CN107109784B - Fabric having uneven design and method for producing same - Google Patents

Fabric having uneven design and method for producing same Download PDF

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Publication number
CN107109784B
CN107109784B CN201580068657.4A CN201580068657A CN107109784B CN 107109784 B CN107109784 B CN 107109784B CN 201580068657 A CN201580068657 A CN 201580068657A CN 107109784 B CN107109784 B CN 107109784B
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polyurethane resin
fabric
fibers
depth
yarn
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CN107109784A (en
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川村和德
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Seiren Co Ltd
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Seiren Co Ltd
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06Q—DECORATING TEXTILES
    • D06Q1/00—Decorating textiles
    • D06Q1/08—Decorating textiles by fixation of mechanical effects, e.g. calendering, embossing or Chintz effects, using chemical means
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00—Making patterns or designs on fabrics
    • D06C23/04—Making patterns or designs on fabrics by shrinking, embossing, moiréing, or crêping
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/70—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment combined with mechanical treatment
    • D06M15/705—Embossing; Calendering; Pressing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
    • D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
    • D06P1/52—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing synthetic macromolecular substances
    • D06P1/5264—Macromolecular compounds obtained otherwise than by reactions involving only unsaturated carbon-to-carbon bonds
    • D06P1/5285—Polyurethanes; Polyurea; Polyguanides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/34—Material containing ester groups
    • D06P3/52—Polyesters
    • D06P3/54—Polyesters using dispersed dyestuffs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/20—Physical treatments affecting dyeing, e.g. ultrasonic or electric
    • D06P5/2044—Textile treatments at a pression higher than 1 atm
    • D06P5/2061—Textile treatments at a pression higher than 1 atm after dyeing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C2700/00—Finishing or decoration of textile materials, except for bleaching, dyeing, printing, mercerising, washing or fulling
    • D06C2700/31—Methods for making patterns on fabrics, e.g. by application of powder dye, moiréing, embossing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32—Polyesters

Abstract

Provided is a fabric which is fine, has bending resistance and abrasion resistance, and is provided with a rugged design. A fabric having a polyurethane resin coating portion on at least a part of the surface side of the fabric, and having a patterned uneven design in the polyurethane resin coating portion. The polyurethane resin coating section is a region where the polyurethane resin after coating is present, and the polyurethane resin penetrates between fibers in at least the surface portion of the fabric, and the surface of the fabric is formed of the polyurethane resin and the fibers. The depth of application of the polyurethane resin in the polyurethane resin coating section is 50 to 200 [ mu ] m, the filling rate of the polyurethane resin is 15 to 45%, and the filling rate of the fibers of the fabric is 50 to 80%.

Description

Fabric having uneven design and method for producing same
Technical Field
The present invention relates to a fabric having a textured design and a method for producing the same.
Background
In the field of clothes, interior materials, vehicle interior materials, and the like, products having high design properties are required, and products having a concave-convex pattern on the surface thereof have been developed. For example, in order to impart a rugged design to a fabric, the surface of the fabric is subjected to embossing. However, the fibers constituting the fabric have elasticity. Therefore, there are problems as follows: even when the embossing is performed by heating and pressing, when the embossing is designed to have a fine uneven shape, a sufficient forming effect cannot be obtained due to the compression restoring force caused by the elasticity of the fibers.
As a method for solving the above-described problems, it is considered to use a fiber having a small fineness as a fiber constituting a fabric to reduce a compression restoring force due to elasticity of the fiber. However, in the above case, although a fine uneven shape can be provided by embossing, there are problems as follows: the uneven shape is not durable, and the uneven shape disappears due to abrasion.
Further, as in patent documents 1 and 2, if a resin film (resin layer) is formed on the surface of a fabric, the resin has better formability than a fiber, and thus a fine uneven shape can be provided. However, there are problems as follows: the film becomes a state of tension on the surface like synthetic leather and plastic film; the soft touch and appearance of the fiber-based material are deteriorated; moreover, cracks may occur during bending.
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 55-132784
Patent document 2: japanese laid-open patent publication No. 2002-242085
Disclosure of Invention
Problems to be solved by the invention
The purpose of the present invention is to provide a fabric which is fine and has bending resistance and abrasion resistance and which is provided with a textured design.
Means for solving the problems
The present invention relates to a fabric, which has a polyurethane resin coating portion on at least a part of a surface side of a fabric formed of fibers, and which has a shaped uneven design in the polyurethane resin coating portion. The polyurethane resin coating section is a region where the applied polyurethane resin is present, and the polyurethane resin penetrates between fibers in at least the surface portion of the fabric to form the fabric surface from the polyurethane resin and the fibers, and the polyurethane resin coating section satisfies the following characteristics.
The depth of the polyurethane resin is 50 to 200 μm.
The filling rate of the polyurethane resin is 15-45%.
The filling rate of the fibers of the fabric is 50 to 80%.
The present invention relates to a method for producing a fabric having an uneven design as described above, in which a polyurethane resin is applied to at least a part of the surface side of the fabric, and then the polyurethane resin-applied portion is formed into an uneven design by embossing.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, there can be provided: the polyurethane resin suppresses the compression recovery force caused by the elasticity of the fiber, and is a fine fabric provided with a rugged design having bending resistance and abrasion resistance.
Drawings
Fig. 1 is a photograph showing the surface of a fabric according to an embodiment.
Fig. 2 is a photograph of a cross section of the fabric according to the example.
Fig. 3 is an enlarged photograph of a cross section of a polyurethane resin-coated portion of the fabric according to an example.
Fig. 4 is a structural diagram of the fabric used in example 5.
Detailed Description
The fabric having an uneven design according to the present embodiment is a fabric having a polyurethane resin coating portion on at least a part of the surface side of the fabric, and the polyurethane resin coating portion has a shaped uneven design. The polyurethane resin coating section is a region where the applied polyurethane resin is present, and the polyurethane resin penetrates between fibers in at least the surface portion of the fabric, and the surface of the fabric is formed of the polyurethane resin and the fibers, and satisfies the following characteristics (1) to (3).
(1) The depth of the polyurethane resin is 50 to 200 μm.
(2) The filling rate of the polyurethane resin is 15-45%.
(3) The filling rate of the fibers of the fabric is 50 to 80%.
By satisfying the characteristics of (1) to (3) and by allowing the polyurethane resin to be present between the fibers in the periphery of the fabric surface, it is possible to obtain a fine uneven design having bending resistance and abrasion resistance while suppressing the compression recovery force due to the elasticity of the fibers.
Fig. 1 is a photograph (25 times) of the surface of a fabric having an uneven design according to an example, and fig. 2 is a photograph (100 times) of the cross section of the same fabric. An embossed pattern, which is a fine uneven design obtained by embossing, is formed on the surface of the fabric.
The photograph of the cross section of the fabric of fig. 3 is a photograph of a cross section in the vertical direction of the polyurethane resin coated portion of the fabric having the uneven design according to the example, and is an example of the state of application of the polyurethane resin in the polyurethane resin coated portion. The polyurethane resin is not in the form of a film covering the surface of the fabric, but is in the form of a block together with the fibers among the fibers penetrating at least the surface portion of the fabric, and exists between the fibers in the periphery of the surface of the fabric so as to bind the fibers to each other. Therefore, it is possible to obtain a fine uneven design having bending resistance and wear resistance while suppressing the compression restoring force due to the elasticity of the fibers. In the present embodiment, the urethane resin coating portion refers to a portion to which the urethane resin is applied, and is a region in which the applied urethane resin is present.
