture S holds said piled fibers 3 and constitutes a base fabric 5 of the three dimensional fabric 1 of the present inven-tion. The length of the part of piled ibers in the intermediate layer is preferably in the range of 1 to 40 mm to sufficiently exhibit the efect of the above described structure of three layers.
Based on this structure, the three dimensional fabric of the present invention has a mass of the scaly structures on its surface layer wherein each scaly struc-ture 7 constituted by a face 4 can move independently to some extent from the adjoining scaly structure 7. Because the three dimensional fabric of the present invention has a unique state and structure like this, the outer appear-ance exhibits an aspect being ~ery rich in a natural feeling which is not seen in the conventional products such as scale-like, mineral-like, surface skin-like o pine tree, bagworm-like and so on and when said three dimensional abric is bent and curved, adjoining scaly structures are separated three-dimensionally and the insides of these scales can be exposed. These unique appearance and movement characteristics of the scaly structure offer a fabric whlch is rich in a new, raw material eeling, an unexpected eeling and a highly _ g _ fashionable characteristic.
Figure 3 is a cross-sectional microscopic pi~ture showlng an example of a cross-sectional shape of the fabric having the unique structure of the present invention and a microscopic picture showing an enlargement of an actual cross-sectional fabric structure correspond-ing to the model figure shown in Fiyure 1.
Figure 4 is a microscopic picture of the fabric structure, which shows an example of the outer appearance oE the scaly structure wherein the area of a constituent unit of the scaly structure of the three dimensional fabric having the unique structure of the present invèntion is relatively larye and the size is not rela-tively uniform.
Figure S is a microscopic picture of the fabric surface showing an example of the outer appearance of the scaly structure wherein the area o~ a constituent unit is relatively small in the fabric having the unique structure of the present in~lention.
Figure 6 is a microscopic picture enlarging ~urther a part of the scaly structura of the fabric having the unique structure of the present invention.
Figure 7 is a microscopic picture of the fabric surface enla~ging further a part of the scaly structure~
Moreover, in three dimensional fabric of the -- 1~ --present invention, it is preferable that at least in a part of the circumferential part of the apex of the scaly structure, a fibrous state partly appears in the split state. The split state exhibiting said fibrous state means, as shown with 9 in Figure 2, a state wherein the circumferential part of the apex of the scaly structure is substantially separated in fibrous state. By controlling the forming state of the scaly structure and the adhering state in a body of the apex of the piles, a new, raw material feeling and a feeling of natural product of the outer portion of the fabric, which the three dimensional fabric of the present invention has, can be stren~thened.
Moreoverl the touch thereby hardly becomes paper-like and it has flexibility and a cubic effect and becomes fashionable.
The three dimensional ;Eabric having the above described unique structure of the present invention can be prepared by (1) using a piled fabric having a number of piled ibers such as the above described double-velludo fabrics such as a single pile, a multi pile and so on, chinchilla fabric, woven and knitted fabrics using chenille yarns, piled tricot, other warp knitted piled products, electric flock, mechanical flock and so on as a raw material fabric, (2) carrying out a pressing treatment under heating and compression on the piled layer of the ~g~
said piled fabric to adhere the piled surface layer which the apexes of the piles form in a body and in a film-shape over a wi~e area, and 13) crumpling thereafter said fabric to split the above described film-like monolithic structure into a number of units of small area and to form thereby a number of scaly structures.
Pile length of the piled fabric largely influ-ences formability of the scaly structure. Namely, if the pile length is large, it is easy to make the apexes of piles in a body with a flat-shape and therefore easy to form a scaly structure. On the other hand, if the length is small, it is difficult to make the apexes of pile in a body and formability of a scaly structure is poor. In view of this fact, 3 mm or more is preferable for the pile length, and 5 mm or more is more preferable. The upper limit of the length of the pile is not specially restricted, but the length up to about 45 mm is practical from the view point of the manufacturing technology of piled fabrics.
Single filament denier of the fiber forming the piled part is not specifically restricted. However, taking formability, durability and esthetic appearance of a scaly structure into consideration, it is preferable that a ~lltra-fine artificial fiber whose denier is denier or less, more preferably 0.5 denier or less, is ~3~
used.
Moreover, as the density of numbers of piles of the piled fabric for the raw material, an amount of more than 5,000 piles/cm2 is preferable. Especially, the production of a super ultra-fine fiber whose denier is 0.01 denier or less is surely possible by means of present manufacturing technology of an ultra-fine piled fabric, so that a piled fabric of an ultra-high pile density whose value is 5 to 6 million piles/cm2 can be prepared with this super ultra-fine fiber. This piled fabric having such an ultra-high pile density can therefore be used to obtain a three dimensional fabric of the present invention. However, to the knowledge of the present inventors, it is preferable that in general, a high pile density of about 10,000 to 200,000 piles/cm2 is used, taking the practical ease of production into consideration. In general, it is desirable that the number of pi~es per unit area is larger because larger numbers of masses and the condition of flat-shape can be more easily prepared in such a case. For these reasons, it is desirable that the above described ultra-fine artificial fiber whose denier is 1 denier or less is used because it can result in an increase in the number of piles.
The average value of the area of a constituent - 13 ~
unit of the scaly structure is an important ~actor for obtaining the expected effects of the present invention, especially the e~fect of the outer appearance having the fashionable characteristics. To the knowledge o~ the present inventors, it is preferable that the value is in the range of 0.5 x 10. 2 cm2 (0.5 mrn square~ to 1 x 102 cm2 (10 cm square~ and it is more preferable that it is in the range of 2 x lQ 2 cm2 to 1 x 10 cm2.
For example, in case of the scaly structure having a small pattern and a mild feeling, the range of about 0.5 x 10 2 cm2 to 6 x 10 2 cm2 is preferable. On the other hand, in case o~ t!l~ scaly structure having an intermediate pattern and a relatively bold feeling, the range of ahout 6 x 10 2 cm2 to 1 x 10 cm2 is preferable.
Moreover, in case of the scaly structure having a large pattern and an even bolder feelincJ, the range of about 1 x 1.0 cm2 to 1 x 102 cm2 is preferable.
In the present invention, the average value of the area of a constituent unit of the scaly structure V
can be obtained by calculating the number of the scaly structures per unit area 100 cm2 from the following equa-tion (1) V = 100 cm2/numbers of the scaly structure ....... (1) Wherein the sampling area of 100 cm2 is not adequate because of a large pattern and so on, larger sampliny area can be properly taken. After all, the average value of the area of a constituent unit should be obtained by dividing the value of the sampling area by the number of the scale structures existing in the area.
If the patterns in these area range of are a mixture of masses having properly random sizes and properly random shapes without any definite pattern, the appearance overflows with natural feeling and it is esthetically excellent.
IE the average value of the area of a constituent unit of the scaly structure is 0.5 x 10 2 cm2 or less, the merit of the existence of the scaly structure decreases and the surface appearance is no different from an ordinary simple piled fabric and lacks uniqueness. On the other hand, if the value exceeds 1 x 102 cm2, the whole surface state is a flat one like an film sheet and lacks a cubic effect and the touch is papery. It i8 nbt desirable in general. However, in the application field such as wall decorative material and so on wherein a material of large si~e is generally used, such a large pattern of the scaly structure as one exceeding 1 x 10 cm2 can be used. After all, the appropriate size changes in accordance with various practical applications.
As a raw material constituting the fabric of the présent invention, elther a natural fiber or a synthetic fiber can be used and a properly blended one can be also used. However, as a fiber forming the piled parts, a heat fusing fiber is preferable, and a synthetic fiber is especially preferable. As the examples of the raw material for the synthetic fiber, polyethylene tere-phthalate or its copolymer ~for example, a copolymerizable component such as 5-sodium sulfoisophthalic acid), poly-butylene terephthalate or its copolymer, polyamides such as nylon 66, nylon 6 and nylon 12, polyacrylonitrile type polymers can be preferably used. Polymer compositions wherein modifiers and additives are blended with these polymers for the purposes of destaticiziny, improving dyeability, delustering, stain-pxoofing, fire retarding and shrink-proofing, can be properly preferably used.
As a practical method for carrying out a press treatment under heating and compression on a pile layer of a piled fabric, adhering a surface layer of the piles formed with apexes of the piles over a wide area and making it into a body with a film-like state, a method wherein the pile layer is pressed by means of heated calendar rolls and heat treatment is carried out while the pile layer is being compressed, is the most practical one.
Besides the calendar roll method, a compression treatment using a heated plate can be used. When a roll or a plate is used for pressing, the face of the press may be either flat or uneven. In the present invention, pressing i~ generally carried ou~ by means of a press surface with a mlrxor surface, but an embossing roll or an embossin~ plate having an embossing pattern of a regular shape or an irregular shape can be used for pressing. By doing so, a three dlmensional fabric haviny a three dimensional pattern with an embossed pattern and being rich in more fashionable feeling is obtained.
