JP2006200099A - Napped pile fabric and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a napped pile fabric which hardly causes grinning, secures high external quality, and presents no ruggedness on the fabric surface to well fit, even when extended along the complex forms such as a folded form or a curved surface form. <P>SOLUTION: The napped pile fabric comprises a ground weave 5 obtained by weaving warps 2 in wefts 3 and planted with pile yarns 4, wherein at least elastic yarns are used as the warps 2, and wound composite yarns are used as the wefts 3, which wound composite yarns are obtained by twining, in a wound around state, core yarns comprising water-soluble fibers with binding yarns comprising water-insoluble fibers and composited with pressing yarns comprising water-soluble fiber to keep the wound around state or the doubled and twisted composite yarn is obtained by doubling and twisting core yarns comprising water-soluble fiber with binding yarns comprising water-insoluble fiber. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a napped pile fabric suitably used as a skin material for a seat seat of a vehicle and a skin material for a furniture chair, for example.

  Conventionally, napped pile fabrics such as moquettes have been used as skin materials for seat sheets of vehicles such as automobiles and railway vehicles and skin materials for furniture chairs. In conventional general moquette skin materials, non-stretchable yarns such as polyamide, polyester, acrylic, and wool have been used (see Patent Document 1).

  By the way, when a skin material for a seat of an automobile is configured using a moquette, the ends of the moquette (100) are sewn with a sewing machine or the like as shown in FIG. It is generally performed to cover the seat pad (110) in such a manner that it is applied to the corner of the pad (110).

  However, in the case where the conventional moquette (100) composed of the non-stretchable yarn is used, as shown in FIG. 5 (b), the pile (103) is formed at the portion bent along the corner portion. There was a problem in that an appearance defect (hereinafter referred to as “grinding”) in which the ground structure (105) appeared in a streak shape with a gap between them occurred. Since the pile is formed continuously along the length direction of orthogonal warp and weft yarns, the ground structure (105) is particularly noticeable when folded along the length direction. Thus, since the state where the ground structure (105) is exposed is similar to the state where the teeth are crushed and exposed, the exposed state of the ground structure at the bent portion is referred to as “greening”. When such a grinding is made to appear, the appearance quality is significantly lowered.

In order to solve the problem of appearance defects due to such grinding, two types of polyester multifilament blended yarns with different shrinkage rates are used as pile yarns, increasing the volume of the pile root and improving bulkiness. It has been proposed to prevent the occurrence of greening (see Patent Document 2).
JP-A-5-279963 (paragraph 0025) JP 2004-238786 A

  However, it was not possible to obtain a sufficient effect in preventing grinding by simply adopting a configuration using two types of polyester multifilament mixed yarns having different shrinkage ratios as pile yarns (the effect was recognized but still insufficient). ).

  In recent years, complex shapes have been increasingly adopted for vehicle seats and furniture chairs, and therefore, even when these skin materials are stretched along complex shapes, the above-mentioned grinding There is a strong demand for the phenomenon not to occur.

  Especially in the field of automotive interior materials, fashionability has become very important. For this reason, it is strongly demanded that the appearance quality of the skin material should be high. There was an urgent need to develop a napped pile fabric that could be used.

  Therefore, the present inventor has developed a ground pile fabric such as a moquette in order to develop a raised pile fabric that does not cause a grinding phenomenon even when stretched in a bent state or along a complicated shape. In order to impart stretchability to the structure, a structure using polyurethane elastic yarn as the warp and weft constituting the ground structure was conceived and prototyped. Although the obtained fabric has excellent stretchability and can prevent glinting to some extent, the balance of elongation in the warp direction and the weft direction is poor, and the surface of the fabric becomes uneven or warps before wearing. In addition, it has been found that there are problems that the unevenness and warpage are obstructed during cutting and sewing and the workability is lowered, and that the unevenness of the fabric surface remains after tensioning and the appearance quality is poor. did. Furthermore, since it is too rich in elasticity as a ground structure, it is difficult to suppress piles at the time of weaving.

  The present invention has been made in view of such a technical background, and even when it is stretched along a bent shape, a curved surface shape, or other complicated shapes, it does not easily cause a grinding phenomenon and ensures a high appearance quality. Another object of the present invention is to provide a napped pile fabric that can be satisfactorily fitted without any unevenness on the surface of the fabric, and has excellent flexibility and a good sitting comfort, and a method for producing the napped pile fabric.

  In order to achieve the above object, the present invention provides the following means.

  [1] In a napped pile fabric in which pile yarns are planted in a ground structure in which warp yarns are woven into weft yarns, at least elastic yarns are used as the warp yarns, and water-insoluble core yarns made of water-soluble fibers are used as the weft yarns. Napped yarn comprising a wound composite yarn in which a entangled yarn made of a water-soluble fiber is wound in a wound state and a presser yarn made of a water-soluble fiber for maintaining this wound state is combined Pile fabric.

  [2] In a napped pile fabric in which a pile yarn is planted in a ground structure in which a warp is woven into a weft, at least an elastic yarn is used as the warp, and a core yarn made of water-soluble fiber and a water-insoluble water are used as the weft. A napped pile fabric in which a twisted composite yarn obtained by twisting an entangled yarn made of a conductive fiber is used.