The fabric to be treated used in the present embodiment, that is, the fabric to be coated with the polyurethane resin is also referred to as a base fabric or a fabric. Such a fabric is not particularly limited, and examples thereof include: known fabrics such as woven fabrics, knitted fabrics, and nonwoven fabrics. The weave of the woven fabric is not particularly limited, and examples thereof include: plain weave, twill weave (twill weave), satin weave, modified weaves of these three-primary weaves, special weaves such as pear peel weave, and mixed weaves obtained by combining 2 or more kinds of these weaves. The knitted fabric is not particularly limited, and examples thereof include: tricot warp knit fabrics, double needle raschel warp knit fabrics, circular knit fabrics.
The fiber material constituting the fabric in the present embodiment is not particularly limited, and conventionally known natural fibers, regenerated fibers, semi-synthetic fibers, and the like can be used. These can be used alone in1 kind, or in combination of 2 or more kinds. Among them, from the viewpoint of durability, particularly mechanical strength, heat resistance and light resistance, the fiber material is preferably a synthetic fiber, more preferably a polyester, and particularly preferably polyethylene terephthalate. Further, from the viewpoint of flame retardancy, flame retardant fibers are preferably used.
A pile may be formed on the surface of the fabric as the base fabric by a known method such as a woven structure or a napping process. The pile length when the fabric has a pile is not particularly limited, and from the viewpoint of abrasion resistance, for example, in the case of a pile (pile) product such as a full cut pile product or an open width product of a double needle raschel warp knitted fabric, the pile length is preferably 1600 μm or less. By setting the thickness to 1600 μm or less, the polyurethane resin can be inhibited from being fixed to the pile surface in a layered state. Therefore, only the urethane resin coated portion is loaded during abrasion, and deterioration of abrasion resistance can be prevented.
The fabric having an uneven design (hereinafter, also referred to as a band-designed fabric) of the present embodiment has a polyurethane resin coated portion in at least a part of the surface side of the fabric. The single fiber fineness (hereinafter, also referred to as single fineness) of the fibers constituting the fabric constituting the polyurethane resin coated portion is preferably mainly 1.5dtex or less. When the single fiber fineness is 1.5dtex or less, the increase of the voids between fibers can be prevented, and the formability of the fine uneven shape obtained by embossing can be improved. The lower limit of the single fiber fineness is not particularly limited, and may be, for example, 0.1dtex or more.
When the fabric as the base fabric is a woven fabric, the fabric has a thickness of 1mm per unit volume in the region to which the uneven design is applied3The total fineness of (A) is preferably 2500 to 5800 dtex. Further, 3000 to 5800dtex is more preferable, and 3500 to 5800dtex is further preferable. When the thickness is 2500dtex or more, the voids between fibers can be reduced, and the formability of the fine uneven shape obtained by embossing can be improved. Further, a good weaving property can be secured by the value of 5800dtex or less.
It should be noted that, 1mm per unit volume3The total fineness of (b) was calculated as follows. That is, the total of the fineness of warp yarn in a volume of 25.4mm in the width direction × 25.4mm in the length direction × the thickness (mm) of fabric was calculated from the product of the density (root/25.4 mm) of warp yarn, the fineness (dtex) of warp yarn, and 25.4mm, with respect to the length direction of the fabric. In this calculation, the warp filaments in the warp direction 25.4mm are made longThe degree is 25.4 mm. Strictly speaking, the warp yarns are not straight but are bent at the interlaced portion with the weft yarns, but are calculated in a straight manner. The total fineness of the weft is also calculated in the same manner as the warp, and the sum of the total fineness of the warp and the total fineness of the weft is calculated. The quotient of the calculated value and the volume (width direction. times. length direction. times. fabric thickness) was calculated as 1mm per unit3Total fineness of (a).
Specifically, it is calculated by the following formula.
1mm per unit volume3Total fineness of (2)
(warp density. times. warp fineness. times. 25.4+ weft density. times. weft fineness. times. 25.4) ÷ (25.4. times. fabric thickness (mm))
When the density of the yarn is different from the substantial density, for example, in the case of the yarn falling off, the density is calculated using the substantial density. For example, if the drawn yarn is 1in3out (i.e., an arrangement of 1 embedded yarn and 3 drawn yarns), it is calculated by multiplying 1/4 by the density of the drawn yarn.
When the fabric as the base fabric is a knitted fabric, the fabric has a thickness of 1mm per unit volume in the region where the uneven design is provided3The total fineness of (A) is preferably 1000 to 5800 dtex. Further, 1200 to 5800dtex is more preferable, and 1500 to 5800dtex is further preferable. By setting the thickness to 1000dtex or more, the voids between the fibers can be reduced, and the formability of the fine uneven shape obtained by embossing can be improved. Further, good knitting properties can be secured by the value of 5800dtex or less.
In the case of a knitted fabric, the knitted fabric has a volume of 1mm per unit volume3The total fineness of (b) was calculated as follows. From the 2-fold of the coil density and the product of the yarn fineness and 25.4mm, the total fineness in the volume of (25.4mm) × length direction (25.4mm) × thickness (mm) of the fabric was calculated with respect to the length direction of the raw fabric. In the cross section perpendicular to the longitudinal direction of the raw fabric, 2 cross sections were observed in1 loop, and therefore, the warp density was calculated by doubling. In addition, in this calculation, the length of the connected loop sections in the width direction of 25.4mm was 25.4 mm. In addition, the knitting yarn is curved because it does not run straight to form a loop, but is calculated to run straight. Calculating calculatedThe quotient of the value and the volume (width direction. times. length direction. times. fabric thickness) was defined as 1mm per unit3Total fineness of (a). When the weave is multiple, the filament fineness in the volume of (25.4mm) in the width direction of the cloth (25.4mm) × in the length direction of the cloth (25.4mm) × in the thickness (mm) of the cloth is calculated for each of the filaments constituting each weave, and the total value is summed up with the quotient of the volume to obtain a value of 1mm per unit volume3Total fineness of (a).
Specifically, it is calculated by the following formula.
1mm per unit volume3Total denier (in the case of tricot and circular knit)
(total of filament fineness of respective filaments)※1X coil density X2X 25.4/25.4 (25.4X fabric thickness (mm))
In addition, the method is as follows: in the case of tricot warp knitted fabric, the total of the filament fineness of the front filament, the middle filament and the rear filament, and in the case of circular knitted fabric, the total of the filament fineness of the face filament, the connecting filament and the bottom filament.