Scaly structures can be effectively formed by crumpling the film-llke monollthic structure formed by the above described process. To i~prove the shape retaining property and durability of the scaly structures, they may be fibers treated wlth a binder resin. The rasin is applied to a surface layer of the monollthic s~ructure be~ore crumpling and thereafter the monolithic structure is spll~ into the scaly struatures. Alternatlvely, the scaly structures are formed at first by crumpling the monolithic structure and then the resin is applied to the scaly structures.
With respect to the touah or hand, a more flexible and softer product can be obtained by the former process order, but the latter process order is superior to the former from the point of durability and shape retaining property.
As the resins used in this process, acrylic, melamine, vinyl acetate and epoxy resins, their copolymer resins, and high polymer elastomers such as butadiene copolymers, vinyl chloride copolymers and polyurethane are used.
As the method for adding the resin, a process comprising impregnation with the resin ~ squeezing drying ~ curing, and coating methods such as direct transferring, gravure, spraying and so on are preferably used, but it is not specially restricted and is properly selected in accordance with the touch and other characteristics desired.
The heating temperature in the calendar roll treatment on a pile layer of a piled fabric should be properly selected in accordance with a raw material of the piled fiber, but in general a range of 120 to 230C is preferable and a range of 160 to 210c is more preferable.
Namely, it is preferable that the treatment is carried out at the temperature wherein the piled fiber reaches a semimolten state. It is therefore difficult to form a scaly structure at too a low temperature condition. On the other hand, at too a high temperature condition, there is a possibility that the physical properties and dyeing fastness of the fabric will decrease. Therefoxe the above described temperature range, 120 to 230C, is the most appropriate temperature.
Five kg/cm2 or more is preferable for the treating pressure of the compression press, and 20 kg/cm2 or more is more preferable. Below 5 kg/cm2, the pressing pressure is too low and scaly structure formation and durability of the formed pattern are insufficient. To treat in a range of 20 to 100 kg/cm2 is an ordinary condition.
When a heat calendar roll machine is used as a means of heat compression press treatment, said calendar roll machine has generally a three roll structure in which the central cylinder roll is heated and the upper and the lower two plastorolls cannot be heated. It is therefore important that the piled part is contacted with the surfaces of heated cylinder rolls and thereby heat treated. As the treating speed, 0.5 to 20 m/min is preferable is accordance with the kind of machine, and 2 to 10 m/min is more preferable. Above 20 m/min, a fusing ef~ect is poor and a desired mass of the apexes of piles is hardly made in a body with a flat-shape and therefore hardly forms a scaly structure. Durability of shape of the scaly structure is also insufficient.
Formation of the scaly structure is largely influenced by the piled condition and the treating direction of a lie of piles of the fabric before heat press treatment. ~amely, to obtain a product whose average area of a constituent unit o~ the scaly structure is 0.5 x 10 2 cm2 to 6 x 10 2 cm2, namely small and whose shapes are relatively uniform, handling and managing of the piles are made in a good condition in advance by means of brushing and treatment with a finishing agent such as silicones and so on. Then a treatment under pressure and heating is performed on the piled fabric to make the pile direction in the following direction, namely, to constitute the pile fiber layer in a laid state, said treatment being carried out at a relatively lower tempera-ture (at around 180C if the raw material of the piles is polyethylene terephthalate).
On the other hand, to obtain a product whose average area of a constituent unit of the scaly structure is 6 x 10 2 cm2 or more and which has a surface condition of an intermediate or large pattern, it is desirable on the contrary that a material wherein handling and managing of the piles are in a bad condition (i.e., the pile direction is in a reverse direction and the pile fiber layer is in a laid state) be treated by means of a press and heat treatment at a higher temperature (at around 200C if the raw material oE the piles is polyethylene terephthalate).
Moreover, to obtain a product wherain var.ious smal.l, intermediate and large patterns exist in a mixed state and whose average area of a constituent unit is in a range of 10 2 cm2 to 102 cm2, it is preferable to crumple the intermediate or large pattern product by hand or mechamically.
To carry out a mechanical crumpling treatment, one can utilize various apparatus, even those not manufactured for the purpose to carry out crumpling treatments. Various apparatus for softening fabrics, for example, a so called vibraker, liquid bath treating apparatus in a such as a wince dyeing machine, a liquid flow dyeing machine and so on, a tumble apparatus which physically lifts up and drops a fabric, a beating apparatus which hlts a fabric ~with a bar, a guiding apparatus constituting plural bars for running a fabxic in a curved way and so:on, can be properly utilized.
Moreover, to obtain the three dimensional fa~ric of the present invention having a substantial number of scaly structures of a fixed pattern, it is possib:le to use a splitting technique such as rubbing and splitting to make an~ optional single shape or mixed shapes such~ as triangles, rectangles, polygons, circles, ellipses and so on and/or optional sizes of these shapes, by using a knife 3 S ~ ~ r~
with an edge and so on.
In the preceding or the following process of making a scaly structure of the three dimensional abric of the present invention, coating treatment of the back surface, desizing-scouring and heat setting treatment, treatment for making ultra-fine fibers in case of using an artificial fiber being capable of making ultra-fine fibers, dyeing, sizing, and drying and so on in the same way as ordinary piled woven and knitted fabrics, are suitably carried out.
Moreover, in the case of the conventional ordinary piled fabrics, a backin~ treatment is generally done on the back surface-of the fabric with a resin coa~ing and so on in many cases to prevent falling out of piles, but on the fabric of the present invention, the problem of piles falling out hardly occurs because the surface layer of th~ fabric is constituted by a scaly structure. The backing treatment is thereore not neces-sarily needed.
Moreover, water repelling treatment, flame retarding treatment, stain resistant treatment and so on may be suitably done, i~ necessary, on the three dimen-sional fabric of the present invention.
The present invention will be more concretely explained by the following examples.
Example 1 The following two types of islands-in-a-sea type composite fibers were spun and drawn to obtain blended composite fibers of 73 denier - 18 filaments.
a~ The islands-in-a-sea type composite fiber No. l Island component: Polyethylene terephthalate ~15 islands) Sea component: Polystyrene b) The islands-in-a-sea type composite fiber NoO2 Island component: Polyethylene terephthalate copolymerized with 10 mole % of isophthalic acid ~16 islands) Sea component: Polystyrene Here, the island-in-a-sea type composite iber No. l comprised 80~ of the island component and 20% of the sea component, and the ~whole fiber was 36.5 denier - 9 filaments. The island-in-a-sea type composite fiber No.2 comprised 80% of the island component and 20% of the sea component, and the whole fiber was 36.5 denier - 9 filaments. Therefore, a blended iber of total 73 denier - 18 filaments was obtained.
; This blended composite fiber was used as a pilable fiber~ A two folded yean comprising 30 denier - 12 filaments of polyethylene terephthalate (a twist-set product whose first twist ~S direction) was 900 T/m and second twist (Z direction~ was 900 T/m) was used as a warp of the ~round, and a twist-modified textured yarn of 150 denier - 48 filaments treated with an added twist of 400 T/m IS direction) and set with a twist-set was used as a weft of the ground. A fabric whose pile length was 10 mm was obtained by means of a double velludo weaving machine. As the fabric density, piled yarn, ground warp and ground weft were 46, 91 and 93 yarns/inch.
Dry heat setting of the fabric thus obtained was carried out and the sea component of the piled composite yarn was removed by treating with trichloroethylene to obtain a piled fabric wherein a number of ultrafine fibers, whose monofilament denier was 0.2 denier, were piled~ ~fter drying trichloroethylene, the back surface of the said fabric was coated with a solution comprising I00 parts of polyurethane, 25 parts of DMF and 0.25 parts of a pigment by means of a knife coater machi~ne. The backing treatment of the back surface of the fabr~c was thereby carried out.
The coating quantity of:polyurethane on the fabric was 14,8 g/m2. It was thereafter put into a liquid-flowing circular dyeing machlne to make the piles in a reverse direction, and the dyeing treatment was :: :
~S~
carried out by the following conditions.
(1~ Scouring (the treating time: 80C x 30 min) The treating agents:
A j Sandet~G-29" (manufactured by Sanyo Chemical --Industries Co., Ltd.) 0.5 g/lit.
Soda ash 0.5 g/lit.
(2) Dyeing (the treating time: 120C x 60 min) Dyes:
Kayalon Polyester Light Red BS 0.5% owf Resoline Blue BBLS 3.0% owf Samalon Blac~s BBL Liq 15020.0% owf LAP-50 0.5 g/lit.
PH 500 0.5 g/lit.
(3) Reduction cleaning (the treating time: 80C x 20 min) The treating agents:
~aOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
Sandet G-29 3 g/lit.
After dyeing, dehydration was done by means of a centrifugal dehydrater.
Then, calender treatments under the following ~ ~1 a le ~na~k conditions (A) and (B) were carried out by means of a hydraulic three-roll plastocalender machine.
Table 1 _ _ .