  [3] The napped pile fabric according to item 1 or 2, wherein at least a polyurethane elastic yarn is used as the warp.

  [4] The napped pile fabric according to item 1 or 2, wherein a polyester filament yarn and a polyurethane elastic yarn are used as the warp.

  [5] The napped pile fabric according to item 3 or 4, wherein the polyurethane elastic yarn has a thickness of 22 to 122 dtex.

  [6] The napped pile fabric according to any one of items 1 to 5, wherein a polyvinyl alcohol fiber is used as the water-soluble fiber constituting the core yarn.

  [7] The napped pile fabric according to any one of items 1 to 6, wherein a polyester fiber is used as the water-insoluble fiber constituting the entangled yarn.

  [8] The napped pile fabric according to item 7 above, wherein the entangled yarn has a thickness of 110 to 330 dtex.

  [9] The napped pile fabric according to any one of items 1 to 8, wherein the ground structure is a ground structure having a cocoon density of 18 to 40 yarns / inch and a weft density of 48 to 80 yarns / inch.

  [10] As the pile yarn, at least two kinds of polyester multifilament mixed yarns having a difference in shrinkage rate are used. The polyester fiber having a large shrinkage rate has crimps and has a crimp expression elongation rate of 1 to 1. 40%, the top end of the polyester fiber having a large shrinkage rate sinks from the pile surface, while the polyester fiber having a small shrinkage rate is also present on the pile surface, thereby forming a multi-step pile. The napped pile fabric according to any one of 9 above.

  [11] A napped pile fabric obtained by removing the core yarn by dissolving the core yarn constituting the composite yarn in water by bringing the pile fabric described in any one of 1 to 10 above into contact with water .

  [12] The napped pile fabric according to item 11 above, wherein the pile fabric has an elongation at 98N load of 10% or more in the warp direction, 10% or more in the weft direction, and 30% or more in the bias direction.

  [13] The napped pile fabric according to item 11 or 12, which is used as a skin material for a seat of a vehicle.

  [14] An entangled yarn made of water-insoluble fiber is wound around a warp yarn containing elastic yarn around a core yarn made of water-soluble fiber in a wound state and a presser made of water-soluble fiber for maintaining this wound state A step of producing a napped pile fabric in which a pile yarn is implanted in a ground structure formed by weaving a wound compound yarn as a weft, and a fabric by dipping the napped pile fabric in a dyed water bath And a step of dissolving the core yarn constituting the composite yarn in a water bath and removing the core yarn.

  [15] A pile yarn in a ground structure in which a warp containing an elastic yarn and a core yarn made of water-soluble fiber and an entanglement yarn made of water-insoluble fiber are twisted and woven as a weft The napped pile fabric is manufactured by immersing the napped pile fabric in a dyeing water bath to dye the fabric and dissolving the core yarn constituting the composite yarn in the water bath to obtain the core yarn. And a step of removing the napped pile fabric.

  In the invention of [1], at least an elastic yarn is used as the warp, and as the weft, an entangled yarn made of a water-insoluble fiber is wound around a core yarn made of a water-soluble fiber while being wound. A wound composite yarn is used in which a presser yarn made of water-soluble fibers is combined, and the pile fabric of the present invention is brought into contact with water to dissolve the core yarn and presser yarn of the wound composite yarn in water. If removed, the remaining entangled yarn functions as a stretchable yarn that can be stretched with a margin of winding, and this, in combination with the function of the elastic yarn of the warp, for example, provides sufficient stretchability to the fabric itself while maintaining the fabric width. Can be granted. Therefore, the napped pile fabric of the present invention can ensure a high appearance quality because it does not easily cause a grinding phenomenon even when it is stretched along a bent shape, curved surface, or other complicated shape. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. Further, the entangled yarn remaining after the dissolution and removal of the core yarn and the presser yarn functions as an elongated yarn that can be extended with a margin for winding, and a void can be secured in the ground structure by removing the core yarn and the presser yarn. Is excellent in flexibility and can ensure a good sitting comfort.

  In the invention of [2], at least an elastic yarn is used as the warp, and a weft composite yarn in which a core yarn made of water-soluble fiber and an entangled yarn made of water-insoluble fiber are twisted is used as the weft. If the pile fabric of the present invention is brought into contact with water and the core yarn of the twisted composite yarn is dissolved and removed in water, the remaining entangled yarn functions as an extended yarn that can be stretched by the margin of the twisted yarn, and this warp yarn Combined with the function of the elastic yarn, for example, the fabric itself can be sufficiently provided with an expansion / contraction function while maintaining the fabric width. Therefore, the napped pile fabric of the present invention can ensure a high appearance quality because it does not easily cause a grinding phenomenon even when it is stretched along a bent shape, curved surface, or other complicated shape. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. Furthermore, the entangled yarn remaining after dissolution / removal of the core yarn functions as an elongated yarn that can be stretched with a margin of winding, and a void can be secured in the ground structure by removing the core yarn, so that the pile fabric is excellent in flexibility. And good sitting comfort can be secured.