1mm per unit volume3Total fineness of (4) (in the case of open width of double needle raschel warp knitting fabric)
{ (total of filament fineness of respective ground filaments + total of filament fineness of respective pile head filaments) × coil density × 2 × 25.4} ÷ (25.4 × 25.4 × thickness (mm))
1mm per unit volume3Total denier of (4) (case of non-open width of double needle raschel warp knit fabric)
{ (total of filament fineness of respective ground filaments + total of filament fineness of respective connecting filaments × 2) × coil density × 2 × 25.4} ÷ (25.4 × 25.4 × thickness (mm))
When the density of the yarn is different from the substantial density, such as when the yarn is peeled off, the substantial density is used for calculation. An example is shown below. In the connecting yarn of the non-open width product of the double needle bar raschel warp knitting fabric, for example, when the yarn off is 1in1out, the following formula is obtained.
1mm per unit volume3Total fineness of (2)
{ (total of filament fineness of respective ground filaments + total of filament fineness of respective connecting filaments × 2 × 1/2) × coil density × 2 × 25.4} ÷ (25.4 × 25.4 × thickness (mm))
The urethane resin used in the present embodiment is not particularly limited, and examples thereof include: polyether-based, polyester-based, and polycarbonate-based polyurethane resins. Among these, a polyester-based polyurethane resin is preferably used from the viewpoint of texture, and a polycarbonate-based polyurethane resin is preferably used from the viewpoint of durability, particularly abrasion resistance.
The softening temperature of the polyurethane resin is preferably 100-200 ℃. The softening temperature of 100 ℃ or higher makes it possible to prevent the resin from being easily eluted even when the vehicle interior material or the like is used under such conditions as being left at a high temperature for a long time. When the softening temperature is 200 ℃ or lower, the heating temperature of the emboss roller can be set low in forming the uneven design, and the base fabric of the portion to which the urethane resin is not applied can be prevented from becoming coarse and hard. The softening temperature was measured by differential scanning calorimetry using a DSC thermal analyzer.
The polyurethane resin may be applied to the entire fabric, or may be applied only around the portion to which the fine uneven design is applied. The amount of polyurethane resin applied to the polyurethane resin coating section varies depending on the structure of the fabric to be treated, for example, the density and fineness, and is preferably approximately 1 to 200g/m2. Through a flow of 1g/m2As described above, the fibers are sufficiently consolidated with each other, and therefore, the abrasion resistance is improved, or the formability of the fine uneven shape obtained by the embossing is improved. The passing rate is 200g/m2The hardness of the hand is suppressed as follows. Here, the polyurethane resin penetrates between fibers in at least the surface portion (surface layer portion) of the fabric to form the surface portion of the fabric together with the fibers, rather than forming a separate surface layer of the polyurethane resin on the entire surface of the fabric as in the case of the synthetic leather with grain. The amount of the urethane resin added is obtained by converting the amount of the urethane resin applied to the portion to be coated with the urethane resin into an amount per square meter, and is a value based on the mass of the solid content after drying.
The depth of the urethane resin applied to the urethane resin-coated portion of the present embodiment is in the range of 50 to 200 μm. When the thickness is 50 μm or more, the fibers are sufficiently consolidated with each other, and therefore, the abrasion resistance is improved, or the formability of the fine uneven shape obtained by the embossing is improved. When the thickness is 200 μm or less, the hardness of the hand is suppressed. Preferably 50 to 130 μm, and more preferably 50 to 100 μm.
The depth of application of the polyurethane resin is a depth from the surface of the fabric of a region where the polyurethane resin is present between fibers of the fabric, and hereinafter, this region is also referred to as a depth-of-application region of the polyurethane resin. Here, the depth to which the urethane resin is applied is the same as the thickness of the urethane resin-coated portion. In fig. 3, the imparted depth of the urethane resin is indicated by white arrows. The depth of application of the urethane resin was determined as follows. The vertical cross section of the polyurethane resin-coated part was photographed with a microscope, and the length of a portion in the vertical direction from the fabric surface to the lower end of penetration of the polyurethane resin, in which the fibers of the polyurethane resin were consolidated and blocked, was measured at any 10 points, and the average was determined.
As described above, the polyurethane resin may permeate into at least the fiber spaces in the surface portion of the fabric, or may permeate through the entire thickness of the fabric. However, from the viewpoint of hand, it is preferable that the polyurethane resin does not penetrate the entire thickness of the fabric, that is, penetrates a part of the surface portion including the fabric in the thickness direction. Specifically, the ratio of the depth of application of the polyurethane resin to the thickness of the fabric with a tape design may be 3 to 30%, or 3 to 10%. The thickness of the fabric with tape design is not particularly limited, and may be, for example, 0.2 to 3.0mm (i.e., 200 to 3000 μm) or 0.3 to 2.8 mm.
The filling rate of the polyurethane resin in the polyurethane resin coating portion of the present embodiment is in the range of 15 to 45%. By setting the ratio to 15% or more, the shape of the uneven shape is improved. When the content is 45% or less, the bending resistance is improved. Preferably 15 to 35%, more preferably 20 to 35%.
The filling ratio of the urethane resin in the urethane resin coating portion is a ratio of the urethane resin in a region of the application depth of the urethane resin (a portion where the fibers are consolidated with each other to form a block shape) and is determined as follows. That is, the filling factor and porosity of the fiber described below are determined by the following formula.
Filling ratio (%) of polyurethane resin 100- (filling ratio of fiber + porosity)
The filling rate of the fibers of the fabric in the polyurethane resin coating section is in the range of 50 to 80%. By 50% or more, the pores between the fibers can be reduced, the consolidation of the fibers can be improved, and the abrasion resistance can be improved. By 80% or less, the bending resistance can be improved. Preferably 55 to 80%, more preferably 55 to 75%.
The filling ratio of the fibers in the urethane resin coating portion is a ratio of the fibers in a depth region (a portion where the fibers are consolidated with each other and form a block) to which the urethane resin is applied, and is determined as follows. That is, a photograph obtained by taking a vertical cross section of the urethane resin coated portion with a microscope was read by a scanner, the number (n) of cross sections of the filaments was measured in a measurement area in which the width of the weft direction was 100 μm and the depth region of the urethane resin was given in the warp direction, and the filling ratio of the fibers was obtained by the following equation. The diameter R (μm) of the filament was determined by measuring and averaging the diameters of the warp and weft directions of the cross section of the filament at any 5 positions.
Filling factor (%) of the fiber (78.5 xr)2Xn) ÷ (100 Xthe imparted depth (. mu.m) of the polyurethane resin))
The filling rate of the fibers in the urethane resin coating portion is an average value of the filling rates of the fibers determined at arbitrary 5 points.
The sum of the outer peripheral lengths of the cross sections of the fibers in the polyurethane resin-coated portion of the present embodiment is preferably 10000 μm per unit area2Is 1500 μm or more, more preferably 1800 μm or more, and still more preferably 2700 μm or more. When the thickness is 1500 μm or more, the adhesion between the polyurethane resin and the fibers is improved, the compression recovery force of the fibers is suppressed, and the formability of the fine uneven shape obtained by embossing is improved. This is considered to be because the larger the sum of the outer peripheral lengths, the larger the amount of the fibers (single fibers) having a small single fiber density, and the pores between the fibersSmall, the polyurethane resin and the fiber are easy to be solidified. Further, it is considered that when the number of fibers having a small single-fiber size is large, the surface area becomes large relative to the total number of the fiber sizes, and therefore, the area covered with the polyurethane resin becomes large, and the consolidation becomes easy. The upper limit of the sum of the outer peripheral lengths of the cross sections of the fibers is not particularly limited, and may be 9000 μm or less, or 6000 μm or less, for example.