(A) (B) Temperature (C~ 180 200 .
Pressure (kg/cm2) 15 80 Treating speed (m/min) 8 8 _ Pile opening state of Sufficient A little the treated fabric unsufficient~
_ . Direction of the fabric Following Reverse : put in the calender : _ :
During the treatment, the piled part of the fabric was made to contact the heated cylinder roll of the calender roIl. Regarding the fabric treated under the condition (A), its pile opening and handling conditions were made good by brushlng beore the calender treatment.
.
~3~3S$~
Treated fabrics thus obtained had a layer of apexes of piles being adhered over a wide area and being made in a body with a film-shape.
Crumpling treatment on this treated fabric was carried out by passing this treated fabric through an apparatus for guiding fabric wherein plural bars were placed alternately on a higher and a lower position to make the zigzag curved running of the fabric possible.
The fabrics thus obtained by both treating level ~A3 and lB) had apexes of piles in a body with a flat-shape and scaly structures.
The area of a constituent unit of said scaly structure of the level (A) wa.s 20 x 10 2 cm2 on the average and had a relatively uniform shape having a relatively small area in the range of 3 x 10 2 cm2 to 36 x 10 cm . The area of the level ~B) was 1.5 x 10 cm on the average and had various shapes and areas, including small as well as large ones in the range of 25 x 10 to 0.8 x 102 cm2. All outer appearances were unique and rich in a natural feeling like a bagworm, coal or a skin of a pine tree and rich in luster characteristic, flexibility and cubic effect. The fabric was rich in esthetic and high class feelings which had never been seen before.
In comparing the level (A) with the level (B), it was found that the level (A) gave a mild feeling because each S L~
scaly structure was small, while the level (B) gave a bold feeling and a feeling being full of rural beauty because each scaly structure was large.
Example 2 As a piled yarn, a filament yarn of 75 denier-18 filaments obtained by spinning and drawing islands-in-a-sea type composite fibers having the following constitution was used.
Island component: Polyethylene terephthalate Sea component: Polystyrene Number of the island component: 6 Ratio of the island/the sea component: 80/20 Monofilament denier of the island component:
0.56 denier A twisted textured yarn of polyethylene tere-phthalate of 75D-36f as a warp of the ground and a twisted textured yarn of the same polymer oE 150D-48f as a weft of the ground were used to obtain a fabric having piles whose length was 11 mm by means of a double velludo weaving machine. Regarding the fabric dsnsity, the piled yarn, ground warp and ground weft were 47, 93 and 94 yarns/inch, respectively.
After dr~ heat settlng of the said piled fabric, the sea component of the composite yarns used for piled yarns was removed by treating with trichloroethylene to obtain a piled fabric wherein a number of ultrafine fibers whose monofilament. denier was 0.56 denier. After drying the trichloroethylene, the back surface of the said fabric was coated with a solution comprising 100 parts of poly-urethane, 13/18 parts` of MEK/toluene, 50/5 parts of water/MEK, 2 parts of a crosslinking agent and 0.25 parts of a pigment by means of a knife coater machine the backing treatment of the back surface of -the piled fabric was carri.ed out. Coating quantity of polyurethane on the fabric was 22 g/m2. It was -thereafter put into a liquid-flowing circular dyeing machine to make the piles in areverse direction during the dyeing treatment and the dyeing treatment was carried out under the following conditions.
(1~ Scouring (the treating I:ime: 80C x 30 min) The treating agents:
"Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltd.) 0.5 g/lit.
Soda ash 0.5 g/lit.
(2) Dyeing (the treating time: 120C x 60 min) Dyes:
Resoline Blue BBLS 2.5~ owf Kayalon Polyester Light Red ~S 3.0~ owf Foron Yellow Brown S-2RFL 4.6~ owf ~s~
Palanil Yellow 3G 1.7~ owf LAP-50 (manufactured by Sanyo Chemical Industries, Co., Ltd.) 0.5 g/lit.
PH-50Q (manufactured by 5anyo Chemical Industries, Co., Ltd.) 0.5 g/lit.
(3) Reduction cleaning (the treating time: 80C x 20 min~
The treating agents:
NaOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
"Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltdo) 3 g/lit.
After dyeing, dehydration was done by means of a centrifugal dehydrater.
Then, a calendar treatment was carried out by means o~ a hydraulic three-roll plastocalendar machine. The treating conditions were as follows.
Temperature- 200C ~The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm2 Treating speed: 8 m/min Pile opening state of the treated fabric: A little ~ unsufficient Direction of the fabric put in the calendar: Reverse After the treatment, some crumpling by hand was done, and a resin treatment was then carried out under the following conditions to obtain a dimensional durability.
Resin treatment: Resin impregnation (Pick up 57%) Drying (100C x 5 min~ ~ Curing (180C x 1 min~
Resin composition: "Sumitex Resin M-3 (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 20 g/lit~
CB-01 (Cosmo Chemical Co., Ltd.) 2 g/lit.
Ammonium Persulphate 2 g/lit.
Resin built-up: 0.9%
Moreover, said fabric was put in a Wince dyeing machine containing warm water at 80C, rotated and moved in the warm water for 20 minutes to crumpling it and dried.
Treated fabrics thus obtained had apexes of piles in a body and good scaly structures. The average area of a constituent unit of said scaly structures was 2.4 x 10 cm2, and the ~abric had various Iarge, intermediate and small shapes and areas in the range of 9 x 10 2 cm2 to 0.8 x 102 cm2, and the outer appearance exhibited excellent scaly structures. An excellent fabric having an outer apperance like mica and being rich in a natural feelinq, a new, raw material feelinq and a fushionable characteristic was obtained.
Moreover, durability of said scaly structure was ~ r~ na~k :~l3~
e~aluated. The methods for testing durability and the results were as follows.
Moreover, .comparison tests on an untreated product without any shape fixing treatment by means of resin treatment were carried out.
Table 2 Fixed product Untreated product _ Test 1 ~ to o Test 2 o to ~ x to Q
Test 3 ~ Q to o Evaluation level : No change in shape after the test o : Li.ttle change in shape after the test a A little chan~e in shape after ~he t~st x : Remarkable change in shape after the test Testing method Test 1: Wearing durability test of an outer coat on both the circumference parts of the elbows and the parts of axillae of which a fabric to be tested was attached was done for one week.
Test 2: Durability test against dry cleanings ~ 32 by means of an ordinary method using perchlene were done for two times in a dry cleaniny shop.
Test 3: Abrasion durability test wherein an abrasive go and back cycle test of 50 times was carried out on a surface to be abraded under a pressing load of 500 g by means of Gakushin type abrasion tester.
It is clear from Table 2 that the products whose scaly structure was formed by making in a body with a resin, had better durability.
Moreover, the products adhered with the resin exhibited excellent luster characteristic. The products without resin adherence showed softer feeling and touch but it is recognized that the products with resin adherence also had sufficiently good flexibility.
Example 3 The following two kinds of islands-in-a-sea type composite fibers were spun and drawn to obtain blended composite fibers of 65 denier - 18 filaments.
a) The islands-in-a-sea type composite fiber No n 1 Island component: Polyethylene terephthalate ~16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid~5-sodium sulfoisophthalic acid/87.5 ~70/30)/12.5 mole %
b) ~he islands-in-a-sea type composi.te iber No.2 Island component: Polyethylene terephthalate - copolymerized with 4.9 mole %
of isophthalic acid ~16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid~5-sodium sulfoisophthalic acid/87.5 (70/30)/12.5 mole %
Here, the islands-in-a-sea type composite iber No.1 comprised 90~ of the island component and 10~ of the sea component and the whole fiber was 32.5 denier - 9 filaments. The .islands-in-a-sea type composite fiber No.2 comprised 90~ of the island component and 10% of the sea~
component and the whole fiber was 32.5 denier - 9 filaments. Therefore, a blended;fiber o total 65 denier - 18 filaments was obtained.
This blended composite fiber was used as a pilable fiber. A false twlsted textured yarn comprising 75 denier - 36 filaments of polyethylene terephthalate; was used as a~warp of the ground, and a false twisted textured yarn of~ 100 denier - ~48 filaments of polyethylene terephthalate was used~as~ a wet of the ground. A Eahric' whose pile length was 6 mm was obtained by means of a : :
double velludo weaving machine. Regarding fabric density, the piled yarn, ground warp and ground weft were 45.5, 91 and 107 yarnslinch.
After dry heat setting of the fabric thus obtained was carried out, the following treatment was carried out by means of a liquid-flowing circular dyeing machine.
(1) Treatment for preparing a ultra-fine fiber The 1st treatment:
Treating agent: Malechead CM (manufactured by Takeda Chemicals Industry Co., Ltd.) 1 g/lit.
Treating temperature x time: 120C x 30 minutes The 2nd treatment:
Treating agent: NaOH (30%) 3 g/lit.