  In the invention of [3], since at least polyurethane elastic yarn is used as the warp, it is possible to sufficiently prevent the occurrence of graining even when the pile fabric is stretched along a bent shape, curved surface or other complicated shape. can do.

  In the invention of [4], polyester filament yarn and polyurethane elastic yarn are used as warp yarns, and the presence of the polyurethane elastic yarn allows the pile fabric to be stretched along a bent shape, a curved shape or other complicated shapes. Even when it is provided, it is possible to sufficiently prevent the occurrence of grinding, and the presence of the polyester filament yarn allows the fabric surface to be fitted in a good state without unevenness.

  In the invention of [5], since the polyurethane elastic yarn has a thickness of 22 to 122 dtex, even when the pile fabric is stretched along a bent shape, a curved surface, or other complicated shapes, the occurrence of grinding is further increased. It can be sufficiently prevented.

  In the invention of [6], a PVA fiber that is easily dissolved in water is used as the water-soluble fiber constituting the core yarn. Therefore, when the core yarn is dissolved and removed in water, the core yarn is dissolved and removed in a short time. Therefore, productivity can be improved.

  In the invention of [7], since the polyester fiber is used as the water-insoluble fiber constituting the entangled yarn, the strength as a ground texture can be improved.

  In the invention of [8], since the thickness of the entangled yarn is 110 to 330 dtex, the strength as the ground structure can be further improved.

  In the invention of [9], a ground structure having a cocoon density of 18 to 40 / inch and a weft density of 48 to 80 / inch is used as the ground structure. There is an advantage that the occurrence of greening can be more effectively prevented. In addition, there is an advantage that the fabric weight can be reduced while maintaining the high appearance quality of the fabric by the finer.

  In the invention of [10], the top end of the crimped polyester fiber (with a high shrinkage rate) sinks from the pile surface and increases the volume (volume) of the root of the pile. Even when it is stretched along a curved surface or other complicated shapes, the occurrence of grinding can be sufficiently prevented. In addition, since the volume of only the root portion can be increased, it is possible to further reduce the biting of the pile by the sewing thread at the sewing portion, and thereby it is possible to more sufficiently prevent the occurrence of grinding.

  The invention [11] is obtained by removing the core yarn by dissolving the core yarn constituting the composite yarn in water by bringing the pile fabric according to any one of the above [1] to [10] into contact with water. Therefore, even when the napped pile fabric is stretched along a bent shape, a curved surface, or other complicated shapes, a glinting phenomenon hardly occurs and a high appearance quality can be secured. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. Furthermore, the entangled yarn remaining after dissolution / removal of the core yarn functions as a stretchable yarn that can be stretched with a margin of winding, and a void is secured in the ground structure by removing the core yarn. It is also excellent in breathability and can ensure good sitting comfort.

  In the invention of [12], the pile fabric has an elongation at 98 N load of 10% or more in the warp direction, 10% or more in the weft direction, and 30% or more in the bias direction. Even when it is stretched along a curved surface or other complicated shapes, the grinding phenomenon can be reliably prevented.

  The invention [13] is a configuration used as a skin material for a seat of a vehicle, and if this skin material is used, a high-grade seat can be provided.

  The raised pile fabric obtained by the invention (manufacturing method) of [14] has a high appearance quality because it is difficult to cause a grinding phenomenon even when it is stretched along a bent shape, curved surface or other complicated shape. Can be secured. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. In addition, the entangled yarn remaining after the dissolution and removal of the core yarn and the presser yarn functions as an extension yarn that can be extended by the margin of winding, and a void is secured in the ground structure by removing the core yarn and the presser yarn. The pile fabric is excellent in flexibility and can secure a good sitting comfort. Furthermore, in this production method, the core yarn and presser yarn of the composite yarn can be dissolved and removed in water at the same time when immersed in a dyeing water bath for dyeing the fabric. Since there is no need to provide a dissolution and removal step, productivity can be improved and cost reduction can be achieved.

  The raised pile fabric obtained by the invention (manufacturing method) of [15] has a high appearance quality because it is difficult to cause a grinding phenomenon even when it is stretched along a bent shape, curved surface, or other complicated shape. Can be secured. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. In addition, the entangled yarn remaining after dissolution / removal of the core yarn functions as a stretchable yarn that can be stretched with a margin of winding, and a void is secured in the ground structure by removing the core yarn, so that the pile fabric is flexible. It is also excellent and can ensure a good sitting comfort. Furthermore, in this production method, the core yarn of the composite yarn can be dissolved and removed in water at the same time when immersed in a dyeing water bath for dyeing the fabric, and it is necessary to provide a separate dissolution removal step for the core yarn. Therefore, productivity can be improved and cost can be reduced.

  Hereinafter, one embodiment of a napped pile fabric according to the present invention will be described with reference to the drawings. The napped pile fabric of the present embodiment is a moquette used as a skin material for seat sheets of vehicles such as automobiles and railway vehicles. FIG. 1 is a schematic perspective view showing an enlarged part of the napped pile fabric (1) of the present embodiment, wherein (2) is a warp, (3) is a weft, and (4) is a cut pile.