The sum of the outer peripheral lengths of the cross sections of the fibers in the polyurethane resin-coated portion was determined as follows. That is, a photograph obtained by taking a vertical cross section of the urethane resin coating portion with a microscope was read by a scanner, the number (n) of cross sections of the filaments was measured in a measurement area in which the width of the weft direction was 100 μm and the depth region of the urethane resin was given in the warp direction, and the sum of the outer peripheral lengths of the fiber cross sections was obtained by the following equation. The diameter R (μm) of the filament was determined by measuring and averaging the diameters of the warp and weft directions of the cross section of the filament at any 5 positions.
The sum of the outer peripheral lengths of the fiber sections (. mu.m) ((31400. times. R.times.n) ÷ (100. times. mu.m) imparted depth of the polyurethane resin)
The sum of the outer peripheral lengths of the fiber cross sections in the polyurethane resin-coated portion is an average value of the sum of the outer peripheral lengths of the fiber cross sections determined at any 5 points.
The porosity in the urethane resin-coated portion is preferably 13% or less, more preferably 9% or less. When the porosity is 13% or less, the uneven shape obtained by embossing can be easily formed. The lower limit of the porosity is not particularly limited, and may be, for example, 0.1% or more, or 2% or more.
The porosity of the urethane resin coating portion is a ratio of a pore portion in a depth region (a portion where fibers are bonded to each other and form a block) to which the urethane resin is applied, and is determined as follows. That is, a photograph obtained by taking a vertical cross section of the polyurethane resin coated portion with a microscope was read by a scanner, and in a measurement area in which the weft direction was a width of 100 μm and the warp direction was a depth region to which the polyurethane resin was applied, the void portion and the other portions were binarized, and the ratio of the void portion in the depth region to which the polyurethane resin was applied of the fabric was calculated. The porosity in the urethane resin-coated portion was an average value of the porosities determined at arbitrary 5 points.
The cross-sectional area of the urethane resin in the urethane resin coating portion is 100 μm per2The number of the fibers (a) is preferably 1.5 or more, more preferably 2.0 or more. When the number of the fibers is 1.5 or more, the number of the fibers per unit of the urethane resin increases, and therefore, the effect of the binder made of the urethane resin can be improved. Therefore, the formability of the fine uneven shape obtained by the embossing can be improved, and the wear resistance can be improved. The upper limit of the number of the fibers is not particularly limited, and may be, for example, 100 or less, 50 or less, or 20 or less.
The urethane resin in the urethane resin coating portion was 100 μm per 100. mu.m2The number of fibers (b) was determined using a photograph obtained by taking a vertical cross section of the urethane resin-coated portion with a microscope, which was similar to the filling ratio of the urethane resin. The number of fiber sections in the measurement area is counted. The area of the urethane resin was calculated as the product of the filling ratio of the urethane resin and the area of the measurement region. From these values, the polyurethane resin was calculated per 100 μm2The number of fibers (c).
As the uneven design in the present embodiment, a fine uneven design (fine uneven design) having a concave shape with a width of 200 to 1500 μm and a maximum depth of 20 to 450 μm is preferable. In addition, the maximum value of the pattern intervals is preferably 10000 μm or less as the uneven design. In a preferred embodiment, the concave-convex design has a width of 200 to 1200 μm, a maximum depth of 20 to 250 μm, and a maximum pattern interval of 5000 μm or less. In a more preferred embodiment, the width of the recessed portions is 200 to 800 μm, the maximum value of the depth of the recessed portions is 20 to 150 μm, and the maximum value of the pattern intervals is 2000 μm or less. By satisfying these ranges, a fine uneven design which has not been obtained by the embossing, for example, a fine uneven design such as a leather grain of natural leather, can be obtained.
The width and depth of the recessed portion in the above-described uneven design can be determined by measuring the width and depth of the recessed portion from a photograph taken by a microscope of a vertical cross section of the urethane resin-coated portion. Specifically, as shown in fig. 2, the width (W) of the concave portion of the uneven design is obtained as follows: for any 3 recesses, the distance from one end to the other end was measured, and the average value was calculated. The depth (D) of the concave portion of the concave-convex design is determined as follows: when the width of the concave portion is measured as described above, the distance of a perpendicular line drawn from a straight line connecting one end of the concave portion to the other end to the deepest portion of the concave portion is measured, and the maximum value for any 3 concave portions is obtained. Then, the maximum value for any 3 groups of projections was determined by measuring the distance between the apexes of adjacent projections from a photograph obtained by taking a photograph of the surface of the polyurethane resin-coated portion with a microscope, for the pattern intervals of the uneven design.
The cross-sectional shape in the vertical direction of the uneven design is not particularly limited, and a wave pattern that can exhibit a finer pattern is preferable. In addition, in the case of the wave shape, in the adjacent concave-convex portions, the inclination angle of the straight line connecting the highest position of the convex portion and the lowest position of the concave portion is preferably 5 to 40 degrees. The inclination angle is more preferably 5 to 30 degrees, and still more preferably 5 to 20 degrees.
The tilt angle of the corrugated design was measured as follows. The angle between the straight line connecting the highest position of the convex portion and the lowest position of the concave portion and the tangent line at the highest position of the convex portion is measured from a photograph obtained by taking a vertical cross section of the urethane resin-coated portion with a microscope.
The fabric having the uneven design of the present embodiment can be obtained as follows: the fabric is obtained by applying a urethane resin to at least a part of the surface side of a fabric as a base fabric and then embossing the urethane resin-applied part with a concavo-convex design.
In the production method of the present embodiment, first, a treatment liquid containing a polyurethane resin is applied to at least a part of the surface side of the fabric. For example, the treatment liquid may be applied to the entire surface side of the fabric. Alternatively, the treatment liquid may be applied to a part of the surface side of the fabric, and in this case, the treatment liquid may be applied in a pattern. The treatment liquid contains at least a polyurethane resin and a medium (e.g., water) for dispersing the polyurethane resin, and may contain additives such as coloring materials (dyes, pigments, metal powders) and thickeners as needed.
The method of applying the treatment liquid is not particularly limited, and examples thereof include: screen printing, rotary printing, ink jet printing, and the like. When the fabric has unevenness, a gravure coater, a comma coater, a reverse coater, or the like may be used.
Next, the polyurethane resin is dried and cured. The drying is not particularly limited as long as the medium does not remain. The boiling point of the medium and the production efficiency can be appropriately set in consideration.
In this manner, the surface of the fabric is coated with a polyurethane resin and dried, and then the entire surface is subjected to embossing. Specifically, for example, the polyurethane resin on the surface of the fabric is softened and shaped by an embossing roll having a temperature of 100 to 160 ℃ and a pressure (linear pressure) of 490 to 1960N/cm. A surface of the emboss roller is engraved with a relief pattern having a relief inverse to the desired fine relief pattern. The temperature of the emboss roller is set in consideration of the softening temperature of the polyurethane resin, the fiber material constituting the fabric, the required durability, and the like.