Treating temperature x time: 80C x 30 minutes (2) Dyeing ~the treating time: 120C x 60 min) Dyes:
Resoline Blue BBLS ; 0.53~ owf Kayalon Polyester Light Red BS 0.73~ owf Foron Yellow ~rown S-2RFL3.2% ow~
(3) Reduction clean~ng The treating agents.
NaOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
~ 7~~aJ~ ~na~
Sandet G-29 1 gtlit.
(4) Silicone treatment Treating agent:
Ultratex~ESC (manufactured by CIBA-GEIGY)0.~% owf Treating temperature x time: 20C x 10 minutes A ultra-fine piled fabric whose monofilament denier was 0.2 denier was obtained by these treatments.
After drying said ultra-fine piled fabric, a calendar treatment using the belsw described conditions was carried out by means of a hydraulic three-roll plastoralendar machine~
The treating conditions were as follows.
Temperature: 190C (The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm2 Treating speed: 8 m/min Pile opening state of the treated fabric: A little unsufficient Direction of the fabric put in the calendar: Reverse A resin treatment under the following conditions was immediately carried out on the calendar treated fabric thus obtained.
Resin treatment process: Resin impregnation (Pick up 41~ Drying (100C x 5 min) ~ Curing (120~C x 3 min) ~ 7 ra le~ n~aT ~
35S~$~
Resin composition: "Sumitex Resin M-3l' (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 28 g/lit.
CB-Ol (Cosmo Chemical Co., Ltd.) 2 g/lit.
Ammonium Persulphate 2 gjlit.
Resin built-up: 0.3%
Moreover, said fabric was put in a liquid-flowing circular dyeing machine and said fabric was circulated in said liquid-flowing circular dyeing machine for 12 minutes to carry out a crumpling treatment. The bath ratio was 1:30, and the nozzle pressure was 1.2 kg/cm2.
The three dimensional fabric of the present invention thus obtained had a scaly structure whose constituent unit was in the range of 1 x lO 2 cm2 to 5 x 10 2 cm2 and relatively small and whose size was rela-t.ively uniform.
This three dimensional fabric had a number o small scaly structures densely covering its surface, and the outer appearance was beautiful with these scaly structures. The fabric exhibited a mild feeling and was rich~in a natural fee~ling, a new, raw material feeling and a fashionable characteristic :
The three dimensional fabric of Example 3 was different from those of Examples 1 and 2 because the piled $~
fabric had no backing treatment with a resin. The touch of the fabric was therefore very soft and the fabric was good for apparel use having excellent drapery.
Industrial Applicability The three dlmensional fabric having a unique structure of the present invention can be widely used in such various applications that fashion characteristics are important by utilizing its new, raw material feeling and unexpected feeling.
Namely, it can be used for fashionable outer wears, fox example, over coatings such as an overcoat, a raincoat, a cape, a shawl and so on, jackets such as a jacket, a suit, a business suit, and so on, trousers such as slacks, pants and so on, and outer wears such as hats, gloves and so on.
It can be also used for a surface raw material for bags rich in a fashionable feeling, for example, bags such as a bag, a handbag and so on, various briefcases and various suitcases.
Moreover, it can be also used ~or wall decora-tive materials suoh as inner and outer wall materials being rich in a new eeling and a new, raw material feeling.
Moreover, it can be also used for interior materials such as a curtain, a floor material, carpets, a chair cloth, a case for exhibiting goods, a tent material of a shop and so on.
Moreover, it can be also used for shoes, boots and so on.
Brief Description of Drawin~
Figure 1 is a rough model cross-sectional picture showing an example of a cross-sectional structure of the three dimensional fabric having the unique structure of the present invention as a model.
Figure 2 is a rough model surface picture showing the scaly structure of the fabric of the present invention as a model.
Figure 3 is a microscopic picture showing an example of a cross-sectional shape of the fabric of the present invention.
Figure 4 is a m.icroscopic picture enlarging the fabric surface, which shows an example of the outer appearance of the scaly structure of the fabric of the present invention wherein the area of a constituent unit is relatively large and the size is not relatively uniform.
Figure 5 is a microscop:ic picture of the fabric surfaee showing an example of the outer appearanee of the scaly structure wherein the area of a constituent unit is relatively small in the fabrie of the present invention.
Figure 6 is a microscopic picture enlarging further a part of the sealy strueture o~ the three dimen-sional fabric of the present invention.
Figure 7 is a microseopie pieture o the fabrie surfaee enlarging further more a part of the sealy struc-ture shown in Figure 6.
Best Mode for Carrying Out the Inv ntlon A three dimensional fabric having the unique strueture of the present invention and its method of preparation will be hereinafter further explained in ~5~2 detail.
The scaly structure in the present invention means a structure wherein apexes of a number of piled fibers are made in a body as a group with a flat-shape and exist on the surface layer of the fabri.c like scales and the Eabric of the present invention is constituted by many of these scaly structures covering the surface of the abric layer.
As the three dimensional fabric having a unique structure of the present invention, the base fabric is constituted by a piled fabric, for example, a double velludo fabric, a chinchilla fabric, woven and knitted fabrics using chenille yarns, a piled tricot, other warp knitted piled products, an electric flock, a mechanical flock and so on, but it is not restricted thereto and any fabric having a lot of piles, for example, piled fabric prepared by other method of preparation, can be used.
Figure 1 is a rough model cross-sectional picture showing an example of a cross-sectional structure of the three dimensional fabric having the unique structure of the present invention as a model.
As shown ln the figure, the three dimensional fabric 1 of the present lnvention exhibits a structure of three layers, and in the upper-most layer, the ~irst layer 2, the apexes of many piled fibers 3 are made in a body with a flat-shape by self-adhering action due to heat-fusion of the polymer constituting said piled fibers or by adhering action of an adhesive when said adhesive, made of a resin and so on, is used in parallel and a face 4 having a proper area is formed. The ground texture of the piled fabric 5 is the most lower layer among three layers and the layer of piled fibers 6 is the intermediate layer among three layers. In the intermediate layer, the piled fibers 3 usually exist in an inclined state and stand close together.
A number of the above described faces 4 shown in Figure 1 are formed on the surface of the fabric in such a way that they cover whole area of said fabric. Figure 2 is a surface picture showing the state of the fabric surface as a model.
Namely, a scaly structure 7 i5 formed as a whole by locating a number of faces 4 covering densely the surface with a crack 8 between. A unit face ~a scale constituting unit3 4 o~ scaly structure adjoining each other i5 separated by a crack 8 from the surface outer appearance, but practically connected through piled fibers 3, a ground texture 5 and other piled fibers 3. Namely, a number of piled fibers 3 existing between the scaly structure 7 and the ground texture ~ are inclined in general but stand close together as piled fibers to form an intermediate layer having high ratio of vacanc~ consti~
tuted by a number of piled fibers, and the ground texture S holds said piled fibers 3 and constitutes a base fabric 5 of the three dimensional fabric 1 of the present inven-tion. The length of the part of piled ibers in the intermediate layer is preferably in the range of 1 to 40 mm to sufficiently exhibit the efect of the above described structure of three layers.
Based on this structure, the three dimensional fabric of the present invention has a mass of the scaly structures on its surface layer wherein each scaly struc-ture 7 constituted by a face 4 can move independently to some extent from the adjoining scaly structure 7. Because the three dimensional fabric of the present invention has a unique state and structure like this, the outer appear-ance exhibits an aspect being ~ery rich in a natural feeling which is not seen in the conventional products such as scale-like, mineral-like, surface skin-like o pine tree, bagworm-like and so on and when said three dimensional abric is bent and curved, adjoining scaly structures are separated three-dimensionally and the insides of these scales can be exposed. These unique appearance and movement characteristics of the scaly structure offer a fabric whlch is rich in a new, raw material eeling, an unexpected eeling and a highly _ g _ fashionable characteristic.
Figure 3 is a cross-sectional microscopic pi~ture showlng an example of a cross-sectional shape of the fabric having the unique structure of the present invention and a microscopic picture showing an enlargement of an actual cross-sectional fabric structure correspond-ing to the model figure shown in Fiyure 1.
Figure 4 is a microscopic picture of the fabric structure, which shows an example of the outer appearance oE the scaly structure wherein the area of a constituent unit of the scaly structure of the three dimensional fabric having the unique structure of the present invèntion is relatively larye and the size is not rela-tively uniform.
Figure S is a microscopic picture of the fabric surface showing an example of the outer appearance of the scaly structure wherein the area o~ a constituent unit is relatively small in the fabric having the unique structure of the present in~lention.
Figure 6 is a microscopic picture enlarging ~urther a part of the scaly structura of the fabric having the unique structure of the present invention.