  The napped pile fabric (1) is formed by weaving two ground structures (5) and (5) by a double pile loom, and locking the pile threads between the two ground structures. It consists of a moquette obtained by cutting the yarn in the middle (dividing it into two sides).

  The raised pile fabric (1) has a structure in which pile yarn (4) is implanted in a ground structure (5) formed by weaving warp yarn (2) into weft yarn (3). That is, as shown in FIG. 1, a pair of warps (2A) and (2B) woven in a plain weave form alternately arranged one above the other for each weft (3) and a pair of warps adjacent to the weft (3) (2A) It has a configuration in which a U-shaped cut pile (4) is locked to a weft (3) between (2B). As the warp (2), at least an elastic yarn (12) is used. In the present embodiment, a yarn (see FIG. 2) in which a polyester filament yarn (11) and a polyurethane elastic yarn (12) are combined is used as the warp yarn (2). In the present embodiment, as the weft yarn (3), the entangled yarn (14) made of water-insoluble fiber is wound around the core yarn (13) made of water-soluble fiber in a wound state and this wound state is maintained. A wound composite yarn (see FIG. 3) in which a presser yarn (15) made of water-soluble fibers is combined is used.

  Furthermore, in this embodiment, at least two kinds of polyester multifilament mixed yarns having a difference in shrinkage rate are used as the pile yarn (4). Among these mixed yarns, polyester fibers having a high shrinkage rate and polyester fibers having a low shrinkage rate have crimps, and the top end of the crimped pile (4B) made of the polyester fibers having a high shrinkage rate sinks from the pile surface. On the other hand, the low shrinkage pile (4A) made of polyester fiber having a small shrinkage rate is also present on the pile surface, thereby forming a multi-step pile (see FIG. 1). The polyester fiber having a large shrinkage rate preferably has a crimp expression elongation rate of 1 to 40%.

The crimp expression elongation rate (%) is a numerical value obtained as follows. That is, a casserole is prepared by winding a crimped shrink yarn 5 times. The apparent fiber is subjected to a dry heat treatment at 170 ° C. for 3 minutes while applying a load of 0.022 g / dtex, and the casket length at this time is L. Next, by applying a constant load of 0.11 g / dtex against the apparent fiber to hank length at this time is L _2. The expression rate of crimp expression (%) = 100 (L ₂ −L) / L. The average value of five samples is adopted as the expression rate of crimp expression.

  In addition, a backing layer is formed on the back surface of the ground structure (5), and the shape stability and cutting property of the fabric are improved along with the prevention of the pile from coming off.

  According to the napped pile fabric (1) having the above-described configuration, when the fabric is brought into contact with water and the core yarn (13) and the presser yarn (15) of the wound composite yarn are dissolved and removed in water, the remaining entangled yarn (14) functions as a stretchable yarn that can be stretched with a margin of winding, and this, combined with the function of the elastic yarn (12) of the warp (2), for example, maintains the fabric width while maintaining the fabric (1) itself. A sufficient expansion / contraction function can be imparted. Therefore, even when the napped pile fabric (1) is stretched along a bent shape, a curved surface shape, or other complicated shapes, it is difficult for a grinding phenomenon to occur and a high appearance quality can be ensured. Also, the stretch in the warp direction, weft direction and bias direction is well balanced, and the fabric surface has no irregularities or warps in the stage before wearing, and it has excellent cutting workability and sewing workability and is A good fit can be achieved later, and the appearance of the fabric can be further improved without irregularities on the fabric surface. Further, the entangled yarn (14) remaining after the dissolution / removal of the core yarn (13) and the presser yarn (15) functions as an extended yarn that can be extended by a margin of winding, and the core yarn (13) and the presser yarn (15). ) Is secured in the ground structure (5), the pile fabric (1) is excellent in flexibility and can ensure a good sitting comfort.

  Furthermore, in this embodiment, since the top end of the crimped pile (4B) made of polyester fiber having a high shrinkage rate sinks from the surface of the pile (4) and increases the volume of the root of the pile (4), Combined with the action of the specific configuration of the warp yarn (2) and the weft yarn (3) constituting (5), the napped pile fabric (1) is bent, curved, or other complicated shapes. Even when it is stretched, the occurrence of grinding can be sufficiently prevented. Further, since the volume of only the root portion of the pile (4) can be increased, it is possible to further reduce the biting of the pile by the sewing thread at the sewing portion, thereby more sufficiently preventing the occurrence of grinding. .

  In the above embodiment, as the weft (3), the entangled yarn (14) made of water-insoluble fiber is wound around the core yarn (13) made of water-soluble fiber in a wound state and this wound state is maintained. However, instead of this, a wound composite yarn (see FIG. 3) in which a presser yarn (15) made of a water-soluble fiber is combined is used. Instead, a core yarn (13) made of water-soluble fiber and a water-insoluble A twisted composite yarn (see FIG. 4) formed by twisting the entangled yarn (14) made of the conductive fiber may be used. In this case, the same effect as in the above embodiment can be obtained.