The fabric after the shaping treatment may be subjected to a heat treatment for the purpose of softening the texture. The heat treatment is preferably performed at 100 to 150 ℃ for 30 seconds to 3 minutes.
As described above, the fabric having the uneven design according to the present embodiment can be obtained. The polyurethane resin penetrates at least between fibers in the surface portion in the thickness direction, and forms the surface portion of the fabric together with the fibers.
The use of the fabric having an uneven design according to the present embodiment is not particularly limited, and the fabric can be used in various fields such as vehicle interior materials, clothes, and bags.
Examples
The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to these examples. The fabric was evaluated by the following method.
(1) Shaping property
The product embossed by the embossing roll A, B, C having the following concave-convex shape was visually confirmed and evaluated according to the following evaluation criteria.
An embossing roller A: a concave-convex cross-sectional shape in the vertical direction, with a concave width of 800 μm, a maximum value of the depth of the concave portion of 150 μm, and a pattern interval of 2000 μm; wave shape, inclination angle of 5-20 degrees, and leather crepe pattern
An emboss roller B: a concave-convex cross-sectional shape in the vertical direction, the width of the concave portion being 1200 μm, the maximum value of the depth of the concave portion being 250 μm, and the pattern interval being 5000 μm; wave shape, inclination angle of 10-30 degrees, and leather crepe pattern
An embossing roller C: the width of the concave part is 1500 μm, the maximum value of the depth of the concave part is 450 μm, the pattern interval is 10000 μm, and the cross section shape of the concave and convex in the vertical direction; ladder-shaped and thread pattern
(evaluation criteria)
1: A. b, C are clearly shaped.
2: the uneven shape of a is unclear, but the uneven shape of B, C is clearly shaped.
3: A. the uneven shape of B is unclear, but the uneven shape of C is clearly shaped.
4: A. b, C are not clear.
(2) Bending resistance
The test piece after evaluation of the forming property was cut into a width of 25mm and a length of 150mm, and then fixed to a German Western bending TESTER (TESTER SANGYO CO, LTD.). 3000 bends with a bending stroke of 57mm and 300 bends per minute. The test piece after bending was observed and evaluated according to the following criteria.
(evaluation criteria)
1: no cracks are generated.
2: cracks are generated.
(3) Wear resistance
The test piece after evaluation of the shape forming property was cut into a width of 70mm and a length of 300mm, and then polyurethane foam having a size of 70mm, 300mm and 10mm in thickness was added to the back surface of the test piece, and the test piece was fixed to a flat abrasion tester T-TYPE (manufactured by Daorhiki Seisakusho K.K.). The test piece was worn by applying a load of 9.8N to the slider covered with cotton cloth (cotton canvas). The rub was abraded reciprocally 10000 times at a speed of 60 reciprocal/min on the surface of the test piece between 140 mm. The cotton canvas was repeatedly exchanged every 2500 times of abrasion, and the total of 10000 times of reciprocal abrasion was performed. The test piece after abrasion was observed and evaluated according to the following criteria.
(evaluation criteria)
1: there was no disappearance of the uneven shape.
2: the concavo-convex shape is slightly disappeared.
3: the disappearance of the concavo-convex shape is obvious.
[ example 1]
167dtex/288f of polyethylene terephthalate false-twisted yarn was used as warp yarn, 167dtex/48f of polyethylene terephthalate false-twisted yarn was used as weft yarn, and 5 satin weaves were performed with the warp yarn floating (Japanese: し linear) to obtain a grey fabric. Next, heat treatment was performed at 190 ℃ for 1 minute by using a heat setting machine. The obtained fabric had a warp density of 178 yarns/25.4 mm, a weft density of 61 yarns/25.4 mm, and a volume per 1mm3The fineness of (A) was 3928 dtex.
Subsequently, a solution of a urethane resin "RYUDTE-W BINDER UF 6025" (manufactured by DIC Co., Ltd., softening temperature: 120 ℃ C.) was applied over the entire surface by a screen printer (solid content: 28 mass%). The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 150 ℃, a roll pressure of 588N/cm and a cloth speed of 3 m/min. The emboss roller used was 3 types of rollers A to C described in the evaluation item shapability.
The obtained fabric had a fine uneven design obtained by embossing, in which the polyurethane resin penetrated between fibers in the surface portion of the fabric, the surface of the fabric was formed of the polyurethane resin and the fibers, and the entire surface of the fabric was provided with the fine uneven designA micro-embossed pattern). The polyurethane resin applied part of the fabric with a design was provided with a polyurethane resin having a depth of 98 μm, a fiber filling rate of 69.1%, a polyurethane resin filling rate of 26.4%, a porosity of 4.5%, and a polyurethane resin content per 100 μm2The number of fibers (2) was 6.5, the length of the periphery of the cross section of each single fiber was 3863 μm, and the thickness of the fabric was 400 μm. The evaluation results are shown in table 1.
[ example 2]
A3-reed tricot machine was used to knit a gray fabric by fully threading through a plain weave (1-0/1-2) for L1 (front yarn) using a polyethylene terephthalate false twist textured yarn of 84dtex/96f with a 3-needle bed and a shoddy weave (1-0/3-4), a shoddy weave (84 dtex/36f for L2 (middle yarn) using a polyethylene terephthalate flame-retardant yarn of 84dtex/36f with a 3-needle bed and a shoddy weave (2-1/1-0) for L3 (rear yarn) using a polyethylene terephthalate flame-retardant yarn of 84dtex/36f with a 3-needle bed. Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Then, full-cut raising was performed by using a card clothing raising machine having card clothing rollers with 12 raising rollers and 12 reverse-needle raising rollers, while raising from the knitting-end direction and raising from the knitting-start direction were alternately performed 13 times at a card clothing roller torque of 2.5MPa and a cloth speed of 12 m/min. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 71 loops/25.4 mm for the stitches and 38 loops/25.4 mm for the wales, and the volume was 1mm per3The fineness of (2) was 2310 dtex.
Subsequently, a solution (solid content 28 mass%) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 120 ℃, a roll pressure of 1470N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The obtained fabric has polyurethane resin impregnated between fibers in the surface part of the fabric, and is composed of the polyurethane resin and the fibersThe fiber forms the surface of the fabric, and the entire surface of the fabric is provided with a fine uneven design obtained by embossing. The polyurethane resin applied part of the fabric with a design was 92 μm in depth, 66.2% in fiber filling rate, 25.4% in polyurethane resin filling rate, 8.4% in porosity, and 100 μm per polyurethane resin2The number of fibers (2) was 4.0, the length of the periphery of the cross section of each single fiber was 2934 μm, and the thickness of the fabric was 610 μm. The evaluation results are shown in table 1.
[ example 3]
A grey fabric was obtained by weaving using 178dtex/24f polyethylene terephthalate false-twisted yarn as warp and 167dtex/144f polyethylene terephthalate false-twisted yarn as weft, with 8 satin weaves by warp yarn floating and 8 satin weaves by weft yarn floating, in a pattern of 10mm intervals. Then, half-cut raising was performed by using a card clothing raising machine having card clothing rolls with 12 raising rolls and 12 reverse-needle raising rolls, while raising in the self-knitting-end direction and raising in the self-knitting-start direction were alternately performed 13 times at a card clothing roll torque of 2.5MPa and a cloth speed of 12 m/min. Next, the resultant was heat-treated at 150 ℃ for 1 minute by a heat setting machine. The obtained fabric had a density of 184 warps/25.4 mm, a density of 88 wefts/25.4 mm, and a volume per 1mm3The fineness of (2) was 3113 dtex.