Figure 7 is a microscopic picture of the fabric surface enla~ging further a part of the scaly structure~
Moreover, in three dimensional fabric of the -- 1~ --present invention, it is preferable that at least in a part of the circumferential part of the apex of the scaly structure, a fibrous state partly appears in the split state. The split state exhibiting said fibrous state means, as shown with 9 in Figure 2, a state wherein the circumferential part of the apex of the scaly structure is substantially separated in fibrous state. By controlling the forming state of the scaly structure and the adhering state in a body of the apex of the piles, a new, raw material feeling and a feeling of natural product of the outer portion of the fabric, which the three dimensional fabric of the present invention has, can be stren~thened.
Moreoverl the touch thereby hardly becomes paper-like and it has flexibility and a cubic effect and becomes fashionable.
The three dimensional ;Eabric having the above described unique structure of the present invention can be prepared by (1) using a piled fabric having a number of piled ibers such as the above described double-velludo fabrics such as a single pile, a multi pile and so on, chinchilla fabric, woven and knitted fabrics using chenille yarns, piled tricot, other warp knitted piled products, electric flock, mechanical flock and so on as a raw material fabric, (2) carrying out a pressing treatment under heating and compression on the piled layer of the ~g~
said piled fabric to adhere the piled surface layer which the apexes of the piles form in a body and in a film-shape over a wi~e area, and 13) crumpling thereafter said fabric to split the above described film-like monolithic structure into a number of units of small area and to form thereby a number of scaly structures.
Pile length of the piled fabric largely influ-ences formability of the scaly structure. Namely, if the pile length is large, it is easy to make the apexes of piles in a body with a flat-shape and therefore easy to form a scaly structure. On the other hand, if the length is small, it is difficult to make the apexes of pile in a body and formability of a scaly structure is poor. In view of this fact, 3 mm or more is preferable for the pile length, and 5 mm or more is more preferable. The upper limit of the length of the pile is not specially restricted, but the length up to about 45 mm is practical from the view point of the manufacturing technology of piled fabrics.
Single filament denier of the fiber forming the piled part is not specifically restricted. However, taking formability, durability and esthetic appearance of a scaly structure into consideration, it is preferable that a ~lltra-fine artificial fiber whose denier is denier or less, more preferably 0.5 denier or less, is ~3~
used.
Moreover, as the density of numbers of piles of the piled fabric for the raw material, an amount of more than 5,000 piles/cm2 is preferable. Especially, the production of a super ultra-fine fiber whose denier is 0.01 denier or less is surely possible by means of present manufacturing technology of an ultra-fine piled fabric, so that a piled fabric of an ultra-high pile density whose value is 5 to 6 million piles/cm2 can be prepared with this super ultra-fine fiber. This piled fabric having such an ultra-high pile density can therefore be used to obtain a three dimensional fabric of the present invention. However, to the knowledge of the present inventors, it is preferable that in general, a high pile density of about 10,000 to 200,000 piles/cm2 is used, taking the practical ease of production into consideration. In general, it is desirable that the number of pi~es per unit area is larger because larger numbers of masses and the condition of flat-shape can be more easily prepared in such a case. For these reasons, it is desirable that the above described ultra-fine artificial fiber whose denier is 1 denier or less is used because it can result in an increase in the number of piles.
The average value of the area of a constituent - 13 ~
unit of the scaly structure is an important ~actor for obtaining the expected effects of the present invention, especially the e~fect of the outer appearance having the fashionable characteristics. To the knowledge o~ the present inventors, it is preferable that the value is in the range of 0.5 x 10. 2 cm2 (0.5 mrn square~ to 1 x 102 cm2 (10 cm square~ and it is more preferable that it is in the range of 2 x lQ 2 cm2 to 1 x 10 cm2.
For example, in case of the scaly structure having a small pattern and a mild feeling, the range of about 0.5 x 10 2 cm2 to 6 x 10 2 cm2 is preferable. On the other hand, in case o~ t!l~ scaly structure having an intermediate pattern and a relatively bold feeling, the range of ahout 6 x 10 2 cm2 to 1 x 10 cm2 is preferable.
Moreover, in case of the scaly structure having a large pattern and an even bolder feelincJ, the range of about 1 x 1.0 cm2 to 1 x 102 cm2 is preferable.
In the present invention, the average value of the area of a constituent unit of the scaly structure V
can be obtained by calculating the number of the scaly structures per unit area 100 cm2 from the following equa-tion (1) V = 100 cm2/numbers of the scaly structure ....... (1) Wherein the sampling area of 100 cm2 is not adequate because of a large pattern and so on, larger sampliny area can be properly taken. After all, the average value of the area of a constituent unit should be obtained by dividing the value of the sampling area by the number of the scale structures existing in the area.
If the patterns in these area range of are a mixture of masses having properly random sizes and properly random shapes without any definite pattern, the appearance overflows with natural feeling and it is esthetically excellent.
IE the average value of the area of a constituent unit of the scaly structure is 0.5 x 10 2 cm2 or less, the merit of the existence of the scaly structure decreases and the surface appearance is no different from an ordinary simple piled fabric and lacks uniqueness. On the other hand, if the value exceeds 1 x 102 cm2, the whole surface state is a flat one like an film sheet and lacks a cubic effect and the touch is papery. It i8 nbt desirable in general. However, in the application field such as wall decorative material and so on wherein a material of large si~e is generally used, such a large pattern of the scaly structure as one exceeding 1 x 10 cm2 can be used. After all, the appropriate size changes in accordance with various practical applications.
As a raw material constituting the fabric of the présent invention, elther a natural fiber or a synthetic fiber can be used and a properly blended one can be also used. However, as a fiber forming the piled parts, a heat fusing fiber is preferable, and a synthetic fiber is especially preferable. As the examples of the raw material for the synthetic fiber, polyethylene tere-phthalate or its copolymer ~for example, a copolymerizable component such as 5-sodium sulfoisophthalic acid), poly-butylene terephthalate or its copolymer, polyamides such as nylon 66, nylon 6 and nylon 12, polyacrylonitrile type polymers can be preferably used. Polymer compositions wherein modifiers and additives are blended with these polymers for the purposes of destaticiziny, improving dyeability, delustering, stain-pxoofing, fire retarding and shrink-proofing, can be properly preferably used.
As a practical method for carrying out a press treatment under heating and compression on a pile layer of a piled fabric, adhering a surface layer of the piles formed with apexes of the piles over a wide area and making it into a body with a film-like state, a method wherein the pile layer is pressed by means of heated calendar rolls and heat treatment is carried out while the pile layer is being compressed, is the most practical one.
Besides the calendar roll method, a compression treatment using a heated plate can be used. When a roll or a plate is used for pressing, the face of the press may be either flat or uneven. In the present invention, pressing i~ generally carried ou~ by means of a press surface with a mlrxor surface, but an embossing roll or an embossin~ plate having an embossing pattern of a regular shape or an irregular shape can be used for pressing. By doing so, a three dlmensional fabric haviny a three dimensional pattern with an embossed pattern and being rich in more fashionable feeling is obtained.
Scaly structures can be effectively formed by crumpling the film-llke monollthic structure formed by the above described process. To i~prove the shape retaining property and durability of the scaly structures, they may be fibers treated wlth a binder resin. The rasin is applied to a surface layer of the monollthic s~ructure be~ore crumpling and thereafter the monolithic structure is spll~ into the scaly struatures. Alternatlvely, the scaly structures are formed at first by crumpling the monolithic structure and then the resin is applied to the scaly structures.
With respect to the touah or hand, a more flexible and softer product can be obtained by the former process order, but the latter process order is superior to the former from the point of durability and shape retaining property.
As the resins used in this process, acrylic, melamine, vinyl acetate and epoxy resins, their copolymer resins, and high polymer elastomers such as butadiene copolymers, vinyl chloride copolymers and polyurethane are used.
As the method for adding the resin, a process comprising impregnation with the resin ~ squeezing drying ~ curing, and coating methods such as direct transferring, gravure, spraying and so on are preferably used, but it is not specially restricted and is properly selected in accordance with the touch and other characteristics desired.
The heating temperature in the calendar roll treatment on a pile layer of a piled fabric should be properly selected in accordance with a raw material of the piled fiber, but in general a range of 120 to 230C is preferable and a range of 160 to 210c is more preferable.
Namely, it is preferable that the treatment is carried out at the temperature wherein the piled fiber reaches a semimolten state. It is therefore difficult to form a scaly structure at too a low temperature condition. On the other hand, at too a high temperature condition, there is a possibility that the physical properties and dyeing fastness of the fabric will decrease. Therefoxe the above described temperature range, 120 to 230C, is the most appropriate temperature.
Five kg/cm2 or more is preferable for the treating pressure of the compression press, and 20 kg/cm2 or more is more preferable. Below 5 kg/cm2, the pressing pressure is too low and scaly structure formation and durability of the formed pattern are insufficient. To treat in a range of 20 to 100 kg/cm2 is an ordinary condition.