  Moreover, in the said embodiment, although all the warp yarns (2) are set as the structure containing an elastic yarn (12), only a part of warp yarn (2) employ | adopts the structure containing an elastic yarn (12). You can also. Moreover, in the said embodiment, although all the wefts (3) are comprised with the said wound composite yarn, the structure by which only a part of the weft (3) was formed with the wound composite yarn is also employable. . Further, the woven form of the ground structure (5) is not particularly limited to that of the above embodiment.

  In FIG. 1, in order to facilitate understanding of the configuration, a schematic diagram is shown with a space between the warps (2) and the wefts (3). In general, the gaps between the wefts and the wefts (3) are packed to the extent that they come into contact with each other or are in contact with each other.

  In the present invention, at least an elastic yarn (12) is used as the warp (2). By using such an elastic yarn for the warp yarn (2), it contributes to the stretchability of the pile fabric and can also contribute to prevention of grinding. The elastic yarn is not particularly limited, and examples thereof include polyurethane elastic yarn and elastic yarn made of olefinic thermoplastic elastomer. Among these, as the warp (2), it is preferable to use a yarn (see FIG. 2) in which a polyester filament yarn (11) and a polyurethane elastic yarn (12) are combined.

  The thickness of the polyurethane elastic yarn is preferably 22 to 122 dtex. By setting it as such a range, even when the pile fabric (1) is stretched along a folded shape, a curved surface shape, or other complicated shapes, the occurrence of grinding can be more sufficiently prevented.

  The core yarn (13) constituting the wound composite yarn is a yarn made of water-soluble fibers. Such a water-soluble fiber is not particularly limited, but polyvinyl alcohol (PVA) fiber is suitable, and when this PVA fiber is used, the PVA fiber is easily dissolved in water. There is an advantage that the yarn (13) can be dissolved and removed in a short time and the production efficiency can be improved.

  The entangled yarn (14) constituting the wound composite yarn is constituted by a yarn made of water-insoluble fibers. Examples of such water-insoluble fibers include polyester fibers, polyamide fibers, and acrylic fibers. It is done. Among these, it is preferable to use a polyester fiber. In this case, there is an advantage that the strength of the ground structure (5) can be improved.

  The thickness of the entangled yarn (14) is preferably 110 to 330 dtex. By setting it as such a range, the intensity | strength of ground organization (5) can further be improved.

  The presser yarn (15) constituting the wound composite yarn is a yarn made of water-soluble fibers, but such water-soluble fibers are not particularly limited, but are polyvinyl alcohol (PVA) fibers. Is preferred.

  The conditions for weaving the ground structure (5) are not particularly limited, but are preferably woven into a ground structure having a cocoon density of 18 to 40 yarns / inch and a weft density of 48 to 80 yarns / inch. When woven under such conditions, the ground texture (5) can be densified, and the occurrence of grinding can be more effectively prevented.

  The pile yarn (4) is not particularly limited, but spun yarn and filament processed yarn are preferably used. The fineness of the pile yarn (4) is not particularly limited, but is 0.01 to 2.20 decitex in that it can sufficiently cover the surface of the ground structure (5) and can secure a better texture. The range of (dtex) is preferable, and a particularly preferable range is 0.30 to 1.10 dtex. Although it does not specifically limit as a raw material of a pile thread | yarn (4), For example, polyester, polyamide, an acryl, etc. are mentioned. Among these, as the pile yarn (4), it is preferable to use at least two types of polyester multifilament mixed yarn having a shrinkage difference as in the above embodiment.

  By removing the core yarn (13) and the presser yarn (15) of the composite yarn constituting the ground structure (5) of the napped pile fabric having the above-described configuration, the skin material for a seat sheet of a vehicle, especially for furniture The napped pile fabric (1) suitably used as a skin material for a chair can be provided. The core yarn (13) and the presser yarn (15) can be removed by, for example, bringing the fabric into contact with water and dissolving the core yarn (13) and the presser yarn (15) in water.

  In particular, the core yarn (13) and the presser yarn (15) are preferably dissolved and removed by immersing the napped pile fabric in a dyed water bath. In this case, the core yarn (13) and the presser yarn (15) of the composite yarn can be dissolved and removed in water simultaneously with the immersion in the dyeing water bath for dyeing the fabric. Therefore, there is no need to provide a presser yarn dissolving and removing step, which is advantageous in that productivity can be improved and costs can be reduced.

  The elongation at the time of 98N load of the napped pile fabric (1) from which the core yarn (13) and the presser yarn (15) are removed as described above is 10% or more in the warp direction (51), and the weft direction ( 52) is preferably 10% or more, and preferably 30% or more in the bias direction (53) (54) (see FIG. 6). In this case, the occurrence of grinding can be reliably prevented.

  In this invention, the backing layer is not an essential component, but it is desirable to provide it on the back surface of the ground structure (5) as in the above embodiment. Thereby, the form stability and cutting property as a pile fabric (1) can be improved.