Next, a solution (solid content: 28 mass%) of a polyurethane resin "RYUDTE-W BINDER UF 6025" (available from DIC) was applied only to the weft portions at a cloth speed of 5 m/min and a roll rotation speed of 12 m/min by using a reverse coater. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The roller rotation speed condition is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 150 ℃, a roll pressure of 588N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The weft yarn portion exposed on the surface of the fabric of the obtained product and coated with the resin is provided with a fine uneven design by embossing, and the polyurethane resin in the polyurethane resin coating portion is provided with a depthA degree of 66 μm, a fiber filling rate of 59.6%, a urethane resin filling rate of 30.9%, a porosity of 9.5%, and a urethane resin per 100 μm2The number of fibers (2) was 2.4, and the length around the cross section of the single fiber was 2353 μm. The thickness of the tape-designed fabric was 600. mu.m. The evaluation results are shown in table 1.
[ example 4]
A3-reed tricot machine was used to knit a gray fabric by fully threading L1 (front yarn) using 84dtex/72f polyethylene terephthalate false twist textured yarn in a 4-needle bed shogging warp knit stitch (1-0/4-5), L2 (middle yarn) using 84dtex/36f polyethylene terephthalate normal yarn in a warp plain knit stitch (1-0/1-2), and L3 (rear yarn) using 84dtex/36f polyethylene terephthalate normal yarn in a 4-needle bed shogging warp knit stitch (2-1/1-0), respectively. Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Then, full-cut raising was performed by using a card clothing raising machine having card clothing rollers with 12 raising rollers and 12 reverse-needle raising rollers, while raising from the knitting-end direction and raising from the knitting-start direction were alternately performed 13 times at a card clothing roller torque of 2.5MPa and a cloth speed of 12 m/min. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 67 loops/25.4 mm for the stitches and 28 loops/25.4 mm for the wales, and the volume per 1mm3The fineness of (2) was 2179 dtex.
Subsequently, a solution (solid content 28 mass%) of a urethane resin "RYUDTE-WBINDER UF 6025" (manufactured by DIC corporation) was applied to the entire surface at a cloth speed of 10 m/min by means of a blade coater. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The shape and position of the doctor blade are set. After the polyurethane resin solution was applied, it was dried for 1 minute with a 130 ℃ dryer. Next, embossing was performed by an embossing machine at a roll temperature of 120 ℃, a roll pressure of 1470N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The obtained fabric had a polyurethane resin impregnated between fibers in the surface portion of the fabric, the surface of the fabric was formed of the polyurethane resin and the fibers, and the surface of the fabric was entirely coated with a polyurethane resinFine concave-convex design obtained by embossing processing. The polyurethane resin-coated portion of the fabric with a tape design had a polyurethane resin-imparted depth of 53 μm, a fiber filling rate of 50.5%, a polyurethane resin filling rate of 42.1%, a porosity of 7.4%, and a polyurethane resin content per 100 μm2The number of fibers (2) was 1.5, the length of the fiber at the periphery of the cross section of the single fiber was 1996. mu.m, and the thickness of the fabric was 610. mu.m. The evaluation results are shown in table 1.
[ example 5]
Using a 26gauge double knit circular knitting machine, as the ground yarns (3F, 6F), 110dtex/48F polyethylene terephthalate flame-retardant yarns were used, as the connecting yarns (2F, 5F), 110dtex/36F polyethylene terephthalate flame-retardant yarns were used, as the face yarns (1F, 3F), 84dtex/94F polyethylene terephthalate false twist processed yarns were used, and the fabric of the double knit was knitted in accordance with the structure diagram of FIG. 4. Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Then, half-cut raising was performed by using a card clothing raising machine having card clothing rollers with 12 raising rollers and 12 reverse-needle raising rollers, while raising from the knitting-end direction and raising from the knitting-start direction were alternately performed 13 times at a card clothing roller torque of 2.5MPa and a cloth speed of 12 m/min. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 73 loops/25.4 mm for the stitches and 34 loops/25.4 mm for the wales, and the volume per 1mm3The fineness of (A) was 2912 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 130 ℃, a roll pressure of 1470N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The obtained fabric was faced with a fabric in which the polyurethane resin penetrated between fibers in the surface portion of the fabric, the surface of the fabric was formed of the polyurethane resin and the fibersThe entire surface of the fabric is provided with a fine uneven design by embossing. The polyurethane resin-coated portion of the fabric with a tape design had a polyurethane resin-imparted depth of 84 μm, a fiber filling rate of 66.2%, a polyurethane resin filling rate of 24.8%, a porosity of 9.0%, and a polyurethane resin content per 100 μm2The number of fibers (2) was 4.1, the length of the periphery of the cross section of each single fiber was 2924 μm, and the thickness of the fabric was 600 μm. The evaluation results are shown in table 1.
[ example 6]
Using a 22gauge double needle raschel knitting machine having 6 reeds, 84dtex/36f polyethylene terephthalate false-twist yarn as ground yarn was threaded into reeds L1 and L6, 110dtex/94f polyethylene terephthalate false-twist yarn as ground yarn was threaded into reeds L2 and L5, 84dtex/216f polyethylene terephthalate false-twist yarn as pile yarn was threaded into reeds L3 and L4, and a blank fabric of the double needle raschel knitting fabric was knitted in accordance with the following structure.
Reed L1: 1-2/1-1/1-0/1-1
Reed L2: 1-0/1-1/1-2/1-1
Reed L3: 1-0/0-1
Reed L4: 1-0/0-1
Reed L5: 1-0/1-1/1-2/1-1
Reed L6: 1-2/1-1/1-0/1-1
The gray fabric is subjected to intermediate cutting and then to needle-carding pre-carding treatment. Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 53 loops/25.4 mm for the stitches and 38 loops/25.4 mm for the wales, and the volume was 1mm per3The fineness of (2) was 1259 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution is coatedIt was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 110 ℃, a roll pressure of 1960N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The obtained fabric had a polyurethane resin permeated between fibers in the surface portion of the fabric, and the surface of the fabric was formed of the polyurethane resin and the fibers, and the entire surface of the fabric was provided with a fine uneven design by embossing. The polyurethane resin-coated portion of the fabric with a tape design had a polyurethane resin-imparted depth of 96 μm, a fiber filling rate of 63.1%, a polyurethane resin filling rate of 27.9%, a porosity of 9.0%, and a polyurethane resin content per 100 μm2The number of fibers (2) was 9.6, the length of the periphery of the cross section of each single fiber was 4609 μm, and the thickness of the fabric was 1200. mu.m. The evaluation results are shown in table 1.