When a heat calendar roll machine is used as a means of heat compression press treatment, said calendar roll machine has generally a three roll structure in which the central cylinder roll is heated and the upper and the lower two plastorolls cannot be heated. It is therefore important that the piled part is contacted with the surfaces of heated cylinder rolls and thereby heat treated. As the treating speed, 0.5 to 20 m/min is preferable is accordance with the kind of machine, and 2 to 10 m/min is more preferable. Above 20 m/min, a fusing ef~ect is poor and a desired mass of the apexes of piles is hardly made in a body with a flat-shape and therefore hardly forms a scaly structure. Durability of shape of the scaly structure is also insufficient.
Formation of the scaly structure is largely influenced by the piled condition and the treating direction of a lie of piles of the fabric before heat press treatment. ~amely, to obtain a product whose average area of a constituent unit o~ the scaly structure is 0.5 x 10 2 cm2 to 6 x 10 2 cm2, namely small and whose shapes are relatively uniform, handling and managing of the piles are made in a good condition in advance by means of brushing and treatment with a finishing agent such as silicones and so on. Then a treatment under pressure and heating is performed on the piled fabric to make the pile direction in the following direction, namely, to constitute the pile fiber layer in a laid state, said treatment being carried out at a relatively lower tempera-ture (at around 180C if the raw material of the piles is polyethylene terephthalate).
On the other hand, to obtain a product whose average area of a constituent unit of the scaly structure is 6 x 10 2 cm2 or more and which has a surface condition of an intermediate or large pattern, it is desirable on the contrary that a material wherein handling and managing of the piles are in a bad condition (i.e., the pile direction is in a reverse direction and the pile fiber layer is in a laid state) be treated by means of a press and heat treatment at a higher temperature (at around 200C if the raw material oE the piles is polyethylene terephthalate).
Moreover, to obtain a product wherain var.ious smal.l, intermediate and large patterns exist in a mixed state and whose average area of a constituent unit is in a range of 10 2 cm2 to 102 cm2, it is preferable to crumple the intermediate or large pattern product by hand or mechamically.
To carry out a mechanical crumpling treatment, one can utilize various apparatus, even those not manufactured for the purpose to carry out crumpling treatments. Various apparatus for softening fabrics, for example, a so called vibraker, liquid bath treating apparatus in a such as a wince dyeing machine, a liquid flow dyeing machine and so on, a tumble apparatus which physically lifts up and drops a fabric, a beating apparatus which hlts a fabric ~with a bar, a guiding apparatus constituting plural bars for running a fabxic in a curved way and so:on, can be properly utilized.
Moreover, to obtain the three dimensional fa~ric of the present invention having a substantial number of scaly structures of a fixed pattern, it is possib:le to use a splitting technique such as rubbing and splitting to make an~ optional single shape or mixed shapes such~ as triangles, rectangles, polygons, circles, ellipses and so on and/or optional sizes of these shapes, by using a knife 3 S ~ ~ r~
with an edge and so on.
In the preceding or the following process of making a scaly structure of the three dimensional abric of the present invention, coating treatment of the back surface, desizing-scouring and heat setting treatment, treatment for making ultra-fine fibers in case of using an artificial fiber being capable of making ultra-fine fibers, dyeing, sizing, and drying and so on in the same way as ordinary piled woven and knitted fabrics, are suitably carried out.
Moreover, in the case of the conventional ordinary piled fabrics, a backin~ treatment is generally done on the back surface-of the fabric with a resin coa~ing and so on in many cases to prevent falling out of piles, but on the fabric of the present invention, the problem of piles falling out hardly occurs because the surface layer of th~ fabric is constituted by a scaly structure. The backing treatment is thereore not neces-sarily needed.
Moreover, water repelling treatment, flame retarding treatment, stain resistant treatment and so on may be suitably done, i~ necessary, on the three dimen-sional fabric of the present invention.
The present invention will be more concretely explained by the following examples.
Example 1 The following two types of islands-in-a-sea type composite fibers were spun and drawn to obtain blended composite fibers of 73 denier - 18 filaments.
a~ The islands-in-a-sea type composite fiber No. l Island component: Polyethylene terephthalate ~15 islands) Sea component: Polystyrene b) The islands-in-a-sea type composite fiber NoO2 Island component: Polyethylene terephthalate copolymerized with 10 mole % of isophthalic acid ~16 islands) Sea component: Polystyrene Here, the island-in-a-sea type composite iber No. l comprised 80~ of the island component and 20% of the sea component, and the ~whole fiber was 36.5 denier - 9 filaments. The island-in-a-sea type composite fiber No.2 comprised 80% of the island component and 20% of the sea component, and the whole fiber was 36.5 denier - 9 filaments. Therefore, a blended iber of total 73 denier - 18 filaments was obtained.
; This blended composite fiber was used as a pilable fiber~ A two folded yean comprising 30 denier - 12 filaments of polyethylene terephthalate (a twist-set product whose first twist ~S direction) was 900 T/m and second twist (Z direction~ was 900 T/m) was used as a warp of the ~round, and a twist-modified textured yarn of 150 denier - 48 filaments treated with an added twist of 400 T/m IS direction) and set with a twist-set was used as a weft of the ground. A fabric whose pile length was 10 mm was obtained by means of a double velludo weaving machine. As the fabric density, piled yarn, ground warp and ground weft were 46, 91 and 93 yarns/inch.
Dry heat setting of the fabric thus obtained was carried out and the sea component of the piled composite yarn was removed by treating with trichloroethylene to obtain a piled fabric wherein a number of ultrafine fibers, whose monofilament denier was 0.2 denier, were piled~ ~fter drying trichloroethylene, the back surface of the said fabric was coated with a solution comprising I00 parts of polyurethane, 25 parts of DMF and 0.25 parts of a pigment by means of a knife coater machi~ne. The backing treatment of the back surface of the fabr~c was thereby carried out.
The coating quantity of:polyurethane on the fabric was 14,8 g/m2. It was thereafter put into a liquid-flowing circular dyeing machlne to make the piles in a reverse direction, and the dyeing treatment was :: :
~S~
carried out by the following conditions.
(1~ Scouring (the treating time: 80C x 30 min) The treating agents:
A j Sandet~G-29" (manufactured by Sanyo Chemical --Industries Co., Ltd.) 0.5 g/lit.
Soda ash 0.5 g/lit.
(2) Dyeing (the treating time: 120C x 60 min) Dyes:
Kayalon Polyester Light Red BS 0.5% owf Resoline Blue BBLS 3.0% owf Samalon Blac~s BBL Liq 15020.0% owf LAP-50 0.5 g/lit.
PH 500 0.5 g/lit.
(3) Reduction cleaning (the treating time: 80C x 20 min) The treating agents:
~aOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
Sandet G-29 3 g/lit.
After dyeing, dehydration was done by means of a centrifugal dehydrater.
Then, calender treatments under the following ~ ~1 a le ~na~k conditions (A) and (B) were carried out by means of a hydraulic three-roll plastocalender machine.
Table 1 _ _ .
(A) (B) Temperature (C~ 180 200 .
Pressure (kg/cm2) 15 80 Treating speed (m/min) 8 8 _ Pile opening state of Sufficient A little the treated fabric unsufficient~
_ . Direction of the fabric Following Reverse : put in the calender : _ :
During the treatment, the piled part of the fabric was made to contact the heated cylinder roll of the calender roIl. Regarding the fabric treated under the condition (A), its pile opening and handling conditions were made good by brushlng beore the calender treatment.
.
~3~3S$~
Treated fabrics thus obtained had a layer of apexes of piles being adhered over a wide area and being made in a body with a film-shape.
Crumpling treatment on this treated fabric was carried out by passing this treated fabric through an apparatus for guiding fabric wherein plural bars were placed alternately on a higher and a lower position to make the zigzag curved running of the fabric possible.
The fabrics thus obtained by both treating level ~A3 and lB) had apexes of piles in a body with a flat-shape and scaly structures.
The area of a constituent unit of said scaly structure of the level (A) wa.s 20 x 10 2 cm2 on the average and had a relatively uniform shape having a relatively small area in the range of 3 x 10 2 cm2 to 36 x 10 cm . The area of the level ~B) was 1.5 x 10 cm on the average and had various shapes and areas, including small as well as large ones in the range of 25 x 10 to 0.8 x 102 cm2. All outer appearances were unique and rich in a natural feeling like a bagworm, coal or a skin of a pine tree and rich in luster characteristic, flexibility and cubic effect. The fabric was rich in esthetic and high class feelings which had never been seen before.
In comparing the level (A) with the level (B), it was found that the level (A) gave a mild feeling because each S L~
scaly structure was small, while the level (B) gave a bold feeling and a feeling being full of rural beauty because each scaly structure was large.
Example 2 As a piled yarn, a filament yarn of 75 denier-18 filaments obtained by spinning and drawing islands-in-a-sea type composite fibers having the following constitution was used.