  The backing layer is not particularly limited. For example, a resin composition is used. Examples of the resin component of the resin composition include styrene-butadiene rubber (SBR), acrylic, urethane, and poly Examples thereof include resins such as vinyl chloride and ethylene-vinyl acetate copolymer (EVA). Among them, it is preferable to use an acrylate resin or a urethane resin because high durability can be ensured and texture adjustment is easy.

  Next, a manufacturing method suitable as a method for manufacturing the napped pile fabric (1) of the present invention will be described. First, a wound yarn (14) made of a water-insoluble fiber is wound around a warp yarn (2) containing an elastic yarn (12) around a core yarn (13) made of a water-soluble fiber in a wound state. Pile yarn (4) to ground structure (5) in which wound composite yarn (see FIG. 3) formed by combining presser yarn (15) made of water-soluble fiber for holding the yarn is woven as weft (3) A napped pile fabric is manufactured. Instead of the wound composite yarn, the warp yarn (2) containing the elastic yarn (12) is combined with the core yarn (13) made of water-soluble fiber and the entangled yarn (14) made of water-insoluble fiber. A twisted composite yarn (see FIG. 4) may be used as the weft (3).

  Next, the napped pile fabric obtained is immersed in a dyed water bath. By this dipping operation, the fabric is dyed and the core yarn (13) and the presser yarn (15) are dissolved in a dyeing water bath to remove the core yarn (13) and the presser yarn (15).

  Next, a resin emulsion is applied to the back side of the fabric texture (5) and dried to form a backing layer.

  In addition, the said manufacturing method is only what showed the example, and the napped pile fabric (1) based on this invention is not specifically limited to what is manufactured with the said manufacturing method.

  The napped pile fabric (1) according to the present invention is preferably used as a skin material for seat sheets of vehicles such as automobiles and railway vehicles, and a skin material for furniture chairs, but is not particularly limited to such applications. .

  Next, specific examples of the present invention will be described.

<Example 1>
A pile yarn of 525 dtex (contracted yarn content ratio: 16% by mass) obtained by combining four polyester multifilament yarns (110 dtex / 144 f) and polyester shrink yarn (crimp yarn) (84 dtex / 36 f) is used as a polyester yarn. A yarn of 347 dtex formed by combining filament yarn (333 dtex / 72f) (11) and polyurethane elastic yarn (44 dtex) (12) is used as warp yarn (2), and core yarn (31 dtex) (13) made of PVA fiber is used as polyester. A tangled yarn (14) made of a multifilament yarn (220 dtex / 48f) is wound in a wound state, and a presser yarn (31 dtex) (15) made of PVA fiber for maintaining the wound state is combined with 308 dtex. The wound composite yarn (see Fig. 3) and weft (3) Then, wetting is performed to form a pile layer (pile density 713 pieces / inch square) (4) on the ground structure (warp density: 23 pieces / inch, weft density: 62 pieces / inch) (5). The ground was made. In addition, the organization form in this moquette place is shown in FIG.

  Next, the obtained moquette was immersed in a dyeing water bath to perform dyeing, and the core yarn constituting the composite yarn was dissolved in the dyeing water bath to remove the core yarn.

Next, an acrylic ester resin emulsion (aqueous emulsion, resin content 40% by mass) was applied to the back of the above moquette using a doctor knife coater at a coating amount of 70 g / m ² (solid content) and then dried. A skin material (moquette) for vehicle seats was produced.

<Example 2>
A 280 dtex yarn (40% by mass shrinkage content) obtained by combining a polyester multifilament yarn (84 dtex / 144f) and a polyester shrink yarn (crimp yarn) (50 dtex / 12f) is used as a pile yarn, and the polyester multifilament yarn 123 dtex yarn composed of (110 dtex / 24f) (11) and polyurethane elastic yarn (44 dtex) (12) is used as warp yarn (2), and core yarn (31 dtex) (13) made of PVA fiber is polyester multifilament A entangled yarn (14) made of yarn (220 dtex / 48f) is wound in a wound state and a presser yarn (31 dtex) (15) made of PVA fiber for maintaining this wound state is combined with 308 dtex Rotating composite yarn (see Fig. 3) as weft yarn (3) Weaving is performed to form a moquette fabric in which a pile layer (pile density: 1156 / inch square) (4) is formed on the ground structure (warp density: 34 / inch, weft density: 68 / inch) (5) Produced. In addition, the organization form in this moquette place is shown in FIG.

  Next, the obtained moquette was immersed in a dyeing water bath to perform dyeing, and the core yarn constituting the composite yarn was dissolved in the dyeing water bath to remove the core yarn.

Next, an acrylic ester resin emulsion (aqueous emulsion, resin content 40% by mass) was applied to the back of the above moquette using a doctor knife coater at a coating amount of 70 g / m ² (solid content) and then dried. A skin material (moquette) for vehicle seats was produced.