[ example 7]
Using a 22gauge double needle raschel knitting machine having 6 reeds, 167dtex/30f polyethylene terephthalate false-twist textured yarn as backing structure ground yarn was threaded into reeds L1, L2 in a full-through manner, 33dtex/1f polyethylene terephthalate false-twist textured yarn as connecting yarn was threaded into reed L3 in a full-through manner, 330dtex/144f polyethylene terephthalate false-twist textured yarn as connecting yarn was threaded into reed L4 in a full-through manner, 220dtex/288f polyethylene terephthalate false-twist textured yarn as facing structure ground yarn was threaded into reed L5 in a full-through manner, 110dtex/144f polyethylene terephthalate false-twist textured yarn as facing structure ground yarn was threaded into reed L6 in3out manner, depending on the following structures, a blank of double needle raschel warp knit fabric is knitted.
Reed L1: 1-0/0-0/2-3/3-3
Reed L2: 0-1/1-1/2-1/1-1
Reed L3: 0-1/0-1/1-0/1-0
Reed L4: 0-0/0-1/0-0/0-1/0-0/0-0/0-0/
0-0/0-0/0-0/0-0/0-0/0-0/0-0/
0-0/0-0/0-0/0-0/0-0/0-0
Reed L5: 0-0/0-1/1-1/1-0
Reed L6: 0-0/4-4/4-4/0-0/0-0/4-4/4-4/
0-0/0-0/8-8/8-8/0-0/0-0/8-8/
8-8
Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 43 loop/25.4 mm for the stitches and 25 loop/25.4 mm for the wales, and the volume per 1mm3The fineness of (3) was 1771 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 100 ℃, a roll pressure of 1764N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The obtained fabric had a polyurethane resin permeated between fibers in the surface portion of the fabric, and the surface of the fabric was formed of the polyurethane resin and the fibers, and the entire surface of the fabric was provided with a fine uneven design by embossing. The polyurethane resin-coated portion of the fabric with a tape design had a polyurethane resin-imparted depth of 95 μm, a fiber filling rate of 70.1%, a polyurethane resin filling rate of 21.9%, a porosity of 8.0%, and a polyurethane resin thickness of 100 μm2The number of fibers in (B) was 5.8, the length of the periphery of the cross section of each single fiber was 3329 μm, and the thickness of the fabric was 2500 μm. The evaluation results are shown in table 1.
Comparative example 1
333dtex/96f polyethylene terephthalate false-twist yarn was used as warp yarn, 600dtex/192f polyethylene terephthalate false-twist yarn was used as weft yarn, and 8 satin weaves in which weft yarn was raised were used to obtain a gray fabric. Next, heat treatment was performed at 190 ℃ for 1 minute by using a heat setting machine. The obtained fabric had a warp density of 78 yarns/25.4 mm and a weft density of 36 yarns/25.4 mm, and a volume per volume1mm3The fineness of (2) was 2341 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 150 ℃, a roll pressure of 588N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The resulting polyurethane resin was imparted with a depth of 37 μm, a fiber filling rate of 64.9%, a polyurethane resin filling rate of 20.1%, a porosity of 15.0%, and a polyurethane resin per 100 μm2The number of the fibers (2) was 1.3, and the length of the fiber around the cross section was 1480. mu.m. The evaluation results are shown in table 1.
Comparative example 2
A2-reed tricot knitting machine was used, and a gray fabric was obtained by knitting L1 (front yarn) with a 55dtex/24f polyethylene terephthalate false-twist yarn on a 2-needle bed side by traversing a pile structure (1-0/4-5), L2 (rear yarn) with a 33dtex/12f polyethylene terephthalate false-twist yarn on a warp-flat structure (1-0/1-2), and by threading each yarn in a full-length manner. Subsequently, dyeing was performed with a grey disperse dye at 130 ℃ for 60 minutes using a dyeing machine. Then, half-cut raising was performed by using a card clothing raising machine having card clothing rollers with 12 raising rollers and 12 reverse-needle raising rollers, while raising from the knitting-end direction and raising from the knitting-start direction were alternately performed 13 times. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine. The density of the obtained fabric was 66 loops/25.4 mm for the stitches and 36 loops/25.4 mm for the wales, and the volume per 1mm3The fineness of (A) was 915 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. After the polyurethane resin was applied, it was dried for 10 minutes by a 90 ℃ dryer. Coating amount of polyurethane resin to obtain dried productIn an amount of about 30g/m2. Next, embossing was performed by an embossing machine at a roll temperature of 120 ℃, a roll pressure of 1470N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The resulting polyurethane resin was imparted with a depth of 27 μm, a fiber filling rate of 14.6%, a polyurethane resin filling rate of 62.0%, a porosity of 23.4%, and a polyurethane resin per 100 μm2The number of fibers (2) was 0.1, and the length of the fiber around the cross section was 409 μm. The evaluation results are shown in table 1.
Comparative example 3
The warp yarn was 167dtex/288f polyethylene terephthalate false-twist yarn, and the weft yarn was 167dtex/288f polyethylene terephthalate false-twist yarn, and the warp yarn was raised to 5 satin stitches to obtain a gray fabric. Next, heat treatment was performed at 190 ℃ for 1 minute by using a heat setting machine. The obtained fabric had a warp density of 178 yarns/25.4 mm, a weft density of 65 yarns/25.4 mm, and a volume per 1mm3The fineness of (2) was 4204 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin is 60g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. The obtained fabric fiber was not exposed on the surface, and a polyurethane resin layer was not formed. Next, embossing was performed by an embossing machine at a roll temperature of 150 ℃, a roll pressure of 588N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The resulting polyurethane resin was imparted with a depth of 35 μm, a fiber filling rate of 70.4%, a polyurethane resin filling rate of 23.6%, a porosity of 6.0%, and a polyurethane resin per 100 μm2The number of fibers (2) was 7.4, and the length of the periphery of the cross section of the single fiber was 3931. mu.m. The urethane resin becomes a film. The evaluation results are shown in table 1.
Comparative example 4
Based on the mass of the polyurethane resin after dryingBecomes 15g/m2Products were obtained in the same manner as in comparative example 1 except that the number of times of coating was changed. The resulting polyurethane resin was imparted with a depth of 40 μm, a fiber filling rate of 64.9%, a polyurethane resin filling rate of 9.5%, a porosity of 25.6%, and a polyurethane resin per 100 μm2The number of the fibers (2) was 2.8, and the length of the filament around the cross section was 1480. mu.m. The evaluation results are shown in table 1.
Comparative example 5
122dtex/444f polyethylene terephthalate partial filament (Japanese: cut Shih) was used as warp, and 244dtex/888f polyethylene terephthalate partial filament was used as weft, and the fabric was knitted with 5 satin stitches raised from the warp to obtain a gray fabric. Next, heat treatment was performed at 190 ℃ for 1 minute by using a heat setting machine. The obtained fabric had a warp density of 232 yarns/25.4 mm, a weft density of 110 yarns/25.4 mm, and a volume per 1mm3The fineness of (a) was 5713 dtex.
Subsequently, a solution (solid content: 28 mass%) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by screen printing. The coating weight of the polyurethane resin is 60g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 150 ℃, a roll pressure of 588N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The resulting polyurethane resin was imparted with a depth of 42 μm, a fiber filling rate of 86.2%, a polyurethane resin filling rate of 10.0%, a porosity of 3.8%, and a polyurethane resin per 100 μm2The number of fibers (2) was 48.2, and the length around the cross section of the single fiber was 7215. mu.m. Further, the urethane resin is formed into a film shape. The evaluation results are shown in table 1.