Island component: Polyethylene terephthalate Sea component: Polystyrene Number of the island component: 6 Ratio of the island/the sea component: 80/20 Monofilament denier of the island component:
0.56 denier A twisted textured yarn of polyethylene tere-phthalate of 75D-36f as a warp of the ground and a twisted textured yarn of the same polymer oE 150D-48f as a weft of the ground were used to obtain a fabric having piles whose length was 11 mm by means of a double velludo weaving machine. Regarding the fabric dsnsity, the piled yarn, ground warp and ground weft were 47, 93 and 94 yarns/inch, respectively.
After dr~ heat settlng of the said piled fabric, the sea component of the composite yarns used for piled yarns was removed by treating with trichloroethylene to obtain a piled fabric wherein a number of ultrafine fibers whose monofilament. denier was 0.56 denier. After drying the trichloroethylene, the back surface of the said fabric was coated with a solution comprising 100 parts of poly-urethane, 13/18 parts` of MEK/toluene, 50/5 parts of water/MEK, 2 parts of a crosslinking agent and 0.25 parts of a pigment by means of a knife coater machine the backing treatment of the back surface of -the piled fabric was carri.ed out. Coating quantity of polyurethane on the fabric was 22 g/m2. It was -thereafter put into a liquid-flowing circular dyeing machine to make the piles in areverse direction during the dyeing treatment and the dyeing treatment was carried out under the following conditions.
(1~ Scouring (the treating I:ime: 80C x 30 min) The treating agents:
"Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltd.) 0.5 g/lit.
Soda ash 0.5 g/lit.
(2) Dyeing (the treating time: 120C x 60 min) Dyes:
Resoline Blue BBLS 2.5~ owf Kayalon Polyester Light Red ~S 3.0~ owf Foron Yellow Brown S-2RFL 4.6~ owf ~s~
Palanil Yellow 3G 1.7~ owf LAP-50 (manufactured by Sanyo Chemical Industries, Co., Ltd.) 0.5 g/lit.
PH-50Q (manufactured by 5anyo Chemical Industries, Co., Ltd.) 0.5 g/lit.
(3) Reduction cleaning (the treating time: 80C x 20 min~
The treating agents:
NaOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
"Sandet G-29" (manufactured by Sanyo Chemical Industries Co., Ltdo) 3 g/lit.
After dyeing, dehydration was done by means of a centrifugal dehydrater.
Then, a calendar treatment was carried out by means o~ a hydraulic three-roll plastocalendar machine. The treating conditions were as follows.
Temperature- 200C ~The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm2 Treating speed: 8 m/min Pile opening state of the treated fabric: A little ~ unsufficient Direction of the fabric put in the calendar: Reverse After the treatment, some crumpling by hand was done, and a resin treatment was then carried out under the following conditions to obtain a dimensional durability.
Resin treatment: Resin impregnation (Pick up 57%) Drying (100C x 5 min~ ~ Curing (180C x 1 min~
Resin composition: "Sumitex Resin M-3 (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 20 g/lit~
CB-01 (Cosmo Chemical Co., Ltd.) 2 g/lit.
Ammonium Persulphate 2 g/lit.
Resin built-up: 0.9%
Moreover, said fabric was put in a Wince dyeing machine containing warm water at 80C, rotated and moved in the warm water for 20 minutes to crumpling it and dried.
Treated fabrics thus obtained had apexes of piles in a body and good scaly structures. The average area of a constituent unit of said scaly structures was 2.4 x 10 cm2, and the ~abric had various Iarge, intermediate and small shapes and areas in the range of 9 x 10 2 cm2 to 0.8 x 102 cm2, and the outer appearance exhibited excellent scaly structures. An excellent fabric having an outer apperance like mica and being rich in a natural feelinq, a new, raw material feelinq and a fushionable characteristic was obtained.
Moreover, durability of said scaly structure was ~ r~ na~k :~l3~
e~aluated. The methods for testing durability and the results were as follows.
Moreover, .comparison tests on an untreated product without any shape fixing treatment by means of resin treatment were carried out.
Table 2 Fixed product Untreated product _ Test 1 ~ to o Test 2 o to ~ x to Q
Test 3 ~ Q to o Evaluation level : No change in shape after the test o : Li.ttle change in shape after the test a A little chan~e in shape after ~he t~st x : Remarkable change in shape after the test Testing method Test 1: Wearing durability test of an outer coat on both the circumference parts of the elbows and the parts of axillae of which a fabric to be tested was attached was done for one week.
Test 2: Durability test against dry cleanings ~ 32 by means of an ordinary method using perchlene were done for two times in a dry cleaniny shop.
Test 3: Abrasion durability test wherein an abrasive go and back cycle test of 50 times was carried out on a surface to be abraded under a pressing load of 500 g by means of Gakushin type abrasion tester.
It is clear from Table 2 that the products whose scaly structure was formed by making in a body with a resin, had better durability.
Moreover, the products adhered with the resin exhibited excellent luster characteristic. The products without resin adherence showed softer feeling and touch but it is recognized that the products with resin adherence also had sufficiently good flexibility.
Example 3 The following two kinds of islands-in-a-sea type composite fibers were spun and drawn to obtain blended composite fibers of 65 denier - 18 filaments.
a) The islands-in-a-sea type composite fiber No n 1 Island component: Polyethylene terephthalate ~16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid~5-sodium sulfoisophthalic acid/87.5 ~70/30)/12.5 mole %
b) ~he islands-in-a-sea type composi.te iber No.2 Island component: Polyethylene terephthalate - copolymerized with 4.9 mole %
of isophthalic acid ~16 islands) Sea component: Copolymer of polyethylene terephthalate/isophthalic acid~5-sodium sulfoisophthalic acid/87.5 (70/30)/12.5 mole %
Here, the islands-in-a-sea type composite iber No.1 comprised 90~ of the island component and 10~ of the sea component and the whole fiber was 32.5 denier - 9 filaments. The .islands-in-a-sea type composite fiber No.2 comprised 90~ of the island component and 10% of the sea~
component and the whole fiber was 32.5 denier - 9 filaments. Therefore, a blended;fiber o total 65 denier - 18 filaments was obtained.
This blended composite fiber was used as a pilable fiber. A false twlsted textured yarn comprising 75 denier - 36 filaments of polyethylene terephthalate; was used as a~warp of the ground, and a false twisted textured yarn of~ 100 denier - ~48 filaments of polyethylene terephthalate was used~as~ a wet of the ground. A Eahric' whose pile length was 6 mm was obtained by means of a : :
double velludo weaving machine. Regarding fabric density, the piled yarn, ground warp and ground weft were 45.5, 91 and 107 yarnslinch.
After dry heat setting of the fabric thus obtained was carried out, the following treatment was carried out by means of a liquid-flowing circular dyeing machine.
(1) Treatment for preparing a ultra-fine fiber The 1st treatment:
Treating agent: Malechead CM (manufactured by Takeda Chemicals Industry Co., Ltd.) 1 g/lit.
Treating temperature x time: 120C x 30 minutes The 2nd treatment:
Treating agent: NaOH (30%) 3 g/lit.
Treating temperature x time: 80C x 30 minutes (2) Dyeing ~the treating time: 120C x 60 min) Dyes:
Resoline Blue BBLS ; 0.53~ owf Kayalon Polyester Light Red BS 0.73~ owf Foron Yellow ~rown S-2RFL3.2% ow~
(3) Reduction clean~ng The treating agents.
NaOH (30%) 3 g/lit.
Hydrosulphite 3 g/lit.
~ 7~~aJ~ ~na~
Sandet G-29 1 gtlit.
(4) Silicone treatment Treating agent:
Ultratex~ESC (manufactured by CIBA-GEIGY)0.~% owf Treating temperature x time: 20C x 10 minutes A ultra-fine piled fabric whose monofilament denier was 0.2 denier was obtained by these treatments.
After drying said ultra-fine piled fabric, a calendar treatment using the belsw described conditions was carried out by means of a hydraulic three-roll plastoralendar machine~
The treating conditions were as follows.
Temperature: 190C (The piled part was contacted with the heated cylinder roll) Pressure: 30 kg/cm2 Treating speed: 8 m/min Pile opening state of the treated fabric: A little unsufficient Direction of the fabric put in the calendar: Reverse A resin treatment under the following conditions was immediately carried out on the calendar treated fabric thus obtained.
Resin treatment process: Resin impregnation (Pick up 41~ Drying (100C x 5 min) ~ Curing (120~C x 3 min) ~ 7 ra le~ n~aT ~
35S~$~
Resin composition: "Sumitex Resin M-3l' (manufactured by Sumitomo Chemical Industries, Co., Ltd.) 28 g/lit.
CB-Ol (Cosmo Chemical Co., Ltd.) 2 g/lit.
Ammonium Persulphate 2 gjlit.
Resin built-up: 0.3%
Moreover, said fabric was put in a liquid-flowing circular dyeing machine and said fabric was circulated in said liquid-flowing circular dyeing machine for 12 minutes to carry out a crumpling treatment. The bath ratio was 1:30, and the nozzle pressure was 1.2 kg/cm2.