<Example 3>
A pile yarn of 525 dtex (contracted yarn content ratio: 16% by mass) obtained by combining four polyester multifilament yarns (110 dtex / 144 f) and polyester shrink yarn (crimp yarn) (84 dtex / 36 f) is used as a polyester yarn. A yarn of 347 dtex formed by combining filament yarn (334 dtex / 72f) (11) and polyurethane elastic yarn (44 dtex) (12) is used as warp yarn (2), and core yarn (31 dtex) (13) made of PVA fiber and polyester Weaving is carried out using a 308 dtex mixed-twisted composite yarn obtained by twisting a tangled yarn (14) made of multifilament yarn (220 dtex / 48f) as a weft (3), and a ground structure (warp density: 23 yarns / inch) , Weft density: 62 / inch) (5) on the pile layer (pile density 71 This / inch square) (4) was prepared moquette fabric which is formed. In addition, the organization form in this moquette place is shown in FIG.

  Next, the obtained moquette was immersed in a dyeing water bath to perform dyeing, and the core yarn constituting the composite yarn was dissolved in the dyeing water bath to remove the core yarn.

Next, an acrylic ester resin emulsion (aqueous emulsion, resin content 40% by mass) was applied to the back of the above moquette using a doctor knife coater at a coating amount of 70 g / m ² (solid content) and then dried. A skin material (moquette) for vehicle seats was produced.

<Comparative Example 1>
A pile yarn of 525 dtex (contracted yarn content ratio: 16% by mass) obtained by combining four polyester multifilament yarns (110 dtex / 144 f) and polyester shrink yarn (crimp yarn) (84 dtex / 36 f) is used as a polyester yarn. A yarn of 347 dtex formed by combining filament yarn (334 dtex / 72f) and polyurethane elastic yarn (44 dtex) is used as warp yarn (2), and polyester multifilament yarn (220 dtex / 48f) and polyurethane elastic yarn (44 dtex) are combined. Weaving is performed using the 233 dtex yarn as a weft (3), and a pile layer (714 pile density / inch square) is formed on the ground structure (warp density: 26 yarns / inch, weft density: 57 yarns / inch). The formed moquette was produced. The organization form in this moquette is the same as that shown in FIG.

Next, an acrylic ester resin emulsion (aqueous emulsion, resin content 40% by mass) was applied to the back of the above moquette using a doctor knife coater at a coating amount of 70 g / m ² (solid content) and then dried. A skin material (moquette) for vehicle seats was produced.

<Comparative example 2>
A pile yarn of 525 dtex (contracted yarn content ratio: 16% by mass) obtained by combining four polyester multifilament yarns (110 dtex / 144 f) and polyester shrink yarn (crimp yarn) (84 dtex / 36 f) is used as a polyester yarn. A yarn of 347 dtex formed by combining filament yarn (334 dtex / 72f) and polyurethane elastic yarn (77 dtex) is used as warp yarn (2), and polyester multifilament yarn (220 dtex / 48f) and polyurethane elastic yarn (44 dtex) are combined. Weaving is performed using the 233 dtex yarn as the weft yarn (3), and a pile layer (pile density of 832 yarns / inch square) is formed on the ground structure (warp density: 26 yarns / inch, weft density: 64 yarns / inch). The formed moquette was produced. The organization form in this moquette is the same as that shown in FIG.

Next, an acrylic ester resin emulsion (aqueous emulsion, resin content 40% by mass) was applied to the back of the above moquette using a doctor knife coater at a coating amount of 70 g / m ² (solid content) and then dried. A skin material (moquette) for vehicle seats was produced.

  About each obtained skin material (moquette), the elongation rate at the time of 98N load was measured. That is, the elongation at 98 N load in the warp direction (51), the weft direction (52), the forward bias direction (53), and the reverse bias direction (54) (see FIG. 6) was measured. The results are shown in Table 1.

  Each skin material (moquette) obtained as described above was evaluated by the following evaluation method. Table 2 shows the results of these evaluations.

<Presence / absence of grinding at the bent part>
The skin material was folded back about 180 ° along the warp direction, and the appearance quality at the bent portion at that time was evaluated. In the folded part, the texture that was low in quality because of the appearance of the ground texture between the piles was rated as “x”, and the high quality that was not visible in the texture between the piles was marked as “◯”.

<Presence or absence of irregularities on the surface of the skin material after stretching>
The ends of the skin material (moquette) are sewn with a sewing machine or the like, and the sewn portion is stretched over the seat pad in such a manner that it is applied to the corner portion of the seat pad of the car seat (see FIG. 5). The surface of the skin material in the installed state is checked for unevenness (ie, fit to the seat pad shape), and “x” is indicated when the unevenness is recognized and inferior to the fit. “△” was assigned to those with a good fit and no irregularities were observed.

<Evaluation of cutting workability>
In handling when cutting work, the surface of the skin material is uneven or warped, and the inferior workability of the cutting process is marked as “x”, and the surface of the skin material is not uneven and does not warp. Those with good cutting workability were marked with “◯”.

<Evaluation of sewing workability>
When handling the sewing work, “X” indicates that the skin material is warped and is inferior in sewing workability, and “○” indicates that the skin material does not warp and has good sewing workability. It was.

<Evaluation of bending resistance>
The bending resistance (mm) of the fabric was measured according to A method (45 ° cantilever method) of 6.19.1 of JIS L1096-1996.

  As is apparent from the table, the napped pile fabrics of Examples 1 to 3 of the present invention are less likely to cause a grinding phenomenon even at a bent portion, can ensure a high appearance quality, and fit in a good state without any irregularities on the fabric surface. Furthermore, it is excellent in cutting workability and sewing workability, and is excellent in flexibility and breathability, and can give a good sitting comfort.

  On the other hand, the napped pile fabrics of Comparative Examples 1 and 2 using polyurethane elastic yarns for both the warp and the weft are inferior in fit because irregularities are recognized on the surface of the fabric after being stretched, and the cutting workability is poor. The sewing workability was poor. Moreover, the flexibility was insufficient.

It is a typical perspective view which expands and shows a part of napped pile fabric which concerns on one Embodiment of this invention. It is an expansion perspective view which shows an example of a warp. It is an expansion perspective view which shows an example of a weft. It is an expansion perspective view which shows the other example of a weft. It is a figure which shows the state which sewed the pile fabric and covered the corner part of a seat pad, Comprising: (a) is a perspective view of the pile fabric which concerns on this invention, (b) is a perspective view of a conventional product. It is explanatory drawing which shows the measurement direction at the time of measuring the elongation rate at the time of 98N load.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Napped pile fabric 2 ... Warp yarn 3 ... Weft yarn 4 ... Cut pile 4A ... Low shrinkage pile 4B ... Crimp pile with large shrinkage 5 ... Ground texture 11 ... Polyester yarn 12 ... Elastic yarn 13 ... Core yarn 14 ... Tangle yarn 15 ... Presser foot thread

Claims (15)

  In a napped pile fabric in which pile yarns are planted in a ground structure in which warp yarns are woven into weft yarns, at least elastic yarns are used as the warp yarns, and the weft yarns are made from water-insoluble fibers as core yarns made of water-soluble fibers. A napped pile fabric is used, in which a wound composite yarn is used in which a wound yarn is wound in a wound state and a presser yarn made of a water-soluble fiber for maintaining the wound state is combined.   In a napped pile fabric in which pile yarns are planted in a ground structure in which warp yarns are woven into weft yarns, at least elastic yarns are used as the warp yarns, and core yarns made of water-soluble fibers and water-insoluble fibers are used as the weft yarns. A napped pile fabric in which a twisted composite yarn obtained by twisting a entangled yarn is used.   The napped pile fabric according to claim 1 or 2, wherein at least a polyurethane elastic yarn is used as the warp.   The napped pile fabric according to claim 1 or 2, wherein a polyester filament yarn and a polyurethane elastic yarn are used as the warp yarn.   The napped pile fabric according to claim 3 or 4, wherein the polyurethane elastic yarn has a thickness of 22 to 122 dtex.   The napped pile fabric according to any one of claims 1 to 5, wherein a polyvinyl alcohol fiber is used as the water-soluble fiber constituting the core yarn.   The napped pile fabric according to any one of claims 1 to 6, wherein a polyester fiber is used as the water-insoluble fiber constituting the entangled yarn.   The napped pile fabric according to claim 7, wherein the thickness of the entangled yarn is 110 to 330 dtex.   The napped pile fabric according to any one of claims 1 to 8, wherein the ground texture is a ground texture having a cocoon density of 18 to 40 yarns / inch and a weft density of 48 to 80 yarns / inch. As the pile yarn, at least two types of polyester multifilament mixed yarn having a shrinkage difference is used,
A polyester fiber having a large shrinkage rate has crimps and a crimp expression elongation rate of 1 to 40%. The top end of the polyester fiber having a large shrinkage rate sinks from the pile surface, while the shrinkage rate is small. The napped pile fabric according to any one of claims 1 to 9, wherein the polyester fiber is also present on the pile surface, thereby forming a multi-step pile.   A napped pile fabric obtained by removing the core yarn by dissolving the core yarn constituting the composite yarn in water by bringing the pile fabric according to any one of claims 1 to 10 into contact with water.   The napped pile fabric according to claim 11, wherein the pile fabric has an elongation at 98 N load of 10% or more in the warp direction, 10% or more in the weft direction, and 30% or more in the bias direction.   The napped pile fabric according to claim 11 or 12, which is used as a skin material for a seat of a vehicle. A warp yarn containing water-soluble fibers is wound around a core yarn made of water-soluble fiber in a wound state, and a presser yarn made of water-soluble fiber is used to maintain this wound state. Producing a napped pile fabric in which pile yarn is planted in a ground structure in which the wound composite yarn is woven as weft;
The napped pile is characterized by including a step of dyeing the fabric by immersing the napped pile fabric in a dyed water bath and dissolving the core yarn constituting the composite yarn in the water bath to remove the core yarn. Fabric manufacturing method. Pile yarn is planted in a ground structure formed by weaving a twisted composite yarn made by weaving a core yarn made of water-soluble fiber and an entangled yarn made of water-insoluble fiber into a warp containing elastic yarn. Producing a raised nail pile fabric,
The napped pile is characterized by including a step of dyeing the fabric by immersing the napped pile fabric in a dyed water bath and dissolving the core yarn constituting the composite yarn in the water bath to remove the core yarn. Fabric manufacturing method.

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