Comparative example 6
333dtex/96f polyethylene terephthalate false-twist yarn was used as warp yarn, and 600dtex/192f polyethylene terephthalate false-twist yarn was used as weft yarn, and the yarn was made to have 5 satin weaves by the floating of warp yarnAnd weaving to obtain the grey cloth. Next, heat treatment was performed at 190 ℃ for 1 minute by using a heat setting machine. The obtained fabric had a warp density of 78 yarns/25.4 mm, a weft density of 36 yarns/25.4 mm, and a volume per 1mm3The fineness of (2) was 2341 dtex.
Subsequently, a solution (solid content: 28% by mass) of a urethane resin "RYUDTE-W BINDER UF 6025" (available from DIC Co., Ltd.) was applied to the entire surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 160 ℃, a roll pressure of 490N/cm and a cloth speed of 3 m/min. The rollers used were the 3 rollers A to C.
The resulting polyurethane resin was imparted with a depth of 130 μm, a fiber filling rate of 72.2%, a polyurethane resin filling rate of 12.4%, a porosity of 15.4%, and a polyurethane resin per 100 μm2The number of fibers (2) was 2.4, and the length of the fiber around the cross section of the single fiber was 1647 μm. The evaluation results are shown in table 1.
Comparative example 7
The woven fabric of comparative example 6 after heat treatment with a heat setting machine was used. Half-cut raising was performed on the back surface (weft floating side) of the woven fabric by using a card clothing raising machine equipped with card clothing rollers having 12 raising rollers and 12 reverse-needle raising rollers, while raising from the weaving-end direction and raising from the weaving-start direction were alternately performed 13 times at a card clothing roller torque of 2.5MPa and a cloth speed of 12 m/min. Next, the resultant was heat-treated at 190 ℃ for 1 minute by a heat setting machine.
Subsequently, a solution (solid content: 28 mass%) of a urethane resin "RYUDTE-W BINDERUF 6025" (available from DIC) was applied to the entire surface of the raised surface by a screen printer. The coating weight of the polyurethane resin was 30g/m in terms of the mass after drying2The number of coating times is set. After the polyurethane resin solution was applied, it was dried in a dryer at 90 ℃ for 10 minutes. Next, embossing was performed by an embossing machine at a roll temperature of 160 ℃, a roll pressure of 490N/cm and a cloth speed of 3 m/min. Roller using the above AC3 rollers.
The resulting polyurethane resin was imparted with a depth of 158 μm, a fiber filling rate of 40.0%, a polyurethane resin filling rate of 20.7%, a porosity of 40.3%, and a polyurethane resin per 100 μm2The number of the fibers was 0.8, and the length of the periphery of the cross section of the single fiber was 888. mu.m. The evaluation results are shown in table 1.
Comparative example 8
The amount of the urethane resin applied was 50g/m by mass after drying2Products were obtained in the same manner as in comparative example 7 except that the embossing was carried out at a roll temperature of 130 ℃. The resulting polyurethane resin was imparted with a depth of 161 μm, a fiber filling rate of 42.1%, a polyurethane resin filling rate of 12.0%, a porosity of 45.9%, and a polyurethane resin per 100 μm2The number of fibers (2) was 1.4, and the length of the periphery of the cross section of the single fiber was 959 μm. The evaluation results are shown in table 1.
Comparative example 9
The amount of the urethane resin applied was 10g/m in terms of mass after drying2Products were obtained in the same manner as in comparative example 7 except that the embossing was carried out at a roll temperature of 130 ℃. The resulting polyurethane resin was imparted with a depth of 31 μm, a fiber filling rate of 42.8%, a polyurethane resin filling rate of 25.7%, a porosity of 30.0%, and a polyurethane resin per 100 μm2The number of fibers (2) was 0.7, and the length of the periphery of the cross section of the single fiber was 977. mu.m. The evaluation results are shown in table 1.
The products obtained in examples 1 to 7 were excellent in all of the evaluation of the shape-imparting property, the bending resistance and the abrasion resistance of the uneven design. On the other hand, the products obtained in comparative examples 1, 2, 4, 8 and 9 were inferior in the evaluation of the forming property and the abrasion resistance. The products obtained in comparative examples 3 and 5 were inferior in the evaluation of the bending resistance. The product obtained in comparative example 6 was inferior in evaluation of the forming property. The wear resistance of the product obtained in comparative example 7 was evaluated poorly.
[ Table 1]
[ Table 2]
Figure BDA0001323203710000261
[ Table 3]
Figure BDA0001323203710000271

Claims (10)

1. A fabric comprising a fabric formed of fibers and, formed on at least a part of the surface side thereof, a polyurethane resin coating section having a patterned uneven design,
the polyurethane resin coating part is a region where the applied polyurethane resin exists, the polyurethane resin is not in a film shape covering the surface of the fabric, but penetrates at least between fibers in the surface part of the fabric, and the surface of the fabric is formed by the polyurethane resin and the fibers,
the polyurethane resin coating portion has a polyurethane resin imparting depth of 50 to 200 [ mu ] m, a polyurethane resin filling rate of 15 to 45%, and a fiber filling rate of 50 to 80%.
2. The fabric according to claim 1, wherein the porosity in the polyurethane resin coated portion is 13% or less.
3. The fabric according to claim 1 or 2, wherein the sum of the outer circumferences of the fiber cross sections in the polyurethane resin coated portion is: 10000 μm per unit area2Is 1500 μm or more.
4. The fabric according to claim 1 or 2, wherein the polyurethane resin in the polyurethane resin coated portion has a unit cross-sectional area of 100 μm2The number of the fibers (A) is 1.5 or more.
5. The fabric according to claim 1 or 2, wherein the polyurethane resin coating portion has a depth of application of the polyurethane resin of 50 to 100 μm, a filling rate of the polyurethane resin of 20 to 35%, and a filling rate of the fiber of 55 to 75%.
6. The fabric according to claim 1 or 2, wherein the ratio of the depth of the polyurethane resin applied to the thickness of the fabric having a textured design is 3 to 30%.
7. The fabric according to claim 1 or 2, wherein the width of the concave portions constituting the uneven design is 200 to 1500 μm, and the maximum value of the depth of the concave portions is 20 to 450 μm.
8. A method for producing a fabric according to any one of claims 1 to 7, wherein,
after a polyurethane resin is applied to at least a part of the surface side of the fabric, the polyurethane resin-applied part is formed into a concave-convex design by embossing.
9. The method for manufacturing a fabric according to claim 8, wherein the fabric to be coated with the polyurethane resin is a woven fabric having a volume per unit volume of 1mm in a region to which the uneven design is applied3The total fineness of (a) is 2500 to 5800 dtex.
10. The method for manufacturing a fabric according to claim 8, wherein the fabric to which the polyurethane resin is applied is a knitted fabric having a volume per unit volume of 1mm in a region to which the uneven design is applied3The total fineness of (a) is 1000 to 5800 dtex.
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