The three dimensional fabric of the present invention thus obtained had a scaly structure whose constituent unit was in the range of 1 x lO 2 cm2 to 5 x 10 2 cm2 and relatively small and whose size was rela-t.ively uniform.
This three dimensional fabric had a number o small scaly structures densely covering its surface, and the outer appearance was beautiful with these scaly structures. The fabric exhibited a mild feeling and was rich~in a natural fee~ling, a new, raw material feeling and a fashionable characteristic :
The three dimensional fabric of Example 3 was different from those of Examples 1 and 2 because the piled $~
fabric had no backing treatment with a resin. The touch of the fabric was therefore very soft and the fabric was good for apparel use having excellent drapery.
Industrial Applicability The three dlmensional fabric having a unique structure of the present invention can be widely used in such various applications that fashion characteristics are important by utilizing its new, raw material feeling and unexpected feeling.
Namely, it can be used for fashionable outer wears, fox example, over coatings such as an overcoat, a raincoat, a cape, a shawl and so on, jackets such as a jacket, a suit, a business suit, and so on, trousers such as slacks, pants and so on, and outer wears such as hats, gloves and so on.
It can be also used for a surface raw material for bags rich in a fashionable feeling, for example, bags such as a bag, a handbag and so on, various briefcases and various suitcases.
Moreover, it can be also used ~or wall decora-tive materials suoh as inner and outer wall materials being rich in a new eeling and a new, raw material feeling.
Moreover, it can be also used for interior materials such as a curtain, a floor material, carpets, a chair cloth, a case for exhibiting goods, a tent material of a shop and so on.
Moreover, it can be also used for shoes, boots and so on.
Claims (25)
1. A three dimensional fabric having:
a face surface, an opposite base fabric, a body of pile fibers therebetween piled from the base fabric, wherein the said pile fibers, at the apex end at the face surface of the fabric, are abutted and joined to form contiguous substantially flat scale-like areas each bounded by a boundary;
and the said scale-like areas cover the face surface of the fabric.
a face surface, an opposite base fabric, a body of pile fibers therebetween piled from the base fabric, wherein the said pile fibers, at the apex end at the face surface of the fabric, are abutted and joined to form contiguous substantially flat scale-like areas each bounded by a boundary;
and the said scale-like areas cover the face surface of the fabric.
2. A three dimensional fabric according to Claim 1, wherein the scale-like areas have substantially no definite pattern.
3. A three dimensional fabric according to Claim 1, wherein the scale-like areas have an average area of 0.5 x 10-2 cm2 to 1 x 102 cm2.
4. A three dimensional fabric according to Claim 1, wherein the scale-like areas have a circumferential part with is split and in which the pile fibers are visible.
5. A three dimensional fabric according to Claim 1, 2, 3 or 4, wherein each of the scale-like areas has a flat-shaped mass in which a number of apexes of the piled fibers are abutted and joined to form the flat-shaped mass.
6. A method for preparing the three dimensional fabric as defined in any one of Claims 1 to 4, which comprises:
pressing a piled layer of a piled fabric having a number of piles made of a fiber under heat and compression to adhere apexes of the piles over a wide area and thereby to make it into a film-like monolithic structure, and crumpling the said fabric and splitting the thus-formed film-like monolithic structure into units of small area, thereby to form a number of the scale-like areas.
pressing a piled layer of a piled fabric having a number of piles made of a fiber under heat and compression to adhere apexes of the piles over a wide area and thereby to make it into a film-like monolithic structure, and crumpling the said fabric and splitting the thus-formed film-like monolithic structure into units of small area, thereby to form a number of the scale-like areas.
7. A method according to Claim 6, wherein the pressing under heating and compression is carried out by using calendar rolls.
8. A method according to Claim 6, wherein the piles are made of an ultra-fine synthetic fiber.
9. A method according to Claim 6, which further comprises the step of applying a binder resin to a surface layer of the film-like monolithic structure before the crumpling treatment.
10. A method according to Claim 6, which further comprises the step of applying a binder resin to at least a part of the scale-like areas after forming the scale-like areas.
11. A method according to Claim 8, wherein the ultra-fine synthetic fiber has a monofilament denier of 1 denier or less.
12. A method according to Claim 11, wherein the ultra-fine synthetic fiber has a monofilament denier of 0.5 denier or less.
13. A three dimensional fabric, which comprises:
a base fabric layer;
an intermediate layer composed of heat-fusible fibers piled from a surface of the base fabric and interstices formed by the piled fibers; and a top layer which substantially entirely covers the said surface of the base fabric and consists of a number of scaly structures which are each composed of a body formed by fusing apexes of the said piled fibers of the said intermediate layer are separated from each other by cracks but as a whole form a monolayer generally parallel to the base fabric layer, wherein the top layer has a scale-like, mineral-like pine tree bark-like or bagworm-like appearance.
a base fabric layer;
an intermediate layer composed of heat-fusible fibers piled from a surface of the base fabric and interstices formed by the piled fibers; and a top layer which substantially entirely covers the said surface of the base fabric and consists of a number of scaly structures which are each composed of a body formed by fusing apexes of the said piled fibers of the said intermediate layer are separated from each other by cracks but as a whole form a monolayer generally parallel to the base fabric layer, wherein the top layer has a scale-like, mineral-like pine tree bark-like or bagworm-like appearance.
14. A three dimensional fabric according to claim 13/ wherein the body is formed by a heat-fusion bonding of the piled fiber apexes without using an adhesive or by the heat-fusion bonding in combination with an adhesive bonding.
15. A three dimensional fabric according to claim 14/ wherein the thickness of the intermediate layer is from 1 to 40 mm and the average area of the scaly structures is from 0.5 x 10 2 cm to 1 x 102 cm2.
16. A three dimensional fabric according to claim 15/ wherein the scaly structures have random shapes without a definite pattern.
17. A three dimensional fabric according to claim 15, wherein when seen from above the top layer, the piled fibers of the intermediate layer are visible in the cracks between the scaly structures.
18. A three dimensional fabric according to claim 15, wherein the thickness of the intermediate layer is not less than 3 mm.
19. A three dimensional fabric according to claim 15, wherein the piled fibers of the intermediate layer are a ultra-fine artificial fiber having a thickness of denier or less, and the density of the piled fibers is more than 5,000 piles/cm2.
20. A three dimensional fabric according to claim 19, wherein the piled fibers of the intermediate layer are a super ultra-fine artificial fiber having a thickness of 0.01 denier or less, and the density of the piled fibers is up to 6 million piles/cm2.
21. A three dimensional fabric according to claim 15, wherein the piled fibers of the intermediate layer are a ultra-fine heat fusible synthetic fiber having a thickness of 0.01 to 1 denier and the density of the piled fibers is 5,000 to 200,000 piles/cm2.
22. A process for producing the three dimensional fabric as defined in any one of claims 14 to 21, which comprises:
heating apexes of fibers piled from a surface of a base fabric layer under pressure of at least 5 kg/cm2, thereby heat-fusing the piled fiber apexes into a film-like monolithic structure over the piled fibers, and crumpling the fabric, thereby splitting the said film-like monolithic structure into the scaly structures.
heating apexes of fibers piled from a surface of a base fabric layer under pressure of at least 5 kg/cm2, thereby heat-fusing the piled fiber apexes into a film-like monolithic structure over the piled fibers, and crumpling the fabric, thereby splitting the said film-like monolithic structure into the scaly structures.
23. A process according to claim 22, wherein the piled fibers are a heat fusible synthetic fiber.
24. A process according to claim 23, wherein the heating under pressure is conducted by using a heated calender roll.
25. A process according to claim 22 wherein:
a binder resin is applied to the film-like monolithic structure or to the scaly structures for improving the shape retaining property or durability of the scaly structures.
a binder resin is applied to the film-like monolithic structure or to the scaly structures for improving the shape retaining property or durability of the scaly structures.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000575800A CA1305602C (en) | 1988-08-26 | 1988-08-26 | Fabric having a scary surface structure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000575800A CA1305602C (en) | 1988-08-26 | 1988-08-26 | Fabric having a scary surface structure |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1305602C true CA1305602C (en) | 1992-07-28 |
Family
ID=32996915
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000575800A Expired - Fee Related CA1305602C (en) | 1988-08-26 | 1988-08-26 | Fabric having a scary surface structure |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1305602C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115637131A (en) * | 2022-11-01 | 2023-01-24 | 吉林大学 | Scale-like super-hydrophobic anti-icing surface and preparation method and application thereof |
-
1988
- 1988-08-26 CA CA000575800A patent/CA1305602C/en not_active Expired - Fee Related
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115637131A (en) * | 2022-11-01 | 2023-01-24 | 吉林大学 | Scale-like super-hydrophobic anti-icing surface and preparation method and application thereof |
| CN115637131B (en) * | 2022-11-01 | 2023-11-28 | 吉林大学 | Scale-like superhydrophobic anti-icing surface as well as preparation method and application thereof |
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| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |